Western Riverside County Regional Wastewater Authority
14 MGD Plant Expansion - Volume IIB September 2014
For Bidding Purposes Only WESTERN RIVERSIDE COUNTY REGIONAL WASTEWATER AUTHORITY 14.0 MGD PLANT EXPANSION
VOLUME IIB
Technical Specifications
Section # of Pages
SECTION 00020 Ð CONTRACT DOCUMENTS TABLE OF CONTENTS TECHNICAL SPECIFICATIONS Ð VOLUME II-B
DIVISION 22 Ð PLUMBING
220050 General Pipes and Fittings ...... 11 220513 Common Motor Requirements for Equipment ...... 7 220517 Sleeves and Sleeve Seals for Piping ...... 2 220518 Escutcheons for Piping ...... 2 220519 Meters and Gages ...... 3 220523 Valves ...... 11 220529 Hangers and Supports for Piping and Equipment ...... 8 220553 Identification for Piping and Equipment ...... 4 220719 Piping Insulation ...... 8 221030 Ductile Iron Pipe ...... 7 221040 Plastic Pipe ...... 6 221050 High Density Polyethylene Pipe and Fittings ...... 5 221055 HDPE Storm Drain Pipe ...... 2 221060 Stainless Steel Piping and Tubing ...... 3 221065 Steel Piping and Fabricated Steel Piping ...... 12 221066 Pipeline Testing ...... 8 221094 Rubber Hose ...... 1 221116 Water Piping ...... 14 221119 Water Piping Specialties ...... 4 221245 High Density Cross-Linked Polyethylene Chemical Storage Tanks ...... 7 221316 Sanitary Waste and Vent Piping ...... 8 221319 Sanitary Waste Piping Specialties ...... 5 227100 Progressive Cavity Pumps ...... 6 227200 Submersible Recirculator Chopper Pumps ...... 4 227300 Archimedes Screw Pumps ...... 8 227400 Submersible Axial Flow Pump ...... 6 227500 Horizontal Dry Pit Pump ...... 5 227535 Multi-Stage Centrifugal Pump System ...... 3 227537 Self-Priming Centrifugal Sample Pumps ...... 3 227540 Vertical Turbine Can Pumps ...... 6 227545 Vertical Mixed Flow Pumps ...... 4 227550 Submersible Wet Well Pumps ...... 6 227560 Chemical Dosing Gear Pumps ...... 4 227563 Motor Diaphragm Metering Pump ...... 3 227565 Variable Speed Peristaltic Pump ...... 6 227590 Submersible Dewatering Pump ...... 3 227600 Horizontal Centrifugal Chopper Pumps ...... 10 227650 Horizontal End Suction Pumps ...... 3 227700 Hot Water Recirculation Pump ...... 3 227750 Centrifugal Hot Water Booster Pumps ...... 3 229000 Single Stage Air Compressor ...... 2
DIVISION 23 Ð HEATING VENTILATING AND AIR CONDITIONING
230000 General Heating Ventilation and Air Conditioning ...... 3 230513 Common Motor Requirements for HVAC Equipment ...... 3 233100 Fiberglass Reinforced Duct ...... 7 233113 Metal Ducts ...... 9 233313 Ductwork Accessories ...... 5 Section # of Pages
233400 Exhaust and Vent Fans ...... 3 233713 Diffusers, Registers, and Grilles ...... 3 234000 Fiberglass Reinforced Fans ...... 3 236200 Packaged Compressor and Condenser Units ...... 4 238316 Radiant Heating Hydronic Piping ...... 10 239000 Fixed Louvers ...... 4
DIVISION 26 Ð ELECTRICAL
260000 General Electrical Requirements ...... 9 260513 Medium Voltage Cable ...... 15 260519 Low-Voltage Electrical Power Conductors and Cables ...... 7 260523 Control-Voltage Electrical Power Cables ...... 7 260526 Grounding and Bonding for Electrical Systems ...... 5 260529 Hangers and Supports for Electrical Systems ...... 5 260533 Raceways and Boxes for Electrical Systems ...... 8 260534 Enclosures ...... 2 260548 Vibration and Seismic Controls for Electrical Systems ...... 5 260553 Identification for Electrical Systems ...... 8 260753 Electrical Testing with Coordination Study ...... 15 261213 Liquid-Filled Medium-Voltage Transformers ...... 3 261300 Medium Voltage Switchgear ...... 14 262200 Low-Voltage Transformers ...... 2 262416 Panelboards ...... 2 262419 Motor-Control Centers ...... 4 262726 Wiring Devices ...... 8 262813 Fuses ...... 3 262816 Enclosed Switches and Circuit Breakers ...... 2 262819 Disconnect Switches ...... 2 262913 Enclosed Controllers ...... 5 262923 Variable-Frequency Motor Controllers ...... 14 263213 Engine Generators ...... 13 263600 Transfer Switches ...... 7 264313 Transient Voltage Suppression for Low-Voltage Electrical Power Circuits ...... 10 265000 Lighting ...... 6
DIVISION 31 Ð EARTHWORK
311000 Site Clearing ...... 4 312000 Earth Moving ...... 11 312319 Dewatering ...... 2 315000 Excavation Support and Protection ...... 2 319000 Geotechnical Report ...... 82
DIVISION 32 Ð EXTERIOR IMPROVEMENTS
321216 Asphalt Paving ...... 6 321313 Concrete Paving ...... 7 323113 Chain Link Fences and Gates ...... 7
DIVISION 33 Ð UTILITIES
331400 Hydraulic Structures Testing ...... 2 335100 Natural Gas Distribution ...... 11 Section # of Pages
338000 Precast Concrete Manholes and Vaults ...... 7
DIVISION 35 Ð WATERWAY CONSTRUCTION
352016 Aluminum Slide Gates ...... 4 352020 Stainless Steel Sluice Gates ...... 5 352030 Stainless Steel Stop Logs ...... 2 352035 Fiberglass Polyester Gates ...... 4 352040 Fiberglass Stop Logs ...... 6 352055 Fiberglass Baffle Walls ...... 3 353000 Stainless Steel Flap Gates ...... 3
DIVISION 40 Ð PROCESS INTEGRATION
409000 Instrumentation and Control for Process Systems ...... 15 409113 Chemical Properties Process Measurement Devices ...... 5 409119 Physical Properties Process Measurement Devices ...... 7 409123 Miscellaneous Properties Process Measurement Devices ...... 13 409433 Human Machine Interfaces ...... 2 409443 Programmable Logic Controllers ...... 4 409513 Process Control Panels and Hardware ...... 14 409533 Process Control Networks...... 14 409600 Process Control Software ...... 2 409635 Process Control Software Programming ...... 2
DIVISION 43 Ð PROCESS GAS HANDLING, PURIFICATION, AND STORAGE EQUIPMENT
431000 Spiral Heat Exchanger ...... 4 432100 Digester Gas Boiler ...... 6 437000 Fixed Radial Beam Digester Cover ...... 6 437100 Digester Gas H2S Scrubber System ...... 3 437600 Digester Gas Safety Equipment ...... 4 437700 Digester Gas Conditioning and Waste Gas Burner System ...... 14
DIVISION 44 Ð POLLUTION CONTROL EQUIPMENT
441000 Biofiltration Odor Control System...... 13
DIVISION 46 Ð WATER AND WASTEWATER EQUIPMENT
460100 General Mechanical Requirements ...... 11 461000 Primary Clarifier Equipment ...... 9 461100 Secondary Clarifier Equipment ...... 12 461500 Aluminum Basin Covers ...... 4 462000 Floating Ball Blanket ...... 2 463000 Grit Classifier ...... 5 466115 Automated Brush System ...... 6 466200 Eductor Tube Mixers ...... 4 466250 Vertical Shaft Turbine Mixers ...... 8 SECTION 220050 – GENERAL PIPES AND FITTINGS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS:
A. Drawings and general provisions of Contract, including General and Special Conditions and Division-1 Specification sections, apply to work of this section.
1.2 SUMMARY:
A. This section is generic in that it describes material and installation required by several other sections of this specification.
B. Types of pipes and pipe fittings specified in this section include the following:
1. Steel Piping
2. Plastic Piping
3. Grooved Joint Piping
4. Miscellaneous Piping Materials/Products.
C. Pipes and pipe fittings furnished as part of factory - fabricated equipment, are specified as part of equipment assembly in other Division - 22 sections.
1.3 QUALITY ASSURANCE:
A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of pipes and pipe fittings of types and sizes required, whose products have been in satisfactory use in similar service for not less than 5 years.
B. Installer's Qualifications:
1. Firm with at least three years history of successful experience on projects of similar nature.
2. Licensed as a firm in the contractor state of origin and in the State of California.
3. Have a publicly registered bonding capacity of sufficient amount to cover this work and all other work in progress by the contractor.
4. All workmen employed on the project shall carry state licenses as journeyman or apprentice pipe fitters with additional certification for welders.
C. Welding Certification:
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-1 1. Each welder shall have passed a qualification test, which shall be in accordance with the ASME Boiler and Pressure Vessel Code, Section IX, "Welding Qualifications", ASME Section VIII, and ANSI 313.
2. The test report shall certify that the welder is qualified to weld the material to be used at the job site.
3. The contractor shall submit three copies of each welder's qualification test report to the Project Manager for approval prior to commencing the work. No welder shall be used on the project until so certified.
1.4 SUBMITTALS:
A. Product Data: Submit manufacturer's technical product data, installation instructions, and dimensioned drawings for each type of pipe and pipe fitting. Submit piping schedule showing manufacturer, pipe or tube weight, fitting type, and joint type for each piping system.
B. Welding Certifications: Submit reports as required for piping work.
C. Brazing Certifications: Submit reports as required for piping work.
D. Maintenance Data: Submit maintenance data and parts lists for each type of mechanical fitting. Include this data, product data, and certifications in maintenance manual; in accordance with requirements of Division 1.
1.5 REFERENCES:
A. Codes and Standards:
1. Welding: Qualify welding procedures, welders and operators in accordance with ASME B31.1, or ASME B31.9, as applicable, for shop and project site welding of piping work.
2. Brazing: Certify brazing procedures, brazers, and operators in accordance with ASME Boiler and Pressure Vessel Code, Section IX, for shop and job-site brazing of piping work.
1.6 DELIVERY, STORAGE, AND HANDLING:
A. Except for concrete, corrugated metal, hub-and-spigot, clay, and similar units of pipe, provide factory-applied plastic end-caps on each length of pipe and tube. Maintain end-caps through shipping, storage and handling as required to prevent pipe-end damage and eliminate dirt and moisture from inside of pipe and tube.
B. Where possible, store pipe and tube inside and protected from weather. Where necessary to store outside, elevate above grade and enclose with durable, waterproof wrapping.
C. Protect flanges and fittings from moisture and dirt by inside storage and enclosure, or by packaging with durable, waterproof wrapping.
PART 2 - PRODUCTS
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-2
2.1 GENERAL:
A. Piping Materials: Provide pipe and tube of type, joint type, grade, size and weight (wall thickness or Class) indicated for each service. Where type, grade or class is not indicated, provide proper selection as determined by Installer for installation requirements, and comply with governing regulations and industry standards.
B. Pipe/Tube Fittings: Provide factory-fabricated fittings of type, materials, grade, class and pressure rating indicated for each service and pipe size. Provide sizes and types matching pipe, tube, valve or equipment connection in each case. Where not otherwise indicated, comply with governing regulations and industry standards for selections, and with pipe manufacturer's recommendations where applicable.
2.2 STEEL PIPES AND PIPE FITTINGS:
A. Galvanized Steel Pipe: ASTM A 53.
B. Galvanized Seamless Steel Pipe: ASTM A 53.
C. Electric-Resistance-Welded Steel Pipe: ASTM A 135.
D. Electric-Fusion-Welded Steel Pipe: ASTM A 671, A 672, or A 691.
E. Cast-Iron Flanged Fittings: ANSI B16.1, including bolting.
F. Cast-Iron Threaded Fittings: ANSI B16.4.
G. Malleable-Iron Threaded Fittings: ANSI B16.3; galvanized or as indicated.
H. Unions: ANSI B16.39; 300 lb. ground joint malleable iron, hexagonal, selected by Installer for proper piping fabrication and service requirements, including style, end connections, and metal-to-metal seats (iron, bronze or brass); plain or galvanized as indicated.
I. Dielectric Unions: 175 psig WSP at 250¼F. Equal to Walter Vallet Company V-line insulating coupling.
J. Threaded Pipe Plugs: ANSI B16.14.
K. Steel Flanges/Fittings: ANSI B16.5, including bolting and gasketing of the following material group, end connection and facing, except as otherwise indicated.
1. Material Group: Group 1.1.
2. End Connections: Buttwelding or slip on flanges.
3. Facings: Raised-face or flat faced.
4. Steel Pipe Flanges For Waterworks Service: AWWA C207.
L. Forged-Steel Socket-Welding and Threaded Fittings: ANSI B16.11, except MSS SP-79 for threaded reducer inserts; rated to match schedule of connected pipe.
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-3
M. Forged Branch-Connection Fittings: Except as otherwise indicated, provide type as determined by Installer to comply with installation requirements.
N. Pipe Nipples: Fabricated from same pipe as used for connected pipe.
2.3 PLASTIC PIPE AND PIPE FITTINGS:
A. Polyvinyl Chloride Pipe (PVC): ASTM D 1785. Schedule 80.
B. PVC Fittings:
1. Schedule 80 Socket: ASTM D 2467.
2. Schedule 80 Threaded: ASTM D 2464.
C. Polypropylene Pipe: Piping and fittings shall be manufactured to Schedule 80 iron pipe dimension, from virgin unpigmented polypropylene pipe grade material, without the addition of normal antioxidants or slip agents. The pipe shall be furnished in 10 foot lengths, cylindrical and straight, and sterile capped at time of manufacture. Pipe and fittings shall meet ASTM D2146, but without additives, and be manufactured to meet dimensional tolerances of ASTM D1785.
Fittings to have electric resistance coils.
2.4 GROOVED PIPING PRODUCTS:
A. General: As Installer's option, mechanical grooved pipe couplings and fittings may be used for piping systems having operating conditions not exceeding 230oF (110oC), excluding steam piping and any other service not recommended by manufacturer, in lieu of welded, flanged, or threaded methods, and may also be used as unions, seismic joints, flexible connections, expansion joints, expansion compensators, or vibration reducers.
B. Coupling Housings Description: Grooved mechanical type, which engages grooved or shouldered pipe ends, encasing an elastomeric gasket which bridges pipe ends to create seal. Cast in two or more parts, secure together during assembly with nuts and bolts. Permit degree of contraction and expansion as specified in manufacturer's latest published literature. (Victaulic style 77) For rigid joints (Victaulic "Zero Flex" style 07).
1. Coupling Housings: Malleable iron conforming to ASTM A 47.
2. Coupling Housings: Ductile iron conforming to ASTM A 536.
3. Standard: Enamel coated, options hot dip galvanized.
C. Gaskets: Mechanical grooved coupling design, pressure responsive so that internal pressure serves to increase seal's tightness, constructed of elastomers having properties as designated by ASTM D 2000.
1. Water Services: EDPM Grade E, with green color code identification.
2. Other Services: As recommended by Manufacturer.
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-4
D. Bolts and Nuts: Stainless Steel.
1. Exposed Locations: Tamper resistant nuts.
E. Branch Stub-Ins: Upper housing with full locating collar for rigid positioning engaging machine-cut hole in pipe, encasing elastomeric gasket conforming to pipe outside diameter around hole, and lower housing with positioning lugs, secured together during assembly with nuts and bolts.
F. Fittings: Grooved or shouldered end design to accept grooved mechanical couplings.
1. Malleable Iron: ASTM A 47.
2. Ductile Iron: ASTM A 536.
3. Fabricated Steel: ASTM A 53, Type F for 3/4" to 1-1/2"; Type E or S, Grade B for 2" to 20".
4. Steel: ASTM A 234.
G. Flanges: Conform to Class 125 cast iron and Class 150 steel bolt hole alignment.
1. Malleable Iron: ASTM A 47.
2. Ductile Iron: ASTM A 536.
H. Grooves: Conform to the following:
1. Standard Steel: Square cut.
2. Lightweight Steel: Roll grooved.
3. Ductile Iron: Radius cut grooved, AWWA C606.
I. Manufacturer: Subject to compliance with requirements, provide grooved piping products of one of the following:
1. ITT Grinnell Corp.
2. Stockham Valves & Fittings, Inc.
3. Victaulic Co. of America.
4. Gustin-Bacon
5. Grippin.
2.5 PIPING SPECIALTIES:
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-5 A. Escutcheons: Chrome-plated, stamped steel, hinged, split-ring escutcheon, with set screw. Inside diameter shall closely fit pipe outside diameter, or outside of pipe insulation where pipe is insulated. Outside diameter shall completely cover the opening in floors, walls, or ceilings.
B. Unions: Malleable-iron, Class 150; hexagonal stock, with ball-and-socket joints, metal-to- metal bronze seating surfaces; female threaded ends unless noted otherwise.
C. Dielectric Unions: Provide dielectric unions with appropriate end connections for the pipe materials in which installed (screwed, soldered, or flanged), which effectively isolate dissimilar metals, prevent galvanic action, and stop corrosion.
D. Dielectric Waterway Fittings: electroplated steel or brass nipple, with an inert and non- corrosive, thermoplastic lining.
E. Y-Type Strainers: Provide strainers full line size of connecting piping, with ends and bodies matching piping system materials. Screens shall be Type 304 stainless steel, NPT, with a 250 micron filter disc. Amiad model T SuperPlastic filter or equal.
1. Provide strainers with 125 psi working pressure rating for low pressure applications, and 250 psi pressure rating for high pressure application.
2.6 EXPANSION JOINTS:
A. Rubber Expansion Joints: Construct of duck and butyl rubber with full-faced integral flanges, internally reinforced with steel retaining rings. Provide steel retaining rings over entire surface of flanges, drilled to match flange bolt holes, and provide external control rods.
B. Expansion Joints for Grooved Piping: Provide expansion joints constructed of cut grooved short pipe nipples and couplings, designed by manufacturer to suit intended service. Select couplings and gasket materials to match balance of piping system.
2.7 FLEXIBLE CONNECTORS:
A. Kevlar reinforced EPDM rubber with 150# stainless steel flanges. Connector shall have a minimum pressure rating of 125 psi at 170¼F, unless noted otherwise on the drawings. Product shall be Metraflex¨ Single MightySphereTM or equal. Connector shall allow for a minimum movement as shown below:
Angular Joint Size ID (in) Compression Elongation Lateral (Degrees)
2 1/2 3/16 3/8 15 2-1/2 1/2 3/16 3/8 15 3 1/2 3/16 3/8 15 4 5/8 3/16 3/8 15 5 5/8 3/16 3/8 15 6 5/8 3/16 3/8 15 8 5/8 3/16 3/8 15 10 3/4 1/4 1/2 15 12 3/4 1/4 1/2 15
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-6
2.8 MISCELLANEOUS PIPING MATERIALS/PRODUCTS:
A. Welding Materials: Except as otherwise indicated, provide welding materials as determined by Installer to comply with installation requirements.
Comply with Section II, Part C, ASME Boiler and Pressure Vessel Code for welding materials.
B. Soldering Materials: Except as otherwise indicated, provide soldering materials as determined by Installer to comply with installation requirements. Use no lead bearing solders in domestic water applications.
Tin-Antimony Solder: ASTM B 32, Grade 95TA.
Silver-Lead Solder: ASTM B 32, Grade 96TS.
C. Brazing Materials: Except as otherwise indicated, provide brazing materials as determined by Installer to comply with installation requirements.
D. Comply with SFA-5.8, Section II, ASME Boiler and Pressure Vessel Code for brazing filler metal materials.
E. Strainer: Strainer shall be NPT, Amiad model T Super Plastic Filter or equal. Mesh size shall be as indicated in the equipment schedules.
F. Gaskets For Flanged Joints: ANSI B16.21; full-faced for flat-faced flanges; ring type for raised face flanges, unless otherwise indicated.
G. Piping Connectors For Dissimilar Non-Pressure Pipe: Elastomeric annular ring insert, or elastomeric flexible coupling secured at each end with stainless steel clamps, sized for exact fit to pipe ends and subject to approval by plumbing code.
1. Acceptable Manufacturers: Subject to compliance with requirements, provide piping connectors of the following:
a. Fernco, Inc. b. Mission. c. Or equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: Install pipes and pipe fittings in accordance with recognized industry practices which will achieve permanently- leakproof piping systems, capable of performing each indicated service without piping failure. Install each run with minimum joints and couplings, but with adequate and accessible union, flanges, etc., for disassembly and maintenance/replacement of valves and equipment. Reduce sizes (where indicated) by use of reducing fittings. Align piping accurately at connections, within 1/16" misalignment tolerance. Do not cold spring. Store filler weld materials in accordance with codes.
Comply with ANSI B31 Code for Pressure Piping.
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-7
B. Locate piping runs, except as otherwise indicated, vertically and horizontally (pitched to drain) and avoid diagonal runs wherever possible. Orient horizontal runs parallel with walls and column lines. Locate runs as shown or described by diagrams, details and notations or, if not otherwise indicated, run piping in shortest route which does not obstruct usable space or block access for servicing building and its equipment. Hold piping close to walls, overhead construction, columns and other clearance to 1/2" where furring is shown for enclosure or concealment of piping, but allow for insulation thickness, if any. Where possible, locate insulated piping for 1" clearance outside insulation. Wherever possible in finished and occupied spaces, conceal piping from view, by locating in column enclosures, in hollow wall construction or above suspended ceilings; do not encase horizontal runs in solid partitions, except as indicated. Provide high point vents, low point drains with valves and extension to drain for all piping.
C. All piping in press room, mechanical rooms, fan rooms, etc., shall be exposed. Do not conceal or imbed piping in walls, floors or other structures.
D. Make changes in direction or size with manufactured fittings. Anchor and support piping for free expansion and movement without damage to piping, equipment or to building.
E. Piping shall be arranged to maintain head room and keep passageways clear.
F. Provide unions at connections to equipment and elsewhere as required to facilitate maintenance.
G. Run full pipe size through shutoff valves, gas cocks, balancing valves, etc. Change pipe size within three pipe size diameters of final connection to equipment, coils, etc.
H. All piping shall be erected to insure proper draining. Air or gas piping shall pitch down in the direction of flow a minimum of 1" per 40 feet unless noted otherwise on the drawings. Domestic water and utility water shall slope down a minimum of 1" per 40 feet towards the drain (low point). Refrigerant suction line shall slope a minimum of 1" per 10 feet towards compressor. Soil, waste, vent, and roof drain lines shall slope in accordance with requirements of Uniform Plumbing Code.
I. Install drains at low points in mains, risers, and branch lines consisting of a tee fitting, 3/4" ball valve, and short 3/4" threaded nipple and cap.
J. Exterior Wall Penetrations: Seal pipe penetrations through exterior walls using sleeves and mechanical sleeve seals. Pipe sleeves smaller than 6" shall be steel; pipe sleeves 6" and larger shall be sheet metal. All sleeves shall be Schedule 40 unless noted otherwise.
K. Fire Barrier Penetrations: Where pipes pass through fire rated walls, partitions, ceilings, or floors, the fire rated integrity shall be maintained.
L. Use fittings for all changes in direction and all branch connections.
M. Install strainers on the supply side of each control valve, pressure reducing or regulating valve, solenoid valve, and elsewhere as indicated.
N. Install unions adjacent to each valve, and at the final connection to each piece of equipment and plumbing fixture having 2" and smaller connections, and elsewhere as indicated.
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-8
O. Install Flanges in piping 2-1/2" and larger, where indicated, adjacent to each valve, and at the final connection to each piece of equipment.
P. Install dielectric unions to connect piping materials of dissimilar metals in dry piping systems (gas, compressed air).
Q. Install dielectric fittings to connect piping materials of dissimilar metals in wet piping systems (water). Insulating fittings are not required between bronze valves and steel pipe or between copper coil headers and steel pipe.
R. Electrical Equipment Spaces: Do not run piping in or through, electrical room, transformer vaults and other electrical or electronic equipment spaces and enclosures or above electrical gear unless authorized and directed. Install drip pan under piping that must be run through electrical spaces.
3.2 EXPANSION AND CONTRACTION
A. Make all necessary provisions for expansion and contraction of piping.
B. Use grooved joint couplings, expansion compensators, offsets or loops as required to prevent undue strain.
C. At piping connection to heat exchangers provide expansion (joint) as shown on drawings.
3.3 FLEXIBLE CONNECTORS:
A. At pumps, engines and at all rotating or vibrating pieces of equipment, provide and install flexible connectors to accommodate alignment and vibration.
B. At engines provide and install flexible connectors.
3.4 PROTECTIVE COATINGS
A. All underground steel pipes shall be wrapped with Scotchwrap No. 50 tape to give not less than two complete layers on the underground piping system, or piping shall have "X-tru Coat", factory applied plastic protective covering, or pipe shall be coated and wrapped with coal tar enamel and Kraft paper, all with coated and taped joints.
3.5 PIPING SYSTEM JOINTS
A. General: Provide joints of type indicated in each piping system.
B. Threaded: Thread pipe in accordance with ANSI B2.1; cut threads full and clean using sharp dies. Ream threaded ends to remove burrs and restore full inside diameter. Apply pipe joint compound, or pipe joint tape (Teflon) where recommended by pipe/fitting manufacturer, on male threads at each joint and tighten joint to leave not more than 3 threads exposed.
C. Brazed: Braze copper tube-and-fitting joints where indicated, in accordance with ASME B31.
D. Soldered: Solder copper tube-and-fitting joints where indicated, in accordance with recognized industry practice. Cut tube ends squarely, ream to full inside diameter, and clean outside of
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-9 tube ends and inside of fittings. Apply solder flux to joint areas of both tubes and fittings. Insert tube full depth into fitting, and solder in manner which will draw solder full depth and circumference of joint. Wipe excess solder from joint before it hardens.
E. Welded:
1. Weld pipe joints in accordance with ASME Code for Pressure Piping, B31.
2. Weld pipe joints in accordance with recognized industry practice and as follows:
3. Weld pipe joints only when ambient temperature is above 0oF (-18oC) where possible, with minimum pipe preheat to 50oF.
4. Bevel pipe ends at a 37.5o angle where possible, smooth rough cuts, and clean to remove slag, metal particles and dirt.
5. Use pipe clamps or tack-weld joints with 1" long welds; 4 welds for pipe sizes to 10", 8 welds for pipe sizes 12" to 20".
6. Build up welds with stringer-bead pass, followed by hot pass, followed by cover or filler pass. Eliminate valleys at center and edges of each weld. Weld by procedures which will ensure elimination of unsound or unfused metal, cracks, oxidation, blow-holes and non-metallic inclusions.
7. Do not weld-out piping system imperfections by tack-welding procedures; refabricate to comply with requirements.
8. At Installer's option, install forged branch-connection fittings wherever branch pipe is indicated; or install regular "T" fitting.
9. At Installer's option, install forged branch-connection fittings wherever branch pipe of size smaller than main pipe is indicated; or install regular "T" fitting.
F. Flanged Joints: Match flanges within piping system, and at connections with valves and equipment. Clean flange faces and install gaskets. Tighten bolts to provide uniform compression of gaskets.
G. Hubless Cast-Iron Joints: Comply with coupling manufacturer's installation instructions.
H. Plastic Pipe/Tube Joints: Comply with manufacturer's instructions and recommendations, and with applicable industry standards:
1. Heat Joining of Thermoplastic Pipe: ASTM D 2657.
2. Making Solvent-Cemented Joints: ASTM D 2235, and ASTM F 402.
I. Grooved Pipe Joints: Comply with fitting manufacturer's instructions for making grooves in pipe ends. Remove burrs and ream pipe ends. Assemble joints in accordance with manufacturer's instructions.
3.6 CLEANING, FLUSHING, INSPECTING:
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-10 A. General: Clean exterior surfaces of installed piping systems of superfluous materials, and prepare for application of specified coatings (if any). Flush out piping systems with clean water before proceeding with required tests. Inspect each run of each system for completion of joints, supports and accessory items.
1. Inspect pressure piping in accordance with procedures of ASME B31 and Section 221066, “Pipeline Testing”.
B. Disinfect water mains and water service piping in accordance with AWWA C601.
END OF SECTION 220050
WRCRWA GENERAL PIPES AND FITTINGS PLANT EXPANSION PROJECT 220050-11 SECTION 220513 – COMMON MOTOR REQUIREMENTS FOR EQUIPMENT
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This Section includes AC induction electric motors to be provided with associated driven equipment. Motor voltage, speed and enclosures are specified in the equipment specifications. Unless otherwise specified, motors shall be provided by the manufacturer of the driven equipment under the provisions of the individual equipment specification.
1.2 MOTOR RATING
A. Motor horsepower ratings as shown on the drawings and noted on the specifications are estimates only and it is the responsibility of the CONTRACTOR and/or VENDOR to furnish motors, electric circuits, power feeds and other equipment whose ratings meet the requirements for the submitted horsepower and amperage.
B. This section applies to electric motors rated 480 V and below.
1.3 CODE AND STANDARDS
A. Electrical Code Compliance: Comply with applicable local electrical code requirements of the authority having jurisdiction and NEC Articles 220, 250, and 430, as applicable to installation, and construction of motor controllers.
B. AFBMA Compliance: Comply with applicable requirements of AFBMA 9 & 11, "Load Rating and Fatigue Life for Ball and Roller Bearings."
C. UL Compliance: Comply with applicable requirements of UL 674, “Electric Motors and Generators, for Use in Division 1 Hazardous (Classified) Locations” and UL 1004, “Electric Motors”.
D. IEEE Compliance: Comply with recommended practices contained in IEEE Standard 112, "Standard Test Procedures for Polyphase Induction Motors and Generators," and IEEE Standard 841, “Standard for Petroleum and Chemical Industry – Totally Enclosed Fan Cooled (TEFC) Squirrel Cage Induction Motors – Up to and Including 500 HP”.
E. NEMA Compliance: Comply with applicable requirements of NEMA Standard ICS 2, "Industrial Control Devices, Controllers and Assemblies", NEMA Standard ICS 6, “Enclosures for Industrial Controls and Systems, ”Pub No. 250, "Enclosures for Electrical Equipment (1000 Volts Maximum)" and NEMA MG 1, “Motors and Generators”.
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 1
1.4 MAINTENANCE DATA
A. Submit maintenance data and parts list for each motor and auxiliary component; including troubleshooting maintenance guide. Also, provide product data and shop drawings in a maintenance manual, in accordance with requirements of the Contract Documents.
1.5 SUBMITTALS
A. Product Data: Submit manufacturer's data and installation instructions for each motor in accordance with the individual equipment specification and Section 013300. As a minimum, the following information shall be provided:
1. Manufacturer name, type and model number 2. Motor outline, dimensions and weight 3. Manufacturer’s general descriptive information relative to motor features 4. Type of bearing and method of lubrication 5. Rated size of motor and service factor 6. Temperature rise and insulation rating 7. Full-load rotative speed 8. Efficiency at full, ¾ and ½ load 9. Full load current 10. Locked-rotor current 11. Space heater wattage and voltage, if applicable 12. If a winding overtemperature device is required, provide a response curve for the temperature device, wiring diagram and specifications 13. If a moisture detection system is required, provide a typical wiring diagram and a moisture detection relay to be installed by the CONTRACTOR or VENDOR in the associated motor controller.
B. Shop Drawings: Submit shop drawings of electric motors showing accurately scaled equipment locations and spatial relationships to associated drive equipment.
C. Wiring Diagrams: Submit power and control wiring diagrams for electric motors showing connections to electrical power panels, feeders, and equipment.
D. Operations and Maintenance Data: Submit operation and maintenance information as required by Section 017823.
PART 2 - PRODUCTS
2.1 GENERAL
A. Except as otherwise indicated, provide electric motors and ancillary components that comply with manufacturer's standard materials, design and construction in accordance with published product information, and as required for a complete installation.
2.2 SERVICE CONDITIONS
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 2
A. Unless specified otherwise, motors shall be suitable for continuous operation at an elevation of 0 to 5200 feet above mean sea level.
B. Unless specified otherwise, motors located outdoors shall be suitable for continuous operation from -25 to 50¡C; motors located indoors shall be suitable for continuous operation from 0 to 50¡C.
C. All motors shall be able to operate under power supply variations in accordance with NEMA MG 1 – 14.30.
2.3 NAMEPLATES
A. Motor nameplates shall be engraved or stamped stainless steel. Information shall include those items as enumerated in NEMA Standard MG 1, as applicable. Nameplates shall be permanently fastened to the motor frame and shall be visibly positioned for inspection.
2.4 CONSTRUCTION
A. All motors provided under this specification shall have the following features of construction:
1. Frames shall be steel for motors smaller than ½ horsepower and cast iron for motors ½ horsepower and larger. 2. Cast metal shrouds and covers for non-sparking fan blades. 3. Non-hygroscopic motor leads. 4. NEMA Design-B as standard design. Other designs if required must be submitted and approved in writing by the ENGINEER. 5. Motor Service Factor of 1.15 for Sine-Wave and 1.0 for Inverter Duty. 6. Grounding terminal 7. Windings shall be copper 8. Rotor cages shall be die cast aluminum or fabricated copper 9. Shafts shall be made from carbon steel.
2.5 MOTORS LESS THAN ½ HORSEPOWER
A. General:
1. Unless specified otherwise, motors less than ½ horsepower shall be squirrel cage, single phase, capacitor start, induction run type. 2. Single phase motors shall have class B insulation as a minimum. 3. Motors for fans less than 1/8 horsepower may be split-phase or shaded pole type. 4. Winding shall be copper.
B. Rating:
1. Unless specified otherwise, motors less than ½ horsepower shall be rated for operation at 115 volts, single phase, 60 Hz, and shall be continuous-time rated in conformance with NEMA Standard MG 1 – 10.35.
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 3
2. Dual voltage (115/230) rated motors are acceptable if all leads are brought out to the conduit box. 3. Motors shall be non-overloading at all points of the equipment operation.
2.6 MOTORS ½ HORSEPOWER AND LARGER
A. General:
1. Unless specified otherwise, motors ½ horsepower and larger shall be 3 phase, squirrel cage, full voltage start induction type. 2. Unless otherwise specified, motors shall have a NEMA MG 1-1.16 design letter B or C torque characteristic as required by the driven equipment’s starting torque requirement. 3. Winding shall be copper. 4. Motors shall be equipped with a set of thermal overload switches with dry contacts available at the motor terminal box:
B. Rating:
1. Unless specified otherwise, motors ½ horsepower and larger shall be rated for operation at 460 volts, 3 phase, 60 Hz, and shall be continuous-time rated in conformance with NEMA Standard MG 1 – 10.35. 2. Dual voltage (230/460) rated motors are acceptable if all leads are brought out to the conduit box. 3. Motors for variable frequency systems shall not be required to deliver more than 80% of the motor’s service factor rating by any load imposed by the driven machine at any specified operating condition or any condition imposed by the driven machine’s performance curve at maximum operating speed.
C. Enclosures and Insulation:
1. Motors shall be classified as Type 1 (Process) or Type 2 (Explosion proof) based upon the location of the motor and the associated area classification. 2. Temperature rise for all motors shall not exceed that permitted by Note II, Paragraph 12.42 of NEMA MG 1. 3. Motor Insulation shall be non-hygroscopic. 4. Type 1 motors (Process):
a. Type 1 motors shall be premium energy-efficient motors, totally enclosed, fan cooled (TEFC) b. All motors shall have Class H insulation with Class B temperature rise. c. All internal surfaces shall be coated with an epoxy paint. d. Motors shall be rated for corrosive atmosphere duty.
5. Type 2 Motors (Explosion Proof):
a. Explosion proof motors shall be UL listed in accordance with UL 674 for Class I, Group D hazardous atmospheres. b. The motor shall have Class H insulation.
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 4
c. A UL-approved Type 316 stainless steel breather/drain device shall be provided in the motor drain hole. d. The motor shall be provided with a frame temperature thermostat which meets the UL frame temperature limit code T2A (280¡C). The thermostat shall contain an automatically reset, normally closed contact rated 2 amperes at 230 VAC.
2.7 MOTORS FOR VARIABLE FREQUENCY DRIVES
A. Motors intended for use with variable frequency drives shall be compatible with the characteristics of the intended variable frequency inverter.
B. Motors shall be Type 1 or Type 2 as specified in 2.06C.
C. Motors shall be capable of withstanding a pulse voltage of at least 1750 volts with a rate of rise up to 750V per microsecond.
D. Motors shall be certified by the manufacturer as suitable for inverter duty and shall have as a minimum a 10:1 turndown ratio (6-60Hz).
E. Motors shall be capable of running above the rated RPM up to 70 Hz (116.67% of rated RPM) so long as the load current does not exceed the full load amps of the motor.
2.8 MOTOR EFFICIENCIES
A. Type 1 and Type 2 motors in accordance with NEMA MG 1 Table 12-11 and 12-12 and Type 2 in accordance with IEEE 841 Table 2 motor minimum nameplate efficiency for 900, 1200 and 1800 rpm motors, when operating on a sinusoidal power source shall conform to the following (in accordance with IEEE 112B testing procedures):
Motor Guaranteed Minimum Efficiency (%) Horsepower 900 RPM 1200 RPM 1800 RPM 1 70.0% 78.5% 81.5% 1.5 72.0% 81.5% 82.5% 2 80.0% 81.5% 82.5% 3 81.5% 86.5% 84.0% 5 82.5% 86.5% 84.0% 7.5 82.5% 88.5% 88.5% 10 86.5% 88.5% 88.5% 15 86.5% 89.5% 89.5% 20 87.5% 90.2% 91.7% 25 87.5% 91.0% 91.7% 30 89.5% 91.0% 91.7% 40 89.5% 92.4% 92.4% 50 90.2% 92.4% 92.4%
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 5
60 90.2% 93.0% 93.0% 75 91.7% 93.0% 93.6% 100 91.7% 93.6% 94.1% 125 92.4% 93.6% 94.1% 150 92.4% 94.5% 94.5% 200 92.4% 94.5% 94.5% 250 93.6% 94.1% 94.1%
2.9 CONDUIT BOXES
A. Conduit boxes shall be sized based on the conduit number and conduit size indicated on the drawings. Provide over-sized boxes with the number of openings as required to accommodate the conduits required.
B. Conduit boxes shall be split construction with threaded hubs and shall conform to IEEE 841 for Type 1 and Type 2 motors. Motors shall be furnished with petroleum-resistant gaskets at the base of the conduit box and between the halves of the conduit box.
C. Conduit boxes shall be designed to rotate in order to permit installation in any of four positions 90 degrees apart.
2.10 BEARINGS
A. Bearings may be oil or grease lubricated ball or angle contact roller bearing rated for a minimum L-10 life of 100,000 hours in accordance with ABMA 9 or 100 at the ambient temperature specified. Motor designs employing cartridge type bearings will not be accepted. Bearings shall be fitted with lubricant fill and drain or relief fittings. Belt loads shall not exceed forces calculated from NEMA MG 1 Table 14-1.
2.11 LIFTING EYES
A. Motors weighing more than 50 pounds shall be fitted with at least one lifting eye and motors weighing over 150 pounds shall be fitted with two lifting eyes.
2.12 SPACE HEATERS
A. Motors that are located outdoors shall be equipped with Space Heaters to prevent condensation inside the motor enclosure after motor shutdown and maintain the temperature of the windings at not less than 5¡C above outside ambient temperature.
B. Heaters shall be flexible wraparound type rated 120 volts, single phase, 60 Hz unless otherwise noted. The space heater rating in watts and volts shall be noted on the motor nameplate or on a second nameplate. Space heater leads H1 and H2 shall be brought to a separate terminal block or pigtails in the motor conduit box or separate conduit box with a threaded conduit opening.
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 6
PART 3 - EXECUTION
A. Install electric in accordance with equipment manufacturer's written instructions, and with recognized industry practices. Comply with applicable requirements of NEC, UL, and NEMA standards, to insure that products fulfill requirements.
B. Tighten connectors and terminals, including screws and bolts, in accordance with equipment manufacturer's published torque values for equipment connectors. Where manufacturer's torque requirements are not indicated, tighten connectors and terminals to comply with tightening torques specified in UL Standards 486A and B, and the National Electrical Code.
C. Ensure that the motor is properly grounded from the incoming motor leads and that the frame is bonded to the grounding electrode system.
D. Verify breather/drain fittings have been installed as specified.
E. Prior to energizing, check circuitry for electrical continuity, and for short-circuits. Winding insulation resistance for motors shall not be less than 10-megohms measured with a 1000-VAC megohmeter at 1-minute at or corrected to 40¡C.
F. Check rotation of each motor for proper direction.
G. Upon completion of installation of motor controller equipment and electrical circuitry, energize controller circuitry and demonstrate functioning of equipment in accordance with requirements.
END OF SECTION 220513
WRCRWA COMMON MOTOR REQUIREMENTS FOR EQUIPMENT PLANT EXPANSION PROJECT 220513 - 7
SECTION 220517 - SLEEVES AND SLEEVE SEALS FOR PIPING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Sleeves. 2. Sleeve-seal systems.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
PART 2 - PRODUCTS
2.1 SLEEVES
A. Cast-Iron Wall Pipes: Cast or fabricated of cast or ductile iron and equivalent to ductile-iron pressure pipe, with plain ends and integral waterstop unless otherwise indicated.
B. Galvanized-Steel Wall Pipes: ASTM A 53/A 53M, Schedule 40, Grade A, with plain ends and welded steel collar; zinc coated. Hot dip galvanize after fabrication.
C. Galvanized-Steel-Pipe Sleeves: ASTM A 53/A 53M, Type E, Grade B, Schedule 40, zinc coated, with plain ends. Hot dip galvanize after fabrication.
D. PVC-Pipe Sleeves: ASTM D 1785, Schedule 40.
2.2 SLEEVE-SEAL SYSTEMS
A. Description: Modular sealing-element unit, designed for field assembly, for filling annular space between piping and sleeve.
1. Sealing Elements: EPDM-rubber interlocking links shaped to fit surface of pipe. Include type and number required for pipe material and size of pipe. 2. Connecting Bolts and Nuts: 316 Stainless Steel of length required to secure pressure plates to sealing elements.
B. Acceptable Manufacturers:
1. Link Seal 2. Or equal.
WRCRWA SLEEVES AND SLEEVE SEALS FOR PIPING PLANT EXPANSION PROJECT 220517 - 1 PART 3 - EXECUTION
3.1 SLEEVE INSTALLATION
A. Install sleeves for piping passing through penetrations in floors, partitions, roofs, and walls.
B. For sleeves that will have sleeve-seal system installed, select sleeves of size large enough to provide 1-inch annular clear space between piping and concrete slabs and walls.
1. Sleeves are not required for core-drilled holes.
C. Install sleeves in concrete floors, concrete roof slabs, and concrete walls as new slabs and walls are constructed.
1. Cut sleeves 1 inch longer than penetration through floors.
2. Use foam and polyurethane caulk to seal space between pipe and sleeve.
D. Install sleeves for pipes passing through interior partitions.
1. Size sleeve for pipe and link seal. 2. Cut sleeves to length for mounting flush with both surfaces. 3. Install sleeves that are large enough to provide 1/4-inch annular clear space between sleeve and pipe or pipe insulation. 4. Seal annular space between sleeve and piping or piping insulation; use joint sealants appropriate for size, depth, and location of joint. Comply with requirements for sealants specified in Section 079200 "Joint Sealants."
3.2 SLEEVE-SEAL-SYSTEM INSTALLATION
A. Install sleeve-seal systems in sleeves in exterior concrete walls and slabs-on-grade at service piping entries into building.
B. Select type, size, and number of sealing elements required for piping material and size and for sleeve ID or hole size. Position piping in center of sleeve. Center piping in penetration, assemble sleeve-seal system components, and install in annular space between piping and sleeve. Tighten bolts against pressure plates that cause sealing elements to expand and make a watertight seal.
END OF SECTION 220517
WRCRWA SLEEVES AND SLEEVE SEALS FOR PIPING PLANT EXPANSION PROJECT 220517 - 2 SECTION 220518 - ESCUTCHEONS FOR PIPING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Escutcheons. 2. Floor plates.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
PART 2 - PRODUCTS
2.1 ESCUTCHEONS
A. One-Piece, Cast-Brass Type: With polished, chrome-plated finish and setscrew fastener.
B. One-Piece, Deep-Pattern Type: Deep-drawn, box-shaped brass with chrome-plated finish and spring-clip fasteners.
C. One-Piece, Stamped-Steel Type: With chrome-plated finish and spring-clip fasteners.
2.2 FLOOR PLATES
A. One-Piece Floor Plates: Cast-iron flange with holes for fasteners.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install escutcheons for piping penetrations of walls, ceilings, and finished floors.
B. Install escutcheons with ID to closely fit around pipe, tube, and insulation of piping and with OD that completely covers opening.
1. Escutcheons for New Piping:
a. Piping with Fitting or Sleeve Protruding from Wall: One-piece, deep-pattern type.
WRCRWA ESCUTCHEONS FOR PIPING PLANT EXPANSION PROJECT 220518 - 1
b. Chrome-Plated Piping: One-piece, cast-brass type with polished, chrome-plated finish. c. Insulated Piping: One-piece, stamped-steel type. d. Bare Piping at Wall and Floor Penetrations in Finished Spaces: One-piece, cast- brass type with polished, chrome-plated finish. e. Bare Piping at Wall and Floor Penetrations in Finished Spaces: One-piece, stamped-steel type. f. Bare Piping at Ceiling Penetrations in Finished Spaces: One-piece, cast-brass type with polished, chrome-plated finish. g. Bare Piping at Ceiling Penetrations in Finished Spaces: One-piece, stamped-steel type. h. Bare Piping in Unfinished Service Spaces: One-piece, cast-brass type with polished, chrome-plated finish. i. Bare Piping in Unfinished Service Spaces: One-piece, stamped-steel type. j. Bare Piping in Equipment Rooms: One-piece, cast-brass type with polished, chrome-plated finish. k. Bare Piping in Equipment Rooms: One-piece, stamped-steel type.
C. Install floor plates for piping penetrations of equipment-room floors.
D. Install floor plates with ID to closely fit around pipe, tube, and insulation of piping and with OD that completely covers opening.
1. New Piping: One-piece, floor-plate type.
3.2 FIELD QUALITY CONTROL
A. Replace broken and damaged escutcheons and floor plates using new materials.
END OF SECTION 220518
WRCRWA ESCUTCHEONS FOR PIPING PLANT EXPANSION PROJECT 220518 - 2
SECTION 220519 – METERS AND GAUGES
PART 1 - GENERAL
1.1 RELATED DOCUMENTS:
A. Drawings and general provisions of Contract, including General and Special Conditions and Technical Specification sections, apply to work of this section.
1.2 DESCRIPTION OF WORK:
A. Extent of meters and gauges required by this section is indicated on drawings and/or specified in other Division-22 sections.
B. Types of gauges specified in this section include the following:
1. Temperature Gauges and Fittings.
a. Glass Thermometers. b. Thermometer Wells. c. Temperature Gauge Connector Plugs.
2. Pressure Gauge and Fittings.
a. Pressure Gauges. b. Pressure Gauge Cocks. c. Pressure Gauge Connector Plugs. d. Pressure Sensors.
3. Installation of magnetic flow meters, sensor and water flow meters, sensors, wells, etc., furnished by Division 16.
1.3 QUALITY ASSURANCE:
A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of meters and gauges, of types and sizes required, whose products have been in satisfactory use in similar service.
1.4 CODES AND STANDARDS:
A. UL Compliance: Comply with applicable UL standards pertaining to meters and gauges.
B. ANSI and ISA Compliance: Comply with applicable portions of ANSI and Instrument Society of America (ISA) standards pertaining to construction and installation of meters and gauges.
C. Certification: Provide meters and gauges whose accuracies, under specified operating conditions, are certified by manufacturer.
1.5 SUBMITTALS:
A. Product Data: Submit manufacturer's technical product data, including installation
WRCRWA METERS AND GAUGES PLANT EXPANSION PROJECT 220519-1
instructions for each type of meter and gauge. Include scale range, ratings and calibrated performance curves, certified where indicated. Submit meter and gauge schedule showing manufacturer's figure number, scale range, location, and accessories for each meter and gauge.
PART 2 - PRODUCTS
2.1 PRESSURE GAUGES:
A. General: Provide pressure gauges of materials, capacities, and ranges indicated, designed and constructed for use in service indicated.
B. Type: General use, 1% of ANSI B40.1 grade A, phospher bronze bourdon type, bottom connection.
C. Case: Brass or phenolic case, glass lens, 4-1/2" diameter.
D. Connector: Brass with 1/4" male NPT. Provide pressure snubber.
E. Scale: White coated aluminum, with permanent etched markings.
F. Range: Conform to the following:
1. Water: 0 - 100 psi.
2. Compressed Air: 0 - 200 psi.
G. Available Manufacturers: Subject to compliance with requirements, manufacturers offering pressure gauges which may be incorporated in the work are:
1. Ametek/U.S. Gauge 2. Marsh Instrument Co.; Unit of General Signal. 3. Marshalltown Instruments, Inc. 4. Trerice (H.O.) Co. 5. Weiss Instruments, Inc. 6. Weksler.
2.2 PRESSURE GAUGE COCKS:
A. General: Provide pressure gauge cocks between pressure gauges and gauge tees on piping systems. Construct gauge cock shall be bar stock needle valve Trerice No. 735 or a full ported ball valve.
B. Snubber: 1/4" brass bushing with corrosion resistant porous metal disc, through which pressure fluid is filtered. Select disc material for fluid served and pressure rating. C. Manufacturer: Same as for pressure gauges.
2.3 PRESSURE GAUGE CONNECTOR PLUGS:
A. General: Provide pressure gauge connector plugs pressure rated for 500 psi and 200 degrees F (93 degrees C). Construct of brass and finish in nickel-plate, equip with 1/2" NPS fitting, with self-sealing valve core type neoprene gasketed orifice suitable for inserting 1/8" O.D. probe assembly from dial type insertion pressure gauge.
WRCRWA METERS AND GAUGES PLANT EXPANSION PROJECT 220519-2
Equip orifice with gasketed screw cap and chain. Provide extension, length equal to insulation thickness, for insulated piping.
B. Manufacturer: Subject to compliance with requirements, provide pressure gauge connector plugs of one of the following:
1. Peterson Equipment Co.
2. Sisco.
2.4 PRESSURE SLEEVE SENSORS:
A. Pressure sensors shall be sensed by a flexible sleeve contained in a flanged stainless steel spool or wafer body, and transmitted to the gauge through a captive fluid. The sleeve shall be of Buna N and fabricated so as to isolate the body from the process liquid. B. Gauges shall be calibrated to read in applicable units, with an accuracy of ± 1 percent, to 150 percent of the working pressure of the system to which they are connected. C. Series 40 Manufacturer, or Equal: Red Valve Company, Inc.;
PART 3 - EXECUTION
3.1 INSPECTION:
A. Examine areas and conditions under which meters and gauges are to be installed.
3.2 INSTALLATION OF PRESSURE GAUGES:
A. General: Install pressure gauges in piping tee with pressure gauge cock, located on pipe at most readable position.
B. Locations: As shown on the drawings.
C. Pressure Gauge Cocks: Install in piping tee with snubber.
D. Pressure Gauge Connector Plugs: Install in piping tee where indicated, located on pipe at most readable position. Secure cap.
3.3 ADJUSTING AND CLEANING:
A. Adjusting: Adjust faces of meters and gauges to proper angle for best visibility.
B. Cleaning: Clean windows of meters and gauges and factory-finished surfaces. Replace cracked or broken windows, repair any scratched or marred surfaces with manufacturer's touch-up paint.
END OF SECTION 220519
WRCRWA METERS AND GAUGES PLANT EXPANSION PROJECT 220519-3
SECTION 220523 – VALVES
PART 1 - GENERAL
1.1 SCOPE:
A. Furnish and install all valves complete and in accordance to the requirements of the Contract Documents.
1.2 SUBMITTALS:
A. Product Data: Submit manufacturer's technical product data, including installation instructions for each type of valve. Include pressure drop curve or chart for each type and size of valve.
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings for each type of valve, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of valve. Include this data, product data, shop drawings in maintenance manual; in accordance with requirements of Division 1.
1.3 QUALITY ASSURANCE:
A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of valves, of types and sizes required, whose products have been in satisfactory use in similar service.
B. Valve Types: Provide valves of same type by same manufacturer.
C. Valve Identification: Provide valves with manufacturer's name (or trademark) and pressure rating clearly marked on valve body.
D. Codes and Standards:
1. MSS Compliance: Mark valves in accordance with MSS-25 "Standard Marking System for Valves, Fittings, Flanges and Unions". 2. ANSI Compliance: For face-to-face and end-to-end dimensions of flanged- or welded-end valve bodies, comply with ANSI B16.10 "Face-to-Face and End-to-End Dimensions of Ferrous Valves".
PART 2 - PRODUCT
2.1 ECCENTRIC PLUG VALVES
A. All plug valves shall be of the tight-closing, resilient faced plug type and shall be of bi- directional eccentric seating such that the opening movement of the closing member results in the closing member rising off the body seat contact.
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-1 B. Valve bodies shall be constructed of cast iron ASTM A-48 Class 40. Flanges shall be faced and drilled in accordance with ANSI B16.1
C. Plug valves shall be furnished with permanently lubricated, sleeve type metallic bearings. Grit excluder seals shall be provided in the upper and lower journals to isolate the bearings.
D. Plug valve shaft seals shall be the self-adjusting type, replaceable without removing the valve bonnet.
E. Manual gear actuators shall be totally enclosed worm and gear type permanently lubricated. Above ground valves 6" and larger shall be provided with gear actuators. Buried valves 4" and larger shall be provided with gear actuators.
F. Available Manufacturers: Subject to compliance with requirements, manufacturers offering eccentric plug valves which may be incorporated into the work are:
1. Dezurik 2. ValMatic 3. Pratt 4. Or equal.
G. Valve Actuators: Actuators shall be noted on the plans. Actuators shall be electric On-Off type with a corrosion resistant NEMA 4X die cast aluminum housing and cover, powder polyurethane coated, stainless steel fasteners, 8,600 in-lbs torque capability (or as required depending on valve size, type, and stem length) self-locking EPI-Cyclical gear train; no brake required, standard manual override with handwheel; manual override can be operated with any lever, clutch or brake upon power outage, visual position indicator, and a 120 VAC power supply. The actuator shall come fully tested and ready for installation. Mounting kits shall be provided.
2.2 STAINLESS STEEL PLUG VALVES
A. All plug valves that are indicated as stainless steel in the valve schedule shall have a body constructed of 316 stainless steel, ASTM A2216 Grade CF-8M.
B. The bearings, bonnet and bonnet screws shall be 316 stainless steel. The plug shall be of the same material as the body.
C. Valves shall DeZurik/APCO PEC Eccentric plug valves or equal.
2.3 AIR/VACUUM RELEASE VALVES
A. Valves shall be manufactured and tested in accordance with AWWA Standard C512.
B. The valve body shall be threaded with NPT inlets and outlets. The body inlet connection shall be hexagonal for a wrench connection.
C. The valve shall have two additional NPT connections for the additions of gauges, testing, and draining.
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-2 D. The cover shall be bolted to the valve body and sealed with a flat gasket. Resilient seats shall be replaceable and provide drop tight shut off to the full valve pressure rating.
E. Floats shall be unconditionally guaranteed against failure including pressure surges. Mechanical linkage shall provide sufficient mechanical advantage so that the valve will open under full operating pressure. Simple lever designs shall consist of a single pivot arm and a resilient orifice button.
F. The valve body and cover shall be constructed of ASTM A126 Class B cast iron for working pressures up to 300 psig.
G. The orifice, float and linkage mechanism shall be constructed of Type 316 stainless steel. Non- metallic floats or linkage mechanisms are not acceptable. The orifice button shall be Viton for simple lever valves and Buna-N for compound lever designs.
H. The exterior of the valve shall be coated with a universal alkyd primer.
I. Valves installed in low pressure applications (e.g. less than 5 PSI operating pressure) shall be factory tested to ensure proper operation and complete sealing at the low operating pressure. Where required, a soft seat shall be provided for the float to prevent leaking in low pressure installations. Refer to the valve schedule and pump schedules for specific low pressure installation locations.
J. Available manufacturers: 1. ValMatic, 2. Or Equal,
2.4 PROCESS AIR BUTTERFLY VALVES
A. Butterfly valves shall be two-piece stem K-LOK butterfly valves, Keystone Series 36 (lug styles) or equal.
B. Valves body shall be constructed of ASTM A351-CF8M stainless steel. The valve disc, seat retainer ring, anti-extrusion ring, bottom cover plate and disc location spacer shall all be 316 stainless steel.
C. The valve stem and taper pins shall be 17-4 PH stainless steel and the sea shall be RTFE (reinforced polyetrafluoroethylene).
2.5 STAINLESS STEEL PROCESS BUTTERFLY VALVES
A. For all process butterfly valves that are indicated to have stainless steel bodies in the valve schedule shall be Bray Series 40/41 lug or wafer style as indicated in the schedule.
B. Stainless steel butterfly valves are required for all process lines involving the biogas distribution and isolation lines.
C. Valve bodies shall be 316 stainless steel ASTM A351 GR CF8M, with a stainless steel disc and 17-4 PH SS stem and taper pines.
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-3 D. The disc spacer, bearing assembly, gland ring, thrust washer, and gland retainer shall be 316 stainless steel.
2.6 PROCESS BUTTERFLY VALVES 22” TO 48”
A. Butterfly valves shall be Bray Series 32/33 or Bray Series 35/36 as indicated in the valve schedule, or equal. Provide Bray Series 32/35 for all applications with maximum design pressures of 50 psi. All other applications require Bray Series 33/36 for pressures up to 150 psi. (Refer to schedule in drawings).
B. For flange-style butterfly valves, valves shall be Bray Series 36 or equal.
C. Valves shall have a wafer body or full flanged body style.
D. Tongue-and-groove seat design with primary hub seal and a molded O-ring suitable for weld- neck and slip on flanges.
E. Seat shall be totally encapsulated with no flange gaskets required.
F. Spherically machined, hand polished disc edge and hub for minimum torque and maximum sealing capability.
G. Equipped with non-corrosive bushing and self-adjusting stem seals.
H. Bi-directional.
I. Valve body shall be Cast Iron ASTM A 126 Class B or Ductile Iron ASTM A536 Gr. 65-45-12.
J. Disc shall consist of 316 Stainless Steel ASTM A351.
K. Stem shall be high-strength, 304 Stainless Steel ASTM A276 Type 304.
L. All valves shall be factory tested to 110% of the specified pressure rating.
M. All valves shall be provided with either an electric actuator or a manual operator that includes a gear box and hand wheel, equivalent to Bray Controls Series 4 operator. The operator shall be a cast iron body with O-ring body seals in weatherproof to IP65. A self-locking worm and worm gear drive holds the valve in the desired position. The operator shall include a durable hand wheel to facilitate operating the valve. Contractor shall install the valve and operator such that it is easily accessible and not obstructed. Refer to the electrical specifications and valve schedule for electric actuator requirements.
2.7 PROCESS BUTTERFLY VALVES 2” TO 20”
A. Butterfly valves shall be Bray Series 30 or equal and shall have a wafer style body (refer to valve schedule in drawings) constructed of ASTM A536 Gr. 65-45-12 ductile iron.
B. Disc edge and hub on metal discs shall be spherically machined and hand polished for torque and maximum sealing capability. Disc shall be ASTM A351 316 stainless steel.
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-4 C. Valve stem shall be one-piece design with no possible leak paths in the disc-to-stem connection. Stem shall be ASTM A351 316 stainless steel.
D. Valve shall be rated for bi-directional service and shall be factory tested to 110% of the specified pressure rating. All valves shall be rated for a minimum service pressure of 150 psi.
E. Valve shall be equipped with non-corrosive bushing and self-adjusting stem seals.
F. All valves 6-inches and under not supplied with an electric actuator shall be furnished with a level or handle type actuator, equivalent to the Bray Series 1 Handle unless another type of actuator is specifically listed in the valve schedule.
G. All valves 8-inches and larger shall be provided with either an electric actuator or a manual operator that includes a gear box and hand wheel, equivalent to Bray Controls Series 4 operator. The operator shall be a cast iron body with O-ring body seals in weatherproof to IP65. A self-locking worm and worm gear drive holds the valve in the desired position. The operator shall include a durable hand wheel to facilitate operating the valve. Contractor shall install the valve and operator such that it is easily accessible and not obstructed. Refer to the electrical specifications and valve schedule for electric actuator requirements.
2.8 HOT WATER BUTTERFLY VALVES
A. Butterfly valves shall be Bray Series 20/21 or equal. (Refer to schedule in drawings)
B. Valves shall have a wafer or lug body style. (Refer to schedule in drawings)
C. Equipped with non-corrosive bushing and self-adjusting stem seals.
D. Bi-directional.
E. Valve body shall be Cast Iron ASTM A 126 Class B or Ductile Iron ASTM A536 Gr. 65-45-12.
F. Disc shall consist of 316 Stainless Steel ASTM A351.
G. Stem shall be high-strength, 304 Stainless Steel ASTM A276 Type 304.
H. All valves shall be factory tested to 110% of the specified pressure rating.
I. Seat shall be EPDM.
2.9 3-WAY BUTTERFLY VALVES
A. 3-way valves shall be wafer style valves with ANSI 125 flanges.
B. Valve body shall be cast iron, with ductile iron, nylon 11 coated discs. Seat shall be EPDM, with 416 stainless steel stem
C. Valves shall be Bray NY series or equal, with IQT actuator for the master valve that is connected to the actuator nut of the slave valve as required in the valve schedule.
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-5 2.10 PLASTIC BALL VALVES (1/2” – 6”)
A. All valves shall be true-union design with 2-way blocking capability. PTFE seats shall have elastomeric backing cushions to provide smooth even stem torque and to compensate for wear.
B. Valve shall have a pressure rating of 150 psi at 70¼F.
C. Ball valves shall be provided with a vented ball for all chemical line service applications, including sodium hypochlorite chemical lines, and as indicated in the valve schedule.
D. Available Manufacturers: Subject to compliance with requirements, manufacturers offering ball valves which may be incorporated in the work are:
1. Asahi America, Inc. 2. George Fischer Sloane 3. Dura Plastic Products, Inc. 4. Apollo 5. Hayward 6. Or equal.
2.11 STAINLESS STEEL BALL VALVES
A. Features:
1. 316 SS Ball Construction 2. SS Body construction 3. RPTFE seat 4. Threaded 5. Full Port 6. Two piece body design 7. Solid Ball Construction 8. SS Lever and Nut 9. Blow out proof stern design 10. Nylon lever grip 11. 150 psi rated
B. Available Manufacturers: Subject to compliance with requirements, manufacturers offering ball valves which may be incorporated in the work are:
1. Apollo Valves 2. Or equal
2.12 PLASTIC BALL CHECK VALVES
A. Ball Check valves shall be PVC, CPVC, PP or PVDF body with EPDM, FKM or PTFE seals. Valves shall be of solid thermoplastic construction, and be designed with an elastomeric uniseat/seal for tight shut-off under pressure. Sizes 1/2" – 2” shall be true union, and sizes 3” & 4” shall be single union.
B. Manufacturer must be ISO-9001 certified. Acceptable manufacturers:
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-6
1. Asahi-America, Inc. 2. George Fisher 3. Or equal. C. Valves shall have a pressure rating of: 150 psi at 70 F sizes 1/2" – 2” 100 psi at 70 F sizes 3” & 4”
2.13 STAINLESS STEEL CHECK VALVES (1/4” TO 2”)
A. Stainless steel check valves shall be threaded (NPT) valves and valve bodies shall consist of ASTM A315 CF8M 316 stainless steel.
B. Retainer, spring, and guides shall consist of 316 stainless steel.
C. Ball check shall be constructed of reinforced Teflon (RPTFE) or similar material suitable for corrosive and chemical exposure environments.
D. Acceptable make/model are Apollo model 62-100 stainless steel ball cone check valves or equal.
2.14 CHEMICAL LINE BACKPRESSURE AND PRESSURE RELIEF VALVES
A. Back pressure and pressure-relief valves for chemical line installations shall be an in-line diaphragm-style back pressure (anti-siphon) control valve with a built-in air release to help prevent air locking.
B. Valve body shall be PVC or CPVC as indicated in the valve schedule and shall have a field adjustable pressure range of 15 to 150 psig. For applications with design pressures less than 15 PSIG, factor shall provide a rubber elastomeric diaphragm.
C. Valve diaphragm shall be Teflon-laminated EPDM except for sodium hypochlorite applications where Viton shall be provided.
D. Ports for gauges (1/4” NPT) shall be provided where indicated in the drawings and/or the valve schedule. Contractor shall provide a liquid-filled gauge complying with the requirements of Division 26.
E. Valves shall be as manufactured by Top Valve model TV B and P (P2) or equal.
2.15 STAINLESS STEEL MUD VALVES
A. Mud valves shall be stainless steel with resilient seats Trumbull series 376 or equal and as described herein. Valves shall be the non-rising stem type and be a heavy duty design. The body flange, yoke, guides and gate shall be cast stainless steel, type 316. After machining, all castings shall be passivated in accordance with ASTM A-380. Valves which include components welded from stainless steel are not acceptable. The resilient seat shall be of SBR rubber and mechanically retained. Resilient seats which are retained to the gate by adhesive or
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-7 tension are not acceptable. Fasteners shall be stainless steel. The valve stem shall be one piece with an integral thrust collar and be cast or machined from type 316 stainless steel. Designs which pin a collar to the stem are not acceptable. The valve stem shall have Acme threads with the minimum diameters as shown below:
Valve Size Minimum Stem Diameter 4” 1-1/4” 6” 1-1/4” 8” 1-1/2” 10” 1-1/2” 12” 1-1/2” 16” 1-1/2” 18” 1-3/4” 20” 1-3/4”
B. The valve shall be capable of withstanding a minimum input torque of 450 foot pounds, without damage to the valve. The valve shall not leak more than one quart per hour, when the valve is closed to a stem torque of 35 foot pounds. The manufacturer shall support leakage and torque testing with a report from an independent test laboratory.
C. The stem shall be coupled to the extension stem with a stainless steel machined coupling or a cast stainless 2” square operating nut and retained with a 5/16” stainless steel spring pin. No welded components of stainless are permitted for this connection or to the valve stem. Stems shall be retained with stainless fasteners assembled through holes drilled in the valve guide and yoke and retained with stainless hex nuts. Valve designs which retain the valve stem by threading stainless screws into tapped holes are not acceptable. The stem shall have a permanently bonded coating to prevent galling with other stainless components. The coating shall be capable of enduring a minimum of 15,000 open-close cycles without galling or excessive wear. The manufacturer shall support cycle testing with a report from an independent test laboratory.
D. The base flange shall be drilled per ANSI 125# standard and have a minimum thickness of ¾”. The base flange shall be machined to provide a smooth seating surface. The extension stem shall be type 316 stainless steel, of either schedule 40 pipe or solid round bar. The top nut, bottom coupling and connecting couplings shall be either cast or machined from type 316 stainless steel, but not include any welded components.
E. Stem Guides shall be constructed of cast stainless steel, type 316. Stem guides fabricated by welding stainless steel shall not be permitted. Stem guides shall include a bronze bushing with an inside diameter 1/16” larger than the outside diameter of the extension stem and shall be retained with two stainless steel screws. The stem guide shall be of the adjustable design for plumb alignment. The adjusting bolt and washer shall be type 316 stainless. Stem guides shall be spaced so that the unsupported length between extension stems shall not exceed 7 feet. Mudvalves shall be operated with extension stems, stem guides and either position indicators or indicating floorstands, as shown on the valve schedule or drawings. Mud valves and stem guides shall be as manufactured by Trumbull Industries, Youngstown, Ohio.
2.16 SUCTION LINE FOOT VALVES
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-8 A. The foot valve shall be Valmatic Series #1900 foot valves flow globe style or equal, designed to provide positive seating and full flow area. The valve body shall be constructed of ASTM A126 Class B cast iron.
B. The valve seat and plug shall be ASTM A351 Grade CF8M stainless steel. The basket screen shall be type 304 stainless steel.
C. Foot valve shall be provided with flanges in accordance with ASNI B16.1 for Class 125 iron flanges.
D. Valves shall be hydrostatically tested at 1.5 times their rated cold working pressure. Exterior of the valve shall be coated with a universal alkyd primer per Section 098000.
2.17 GLOBE STYLE CHECK VALVES
A. Globe style valve bodies shall be Valmatic Series 1800 globe style check valves constructed of ASTM A536 Grade 65-45-12 ductile iron.
B. Globe and wafer seat and disc shall be ASTM B148 Alloy C95200 aluminum bronze. The globe compression spring shall be ASTM A313 type 316 stainless steel.
C. The valve shall incorporate a center guided, spring loaded disc and shall not be affected by the position of installation. Valve shall be capable of operating in the vertical or horizontal position with flow in either direction. Spring shall be designed to withstand 100,000 cycles without failure and provide a cracking pressure of 0.5 psi.
D. All components shall be field replaceable
E. Globe style valves shall have flat faced flanges in accordance with ASME B16.1 for Class 125 of Class 250 iron flanges.
2.18 SWING CHECK VALVES
A. The valves shall be designed, manufactured, tested and certified to ANSI/AWWA standards (C508). The valves shall be provided with flanges in accordance with ANSI B16.1 Class 125 (or above as required for each installation).
B. The rubber flapper swing check valve shall be constructed of ASTM A536 Grade 65-45-12 ductile iron for sizes less than 30-inch diameter and cast iron body and cover in accordance with ASTM A126 Grade B for sizes 30-inches and larger. The body shall be long pattern design (not wafer) with integrally cast-on end flanges. The flapper shall be Buna-N, or other elastomer, having an O-ring seating edge and be internally reinforced with steel.
C. Flapper to be captured between the body and the body cover in a manner to permit the flapper to flex from closed to full open position. Flapper shall be easily removed without the need to remove the valve from line. Check Valves to have full pipe size flow area. Seating surface to be on a 45 degree requiring the flapper to travel only 35 degrees from closed to full open position for minimum headloss. Valve has non-slam closure characteristics.
D. Buna-N flapper which creates an elastic spring effect to assist the flapper to close against a slight head to prevent or minimize slamming.
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-9 E. Valve designed for 175 psi differential pressure for water, sewage, oil or gas (higher pressure available). The valve shall be suitable for buried service, in which case, stainless cover bolts must be furnished.
F. When necessary to prime or backflush a clogged pump, an external backflow device can be furnished—sizes 3” and larger.
G. Acceptable Manufacturers: Subject to compliance with requirements, manufacturers offering swing check valves which may be incorporated in the work are:
1. ValMatic 2. Or equal.
2.19 FLOW CONVERGING VALVES
A. Flow converging valves shall be sized and configured as required for each specific installation location. Contractor shall coordinate between Owner, Engineer, and the manufacturer to ensure that the proper configuration is provided for each application.
B. Flow converging and balancing valves shall be Fisher series YD, or equal.
C. Valves shall be provided with flanged connections per ASME B16.1. Valve bodies shall be constructed of cast iron with 17-4PH SST plug, and stainless steel upper and lower cages.
2.20 PRESSURE REDUCING VALVES
A. Valve shall be constructed of stainless steel housing and connection threads. Interior mesh shall be stainless steel.
B. The filter bowl shall be stainless steel.
C. The valve shall be equipped with a spring steel adjustment spring and fiber-reinforced NBR diaphragm and NBR seals.
D. The valve shall be designed to handle an inlet pressure of at least 230 psi while providing an adjustable, stable outlet pressure between 15 and 90 psi.
E. Pressure reducing valve shall be provided with pressure gauge connections on the upstream and downstream side of the valve.
F. Valves shall be Honeywell model D06FI or equal.
PART 3 - EXECUTION
3.1 INSTALLATION:
A. General: Except as otherwise indicated, comply with the following requirements:
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-10 Install valves where required for proper operation of piping and equipment, including valves in branch lines where necessary to isolate sections of piping. Locate valves so as to be accessible and so that separate support can be provided when necessary.
Install valves with stems pointed up, in vertical position where possible, but in no case with stems pointed downward from horizontal plane.
B. Insulation: Where insulation is indicated, install extended-stem valves, arranged in proper manner to receive insulation.
C. Selection of Valve Ends (Pipe Connections): Except as otherwise indicated, select and install valves with the following ends or types of pipe/tube connections.
1. Pipe Size 2" and Smaller: One of the following, at Installer's option:
a. Threaded valves. b. Flanged valves.
2. Pipe Size 2-1/2" and Larger:
a. Flanged valves. b. Grooved joint valves.
D. Valve System: Select and install valves with outside screw and yoke stems, except provide inside screw non-rising stem valves where headroom prevents full opening of OS&Y valves.
E. Renewable Seats: Select and install valves with renewable seats, except where otherwise indicated.
3.2 ADJUSTING AND CLEANING:
A. Valve Adjustment: After piping systems have been tested and put into service, but before final testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace packing to stop leaks, replace valve if leak persists.
B. Valve Identification: Tag each valve in accordance with Division-22 section "Identification for Piping and Equipment".
3.3 VALVE INSTALLATION:
A. Locate all valves in locations which will allow easy operation and facilitates maintenance.
B. Provide chain operators for any valves located more than 8 feet above finished floor. This means double acting lever handles for quarter turn valves, or chain wheels for multi-turn valves. Arrange valves and set up chain length for proper operation.
END OF SECTION 220523
WRCRWA VALVES PLANT EXPANSION PROJECT 220523-11 SECTION 220529 - HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Metal pipe hangers and supports. 2. Thermal-hanger shield inserts. 3. Fastener systems. 4. Pipe positioning systems. 5. Equipment supports.
1.2 PERFORMANCE REQUIREMENTS
A. Delegated Design: Design trapeze pipe hangers and equipment supports, including comprehensive engineering analysis by a qualified professional engineer, using performance requirements and design criteria indicated.
B. Structural Performance: Hangers and supports for piping and equipment shall withstand the effects of gravity loads and stresses within limits and under conditions indicated according to ASCE/SEI 7.
1. Design supports for multiple pipes capable of supporting combined weight of supported systems, system contents, and test water. 2. Design equipment supports capable of supporting combined operating weight of supported equipment and connected systems and components. 3. Design seismic-restraint hangers and supports for piping and equipment.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Shop Drawings: Show fabrication and installation details and include calculations for the following; include Product Data for components:
1. Trapeze pipe hangers. 2. Equipment supports.
C. Delegated-Design Submittal: For trapeze hangers indicated to comply with performance requirements and design criteria, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 1 1.4 INFORMATIONAL SUBMITTALS
A. Welding certificates.
1.5 QUALITY ASSURANCE
A. Structural Steel Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."
B. Pipe Welding Qualifications: Qualify procedures and operators according to ASME Boiler and Pressure Vessel Code.
PART 2 - PRODUCTS
2.1 METAL PIPE HANGERS AND SUPPORTS
A. Carbon-Steel Pipe Hangers and Supports:
1. Description: MSS SP-58, Types 1 through 58, factory-fabricated components. 2. Galvanized Metallic Coatings: Pregalvanized or hot dipped. 3. Nonmetallic Coatings: Plastic coating, jacket, or liner. 4. Padded Hangers: Hanger with fiberglass or other pipe insulation pad or cushion to support bearing surface of piping. 5. Hanger Rods: Continuous-thread rod, nuts, and washer made of stainless steel.
B. Stainless-Steel Pipe Hangers and Supports:
1. Description: MSS SP-58, Types 1 through 58, factory-fabricated components. 2. Padded Hangers: Hanger with fiberglass or other pipe insulation pad or cushion to support bearing surface of piping. 3. Hanger Rods: Continuous-thread rod, nuts, and washer made of stainless steel.
2.2 TRAPEZE PIPE HANGERS
A. Description: MSS SP-69, Type 59, shop- or field-fabricated pipe-support assembly made from structural carbon-steel shapes with MSS SP-58 carbon-steel hanger rods, nuts, saddles, and U- bolts.
2.3 THERMAL-HANGER SHIELD INSERTS
A. Insulation-Insert Material for Cold Piping: ASTM C 552, Type II cellular glass with 100-psig or ASTM C 591, Type VI, Grade 1 polyisocyanurate with 125-psig minimum compressive strength and vapor barrier.
B. For Trapeze or Clamped Systems: Insert and shield shall cover entire circumference of pipe.
C. For Clevis or Band Hangers: Insert and shield shall cover lower 180 degrees of pipe.
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 2 D. Insert Length: Extend 2 inches beyond sheet metal shield for piping operating below ambient air temperature.
2.4 FASTENER SYSTEMS
A. Powder-Actuated Fasteners: Threaded-steel stud, for use in hardened Portland cement concrete with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used.
B. Mechanical-Expansion Anchors: Insert-wedge-type, stainless-steel anchors, for use in hardened Portland cement concrete; with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used.
2.5 PIPE POSITIONING SYSTEMS
A. Description: IAPMO PS 42, positioning system of metal brackets, clips, and straps for positioning piping in pipe spaces; for plumbing fixtures in commercial applications.
2.6 EQUIPMENT SUPPORTS
A. Description: Welded, shop- or field-fabricated equipment support made from structural carbon- steel shapes (HDG unless noted otherwise).
2.7 MISCELLANEOUS MATERIALS
A. Structural Steel: ASTM A 36/A 36M, carbon-steel plates, shapes, and bars; black and galvanized.
B. Grout: ASTM C 1107, factory-mixed and -packaged, dry, hydraulic-cement, nonshrink and nonmetallic grout; suitable for interior and exterior applications.
1. Properties: Nonstaining, noncorrosive, and nongaseous. 2. Design Mix: 5000-psi, 28-day compressive strength.
PART 3 - EXECUTION
3.1 HANGER AND SUPPORT INSTALLATION
A. Metal Pipe-Hanger Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from the building structure.
B. Thermal-Hanger Shield Installation: Install in pipe hanger or shield for insulated piping.
C. Fastener System Installation:
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 3 1. Install powder-actuated fasteners for use in lightweight concrete or concrete slabs less than 4 inches thick in concrete after concrete is placed and completely cured. Use operators that are licensed by powder-actuated tool manufacturer. Install fasteners according to powder-actuated tool manufacturer's operating manual. 2. Install mechanical-expansion anchors in concrete after concrete is placed and completely cured. Install fasteners according to manufacturer's written instructions.
D. Pipe Positioning-System Installation: Install support devices to make rigid supply and waste piping connections to each plumbing fixture.
E. Install hangers and supports complete with necessary attachments, inserts, bolts, rods, nuts, washers, and other accessories.
F. Equipment Support Installation: Fabricate from welded-structural-steel shapes.
G. Install hangers and supports to allow controlled thermal and seismic movement of piping systems, to permit freedom of movement between pipe anchors, and to facilitate action of expansion joints, expansion loops, expansion bends, and similar units.
H. Install lateral bracing with pipe hangers and supports to prevent swaying.
I. Install building attachments within concrete slabs or attach to structural steel. Install additional attachments at concentrated loads, including valves, flanges, and strainers, NPS 2-1/2 and larger and at changes in direction of piping. Install concrete inserts before concrete is placed; fasten inserts to forms and install reinforcing bars through openings at top of inserts.
J. Load Distribution: Install hangers and supports so that piping live and dead loads and stresses from movement will not be transmitted to connected equipment.
K. Pipe Slopes: Install hangers and supports to provide indicated pipe slopes and to not exceed maximum pipe deflections allowed by ASME B31.9 for building services piping.
L. Insulated Piping:
1. Attach clamps and spacers to piping.
a. Piping Operating above Ambient Air Temperature: Clamp may project through insulation. b. Piping Operating below Ambient Air Temperature: Use thermal-hanger shield insert with clamp sized to match OD of insert. c. Do not exceed pipe stress limits allowed by ASME B31.9 for building services piping.
2. Install MSS SP-58, Type 39, protection saddles if insulation without vapor barrier is indicated. Fill interior voids with insulation that matches adjoining insulation.
a. Option: Thermal-hanger shield inserts may be used. Include steel weight- distribution plate for pipe NPS 4 and larger if pipe is installed on rollers.
3. Install MSS SP-58, Type 40, protective shields on cold piping with vapor barrier. Shields shall span an arc of 180 degrees.
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 4 a. Option: Thermal-hanger shield inserts may be used. Include steel weight- distribution plate for pipe NPS 4 and larger if pipe is installed on rollers.
4. Shield Dimensions for Pipe: Not less than the following:
a. NPS 1/4 to NPS 3-1/2: 12 inches long and 0.048 inch thick. b. NPS 4: 12 inches long and 0.06 inch thick. c. NPS 5 and NPS 6: 18 inches long and 0.06 inch thick. d. NPS 8 to NPS 14: 24 inches long and 0.075 inch thick. e. NPS 16 to NPS 24: 24 inches long and 0.105 inch thick.
5. Pipes NPS 8 and Larger: Include wood or reinforced calcium-silicate-insulation inserts of length at least as long as protective shield. 6. Thermal-Hanger Shields: Install with insulation same thickness as piping insulation.
3.2 EQUIPMENT SUPPORTS
A. Fabricate structural-steel stands to suspend equipment from structure overhead or to support equipment above floor.
B. Grouting: Place grout under supports for equipment and make bearing surface smooth.
C. Provide lateral bracing, to prevent swaying, for equipment supports.
D. Provide concrete housekeeping bases for all floor mounted equipment furnished. Size bases to extend a minimum of 4” beyond equipment base in any direction; and 4” above finished floor elevation. Construct of reinforced concrete, roughen floor slab beneath base for bond, and provide steel rod anchors between floor and base. Locate anchor bolts using equipment manufacturer’s templates. Chamfer top and edge corners.
3.3 METAL FABRICATIONS
A. Cut, drill, and fit miscellaneous metal fabrications for trapeze pipe hangers and equipment supports.
B. Fit exposed connections together to form hairline joints. Field weld connections that cannot be shop welded because of shipping size limitations.
C. Field Welding: Comply with AWS D1.1/D1.1M procedures for shielded, metal arc welding; appearance and quality of welds; and methods used in correcting welding work; and with the following:
1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals. 2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. Finish welds at exposed connections so no roughness shows after finishing and so contours of welded surfaces match adjacent contours.
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 5 3.4 ADJUSTING
A. Hanger Adjustments: Adjust hangers to distribute loads equally on attachments and to achieve indicated slope of pipe.
B. Trim excess length of continuous-thread hanger and support rods to 1-1/2 inches.
3.5 PAINTING
A. Touchup: Clean field welds and abraded areas of shop paint. Paint exposed areas immediately after erecting hangers and supports. Use same materials as used for shop painting. Comply with SSPC-PA 1 requirements for touching up field-painted surfaces.
1. Apply paint by brush or spray to provide a minimum dry film thickness of 2.0 mils.
B. Touchup: Use shop paint for cleaning and touchup painting of field welds, bolted connections, and abraded areas on miscellaneous metal.
C. Galvanized Surfaces: Clean welds, bolted connections, and abraded areas and apply galvanizing-repair paint to comply with ASTM A 780.
3.6 HANGER AND SUPPORT SCHEDULE
A. Specific hanger and support requirements are in Sections specifying piping systems and equipment.
B. Comply with MSS SP-69 for pipe-hanger selections and applications that are not specified in piping system Sections.
C. Use hangers and supports with galvanized metallic coatings for piping and equipment that will not have field-applied finish.
D. Use nonmetallic coatings on attachments for electrolytic protection where attachments are in direct contact with copper tubing.
E. Use carbon-steel pipe hangers and supports and attachments for general service applications.
F. Use stainless-steel pipe hangers and stainless-steel attachments for hostile environment applications.
G. Use copper-plated pipe hangers and copper or stainless-steel attachments for copper piping and tubing.
H. Use padded hangers for piping that is subject to scratching.
I. Use thermal-hanger shield inserts for insulated piping and tubing.
J. Horizontal-Piping Hangers and Supports: Unless otherwise indicated and except as specified in piping system Sections, install the following types:
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 6 1. Adjustable, Steel Clevis Hangers (MSS Type 1): For suspension of noninsulated or insulated, stationary pipes NPS 1/2 to NPS 30. 2. Yoke-Type Pipe Clamps (MSS Type 2): For suspension of up to 1050 deg F, pipes NPS 4 to NPS 24, requiring up to 4 inches of insulation. 3. Carbon- or Alloy-Steel, Double-Bolt Pipe Clamps (MSS Type 3): For suspension of pipes NPS 3/4 to NPS 36, requiring clamp flexibility and up to 4 inches of insulation. 4. Adjustable, Steel Band Hangers (MSS Type 7): For suspension of noninsulated, stationary pipes NPS 1/2 to NPS 8. 5. U-Bolts (MSS Type 24): For support of heavy pipes NPS 1/2 to NPS 30. 6. Pipe Saddle Supports (MSS Type 36): For support of pipes NPS 4 to NPS 36, with steel- pipe base stanchion support and cast-iron floor flange or carbon-steel plate. 7. Pipe Stanchion Saddles (MSS Type 37): For support of pipes NPS 4 to NPS 36, with steel-pipe base stanchion support and cast-iron floor flange or carbon-steel plate, and with U-bolt to retain pipe. 8. Single-Pipe Rolls (MSS Type 41): For suspension of pipes NPS 1 to NPS 30, from two rods if longitudinal movement caused by expansion and contraction might occur.
K. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system Sections, install the following types:
1. Extension Pipe or Riser Clamps (MSS Type 8): For support of pipe risers NPS 3/4 to NPS 24. 2. Carbon- or Alloy-Steel Riser Clamps (MSS Type 42): For support of pipe risers NPS 3/4 to NPS 24 if longer ends are required for riser clamps.
L. Hanger-Rod Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types:
1. Steel Turnbuckles (MSS Type 13): For adjustment up to 6 inches for heavy loads. 2. Steel Clevises (MSS Type 14): For 120 to 450 deg F piping installations.
M. Building Attachments: Unless otherwise indicated and except as specified in piping system Sections, install the following types:
1. Steel or Malleable Concrete Inserts (MSS Type 18): For upper attachment to suspend pipe hangers from concrete ceiling. 2. Top-Beam C-Clamps (MSS Type 19): For use under roof installations with bar-joist construction, to attach to top flange of structural shape. 3. Side-Beam or Channel Clamps (MSS Type 20): For attaching to bottom flange of beams, channels, or angles. 4. Center-Beam Clamps (MSS Type 21): For attaching to center of bottom flange of beams. 5. Welded Beam Attachments (MSS Type 22): For attaching to bottom of beams if loads are considerable and rod sizes are large. 6. C-Clamps (MSS Type 23): For structural shapes. 7. Welded-Steel Brackets: For support of pipes from below, or for suspending from above by using clip and rod. Use one of the following for indicated loads:
a. Light (MSS Type 31): 750 lb. b. Medium (MSS Type 32): 1500 lb. c. Heavy (MSS Type 33): 3000 lb.
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 7 8. Side-Beam Brackets (MSS Type 34): For sides of steel or wooden beams. 9. Plate Lugs (MSS Type 57): For attaching to steel beams if flexibility at beam is required.
N. Saddles and Shields: Unless otherwise indicated and except as specified in piping system Sections, install the following types:
1. Steel-Pipe-Covering Protection Saddles (MSS Type 39): To fill interior voids with insulation that matches adjoining insulation. 2. Protection Shields (MSS Type 40): Of length recommended in writing by manufacturer to prevent crushing insulation. 3. Thermal-Hanger Shield Inserts: For supporting insulated pipe.
O. Comply with MSS SP-69 for trapeze pipe-hanger selections and applications that are not specified in piping system Sections.
P. Use powder-actuated fasteners or mechanical-expansion anchors instead of building attachments where required in concrete construction.
Q. Use pipe positioning systems in pipe spaces behind plumbing fixtures to support supply and waste piping for plumbing fixtures.
END OF SECTION 220529
WRCRWA HANGERS AND SUPPORTS FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220529 - 8 SECTION 220553 – IDENTIFICATION FOR PIPING AND EQUIPMENT
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of Contract, including General and Special Conditions and Division-1 Specification sections, apply to work of this section.
B. This section is Division-22 General Mechanical Materials and Methods section, and is part of each Division-22 section making reference to identification devices specified herein.
1.2 DESCRIPTION OF WORK
A. Furnish mark and install identification devices for all exposed piping installed in this work.
B. Furnish and securely attach an engraved plastic nameplate to all new pieces of equipment (Owner or Contractor furnished).
C. Tag all valves installed in this work.
1.3 QUALITY ASSURANCE
A. Codes and Standards:
B. ANSI Standards:
C. Comply with ANSI A13.1 for lettering size, length of color field, colors, and viewing angles of identification devices.
PART 2 - PRODUCTS
2.1 IDENTIFICATION OF PIPING
A. Identification of all exposed pipe shall be accomplished by color-coding with bands and by lettering. Color bands shall be pressure-sensitive adhesive-backed vinyl cloth or plastic tape.
B. Each pipe identification shall consist of 2 color-coded bands, a printed label identifying the name of the pipe, and a flow arrow to indicate direction of flow in the pipe. All labels shall be preprinted on pressure-sensitive adhesive-backed vinyl cloth or plastic tape. Arrows shall be die-cut of the same type of material as the labels.
C. Preprinted identification devices shall be as manufactured by W.H. Brady Co., Seton Nameplate Corp., or equal.
2.2 VALVE TAGS
WRCRWA IDENTIFICATION FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220553-1 A. Valve Tags: Provide 1-1/2" x 3" size stainless steel or plastic valve tags with stamp-engraved 1/8" high letters.
B. Valve Tag Fasteners: Provide manufacturer's standard solid stainless steel chain (wire link or beaded type), or solid S-hooks of the sizes required for proper attachment of tags to valves, and manufactured specifically for that purpose.
2.3 ENGRAVED PLASTIC-LAMINATE SIGNS
A. General: Provide engraving stock melamine plastic laminate, complying with FS L-P-387, in the sizes and thicknesses indicated, engraved with engraver's standard letter style of the sizes and wording indicated, black with white core (letter color) except as otherwise indicated, punched for mechanical fastening except where adhesive mounting is necessary because of substrate.
PART 3 - EXECUTION
3.1 GENERAL INSTALLATION REQUIREMENTS
A. Coordination: Where identification is to be applied to surfaces which require insulation, painting or other covering or finish, including valve tags in finished mechanical spaces, install identification after completion of covering and painting.
3.2 PIPING SYSTEM IDENTIFICATION
A. General: Install pipe markers on each piping system, and include arrows to show normal direction of flow: Example of System Identification:
FLUID FUNCTION ID ABBREVIATION IDENTIFICATION COLOR
SD SANITARY DRAINS & VENTS BLUE UW NON-POTABLE (RECYCLED) WATER PURPLE WAS WASTE ACTIVATED SLUDGE BROWN
Coordinate with the Owner for other piping systems identification ID Coloring.
B. Locate pipe markers and color bands as follows wherever piping is exposed to view in occupied spaces, machine rooms, accessible maintenance spaces (shafts, crawl spaces, plenums) and exterior non-concealed locations.
1. Near each valve and control device. 2. Near each branch, excluding short take-offs for fixtures and terminal units; mark each pipe at branch, where there could be question of flow pattern. 3. Near locations where pipes pass through walls or floors/ ceilings, or enter non-accessible enclosures. 4. Near major equipment items and other points of origination and termination.
WRCRWA IDENTIFICATION FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220553-2 5. Spaced intermediately at maximum spacing of 50' along each piping run, except reduce spacing to 25' in congested areas of piping and equipment.
3.3 VALVE IDENTIFICATION
A. General: Provide valve tag on every valve, cock and control device in each piping system; exclude check valves, valves within factory-fabricated equipment units, plumbing fixture faucets, convenience and lawn-watering hose bibs, and shut-off valves at plumbing fixtures. List each tagged valve in valve schedule for each piping system. Valve tags shall include the following minimum information:
1. Plan Identification 2. Normal Position 3. Duty 4. Area served 5. Valve type.
B. Example of typical valve tag (where it is apparent what valve is serving):
B-14 Automatic 3-way mixing chlorine feed pump rate control Position: 1/2 open Function: Control flow rate
3.4 MECHANICAL EQUIPMENT IDENTIFICATION
A. General: Install engraved plastic laminate sign or plastic equipment marker on or near each major item of mechanical equipment and each operational device, as specified herein if not otherwise specified for each item or device. Provide signs for the following general categories of equipment and operational devices:
1. Main control and operating valves, including safety devices and hazardous units such as non-potable water outlets. For non-potable water outlets use red engraved laminate with white lettering. 2. Pumps, compressors. 3. Press. 4. Air Handlers and Exhaust Fans, Furnaces, Condensing Units. 5. Polymer Feed Units. 6. Tanks and pressure vessels. 7. Open Control Equipment.
B. Lettering Size:
Minimum 1/4" high lettering for name of unit where viewing distance is less than 2'-0", 1/2" high for distances up to 6'-0", and proportionately larger lettering for greater distances. Provide secondary lettering of 2/3 to 3/4 of size of the principal lettering.
C. Text of Signs:
WRCRWA IDENTIFICATION FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220553-3 In addition to name of identified unit, provide lettering to distinguish between multiple units, inform operator of operational requirements, indicate safety and emergency precautions, and warn of hazards and improper operations.
D. A sample identification tag for equipment could be as follows:
Heating water pump Symbol P-1 Rating: 900 gpm, 120 ft. hd. Maintenance: Lubricate with type C lubricant.
3.5 PANEL IDENTIFICATION
A. All panel devices on panel faces shall have engraved black face formica with white engraved lettering labels.
B. All internal panel components shall have engraved black face formica with white engraved lettering labels. Fasten label beneath each device.
C. All panel wiring and tubing shall be numerically or alphabetically coded.
3.6 ADJUSTING AND CLEANING
A. Adjusting: Relocate any mechanical identification device which has become visually blocked by work of this division.
B. Cleaning: Clean face of identification devices.
END OF SECTION 220553
WRCRWA IDENTIFICATION FOR PIPING AND EQUIPMENT PLANT EXPANSION PROJECT 220553-4 SECTION 220719 – PIPING INSULATION
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes insulating the following plumbing piping services and related systems:
1. Non potable water piping. 2. Above ground interior hot water recirculation lines. 3. Sodium Bisulfite piping.
1.2 RELATED SECTIONS
A. Section 098000 – Protective Coatings
B. Section 220553 – Identification for Piping and Equipment
C. Section 221030 – Ductile Iron Piping
1.3 DEFINITIONS
A. Exterior – Piping that is installed under canopies, outside a building, in the yard or within a trench or tunnel.
B. Interior – Piping that is installed inside a building.
1.4 ACTION SUBMITTALS
A. Product Data: For each type of product indicated. 1. Insulation properties: Include K factor, thickness, density, operating temperature limits, tensile strength, compressive strength, moisture absorption, flame spread, and smoke developed in accordance with ASTM E84 and corrosivity to stainless steel piping in accordance with ASTM C 795. 2. Jacket properties: Include covering material, cover thickness, tensile strength, tear strength, permeability on accordance with ASTM E 96, flame spread, and smoke developed in accordance with ASTM E84, closure type or devices, and accessories. 3. Insulating blankets: Include materials, performance characteristics, listing of installation locations. 4. Organic Emissions from Various Sources Using Small-Scale Environmental Chambers.
B. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work.
1. Detail application of protective shields, saddles, and inserts at hangers for each type of insulation and hanger. 2. Detail attachment and covering of heat tracing inside insulation. 3. Detail insulation application at pipe expansion joints for each type of insulation. WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-1
4. Detail insulation application at elbows, fittings, flanges, valves, and specialties for each type of insulation. 5. Detail removable insulation at piping specialties, equipment connections, and access panels. 6. Detail application of field-applied jackets. 7. Detail application at linkages of control devices.
1.5 SEQUENCING AND SCHEDULING
A. Pressure test piping and complete application of coating system before applying insulation.
B. When piping is to be heat traced, install and functionally test heat tracing before installation of insulation.
C. Before the installation of piping insulation verify acceptance of pressure piping tests, pipe coating application, and heat tracing tests by the Engineer.
PART 2 - PRODUCTS
2.1 PIPE INSULATION, GENERAL REQUIREMENTS
A. Insulation thicknesses: Provide insulation thickness in inches in accordance with the following table. Insulation thickness shown is nominal. Manufacturing tolerance of 15% variation is permissible.
Required Insulation Thicknesses (inches)
Service Temperature Range as Nominal Pipe Diameters Designated in Insulation Schedule at End of this Section >1” 1.25” to 2” 2.5” to 4” 5” to 10” 10”<
Above 200 degrees Fahrenheit 2 2.5 3 3.5 3.5
100 to 200 degrees Fahrenheit 1.5 1.5 1.5 2 2.5
40 to 100 degrees Fahrenheit 0.5 1 1 1.5 2
Below 40 degrees Fahrenheit 1 1 1.5 2 2
2.2 PIPE INSULATION
A. Insulation Types: Provide in accordance with the insulation types listed in the table provided in Paragraph 3.8 of this section.
B. Insulation, Type 1: 1. Insulation material: Closed cell elastomeric insulation 2. Manufacturers: One of the following or equal
WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-2
a. Armstrong world industries, AP Armaflex b. Dyplast Products, ISO-C1 3. Thermal conductivity at 75F shall not be more than 0.27 BTU in/hr ft2 F. 4. Joints: Seal with manufacturer’s recommended contact adhesive to foam continuous barrier.
C. Insulation, Type 2. 1. Insulation material: Styrofoam 2. Manufacturers: One of the following or equal a. Polyguard products Dow Styrofoam PIB b. The Dow Chemical Company Styrofoam Brand Pipe Insulation 3. Thermal conductivity at 75F shall not be more than 0.27 BTU in/hr ft2 F. 4. Joints: Seal with manufacturer’s recommended contact adhesive to foam continuous barrier.
2.3 INSULATION JACKETS
A. Jacket, Type 1: 1. Material: Ultraviolet resistant polyvinyl chloride jacketing, 20 mm minimum thickness. 2. Color: White 3. Overlap: 1-inch minimum at joints and fittings 4. Joint seal: PVC solvent welded or adhesive as recommended by the manufacturer. 5. Fittings: Factory made with full thickness insulation 6. Manufacturers: One of the following or equal: a. Johns Manville, Zeston 2000 PVC b. ProtoCorp., LoSMOKE PVC c. Speedline Smoke Safe PVC Jacketing System d. Knaul Covering System, Proto PVC
B. Jacket, Type 2: 1. Material: 0.024” thick embossed aluminum. 2. Joint seal: ½” stainless steel bands 3. Manufacturers: One of the following or equal: a. ITW Insulation systems Aluminum Roll Jacketing b. Profiles RH llc., Aluminum Roll Jacketing c. CJ metal Erectors ltd., Aluminum Roll Jacketing
2.4 REMOVABLE INSULATING BLANKETS
A. In piping systems specified to be insulated, use removable insulating blankets for valves, meters, strainers, filters, and other in-line piping appurtenances and equipment requiring periodic servicing.
B. Size limits: use removable insulating blankets for equipment and piping that are 3-inch in nominal size and larger. Insulate equipment and piping appurtenances less than 3-inch with molded sections of insulation or by field cutting insulation to conform to the shape of the component and to fit tightly around the component.
C. Manufacturers: One of the following, or equal
WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-3
1. Pittsburgh Corning, Temp-Mat 2. Accessible Products, Thermazip 2000 Jacket 3. Thermal Energy Products, Inc., Energy Wrap
PART 3 - EXECUTION
3.1 GENERAL INSTALLATION REQUIREMENTS
A. Install insulation materials, accessories, and finishes with smooth, straight, and even surfaces; free of voids throughout the length of piping including fittings, valves, and specialties.
B. Install insulation materials, forms, vapor barriers or retarders, jackets, and thicknesses required for each item of pipe system as specified in insulation system schedules.
C. Install accessories compatible with insulation materials and suitable for the service. Install accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state.
D. Install insulation with longitudinal seams at top and bottom of horizontal runs.
E. Install multiple layers of insulation with longitudinal and end seams staggered.
F. Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties.
G. Keep insulation materials dry during application and finishing.
H. Install insulation with tight longitudinal seams and end joints. Bond seams and joints with adhesive recommended by insulation material manufacturer.
I. Install insulation with least number of joints practical.
J. Where vapor barrier is indicated, seal joints, seams, and penetrations in insulation at hangers, supports, anchors, and other projections with vapor-barrier mastic.
1. Install insulation continuously through hangers and around anchor attachments. 2. For insulation application where vapor barriers are indicated, extend insulation on anchor legs from point of attachment to supported item to point of attachment to structure. Taper and seal ends at attachment to structure with vapor-barrier mastic. 3. Install insert materials and install insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by insulation material manufacturer. 4. Cover inserts with jacket material matching adjacent pipe insulation. Install shields over jacket, arranged to protect jacket from tear or puncture by hanger, support, and shield.
K. Apply adhesives, mastics, and sealants at manufacturer's recommended coverage rate and wet and dry film thicknesses.
L. Install insulation with factory-applied jackets as follows:
1. Draw jacket tight and smooth. WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-4
2. Cover circumferential joints with 3-inch- (75-mm-) wide strips, of same material as insulation jacket. Secure strips with adhesive and outward clinching staples along both edges of strip, spaced 4 inches (100 mm) o.c. 3. Overlap jacket longitudinal seams at least 1-1/2 inches (38 mm). Install insulation with longitudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 2 inches (50 mm) o.c.
a. For below-ambient services, apply vapor-barrier mastic over staples.
4. Cover joints and seams with tape, according to insulation material manufacturer's written instructions, to maintain vapor seal. 5. Where vapor barriers are indicated, apply vapor-barrier mastic on seams and joints and at ends adjacent to pipe flanges and fittings.
M. Cut insulation in a manner to avoid compressing insulation more than 75 percent of its nominal thickness.
N. Finish installation with systems at operating conditions. Repair joint separations and cracking due to thermal movement.
O. Repair damaged insulation facings by applying same facing material over damaged areas. Extend patches at least 4 inches (100 mm) beyond damaged areas. Adhere, staple, and seal patches similar to butt joints.
P. For above-ambient services, do not install insulation to the following:
1. Vibration-control devices. 2. Testing agency labels and stamps. 3. Nameplates and data plates. 4. Cleanouts.
3.2 PENETRATIONS
A. Insulation Installation at Floor Penetrations:
1. Pipe: Install insulation continuously through floor penetrations. 2. Seal penetrations through fire-rated assemblies. Comply with requirements in Section 078413 "Penetration Firestopping."
3.3 GENERAL PIPE INSULATION INSTALLATION
A. Requirements in this article generally apply to all insulation materials except where more specific requirements are specified in various pipe insulation material installation articles.
B. Insulation Installation on Fittings, Valves, Strainers, Flanges, and Unions:
1. Install insulation over fittings, valves, strainers, flanges, unions, and other specialties with continuous thermal and vapor-retarder integrity unless otherwise indicated. 2. Insulate pipe elbows using preformed fitting insulation or mitered fittings made from same material and density as adjacent pipe insulation. Each piece shall be butted tightly WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-5
against adjoining piece and bonded with adhesive. Fill joints, seams, voids, and irregular surfaces with insulating cement finished to a smooth, hard, and uniform contour that is uniform with adjoining pipe insulation. 3. Insulate tee fittings with preformed fitting insulation or sectional pipe insulation of same material and thickness as used for adjacent pipe. Cut sectional pipe insulation to fit. Butt each section closely to the next and hold in place with tie wire. Bond pieces with adhesive. 4. Insulate valves using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. For valves, insulate up to and including the bonnets, valve stuffing-box studs, bolts, and nuts. Fill joints, seams, and irregular surfaces with insulating cement. 5. Insulate strainers using preformed fitting insulation or sectional pipe insulation of same material, density, and thickness as used for adjacent pipe. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. Fill joints, seams, and irregular surfaces with insulating cement. Insulate strainers so strainer basket flange or plug can be easily removed and replaced without damaging the insulation and jacket. Provide a removable reusable insulation cover. For below-ambient services, provide a design that maintains vapor barrier. 6. Insulate flanges and unions using a section of oversized preformed pipe insulation. Overlap adjoining pipe insulation by not less than two times the thickness of pipe insulation, or one pipe diameter, whichever is thicker. 7. Cover segmented insulated surfaces with a layer of finishing cement and coat with a mastic. Install vapor-barrier mastic for below-ambient services and a breather mastic for above-ambient services. Reinforce the mastic with fabric-reinforcing mesh. Trowel the mastic to a smooth and well-shaped contour. 8. For services not specified to receive a field-applied jacket except for flexible elastomeric and polyolefin, install fitted PVC cover over elbows, tees, strainers, valves, flanges, and unions. Terminate ends with PVC end caps. Tape PVC covers to adjoining insulation facing using PVC tape. 9. Stencil or label the outside insulation jacket of each union with the word "union." Match size and color of pipe labels.
C. Insulate instrument connections for thermometers, pressure gages, pressure temperature taps, test connections, flow meters, sensors, switches, and transmitters on insulated pipes. Shape insulation at these connections by tapering it to and around the connection with insulating cement and finish with finishing cement, mastic, and flashing sealant.
D. Install removable insulation covers at locations indicated. Installation shall conform to the following:
1. Make removable flange and union insulation from sectional pipe insulation of same thickness as that on adjoining pipe. Install same insulation jacket as adjoining pipe insulation. 2. When flange and union covers are made from sectional pipe insulation, extend insulation from flanges or union long at least two times the insulation thickness over adjacent pipe insulation on each side of flange or union. Secure flange cover in place with stainless- steel or aluminum bands. Select band material compatible with insulation and jacket.
WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-6
3. Construct removable valve insulation covers in same manner as for flanges, except divide the two-part section on the vertical center line of valve body. 4. When covers are made from block insulation, make two halves, each consisting of mitered blocks wired to stainless-steel fabric. Secure this wire frame, with its attached insulation, to flanges with tie wire. Extend insulation at least 2 inches (50 mm) over adjacent pipe insulation on each side of valve. Fill space between flange or union cover and pipe insulation with insulating cement. Finish cover assembly with insulating cement applied in two coats. After first coat is dry, apply and trowel second coat to a smooth finish. 5. Unless a PVC jacket is indicated in field-applied jacket schedules, finish exposed surfaces with a metal jacket.
3.4 INSTALLATION OF MINERAL-FIBER PREFORMED PIPE INSULATION
A. Insulation Installation on Straight Pipes and Tubes:
1. Secure each layer of preformed pipe insulation to pipe with wire or bands and tighten bands without deforming insulation materials. 2. Where vapor barriers are indicated, seal longitudinal seams, end joints, and protrusions with vapor-barrier mastic and joint sealant. 3. For insulation with factory-applied jackets on above-ambient surfaces, secure laps with outward clinched staples at 6 inches (150 mm) o.c. 4. For insulation with factory-applied jackets on below-ambient surfaces, do not staple longitudinal tabs. Instead, secure tabs with additional adhesive as recommended by insulation material manufacturer and seal with vapor-barrier mastic and flashing sealant.
B. Insulation Installation on Pipe Flanges:
1. Install preformed pipe insulation to outer diameter of pipe flange. 2. Make width of insulation section same as overall width of flange and bolts, plus twice the thickness of pipe insulation. 3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with mineral-fiber blanket insulation. 4. Install jacket material with manufacturer's recommended adhesive, overlap seams at least 1 inch (25 mm), and seal joints with flashing sealant.
C. Insulation Installation on Pipe Fittings and Elbows:
1. Install preformed sections of same material as straight segments of pipe insulation when available. 2. When preformed insulation elbows and fittings are not available, install mitered sections of pipe insulation, to a thickness equal to adjoining pipe insulation. Secure insulation materials with wire or bands.
D. Insulation Installation on Valves and Pipe Specialties:
1. Install preformed sections of same material as straight segments of pipe insulation when available. 2. When preformed sections are not available, install mitered sections of pipe insulation to valve body.
WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-7
3. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation. 4. Install insulation to flanges as specified for flange insulation application.
3.5 FIELD-APPLIED JACKET INSTALLATION
A. Where PVC jackets are indicated, install with 1-inch (25-mm) overlap at longitudinal seams and end joints. Seal with manufacturer's recommended adhesive.
1. Apply two continuous beads of adhesive to seams and joints, one bead under lap and the finish bead along seam and joint edge.
B. Where metal jackets are indicated, install with 2-inch (50-mm) overlap at longitudinal seams and end joints. Overlap longitudinal seams arranged to shed water. Seal end joints with weatherproof sealant recommended by insulation manufacturer. Secure jacket with stainless- steel bands 12 inches (300 mm) o.c. and at end joints.
3.6 FINISHES
A. Do not field paint aluminum or PVC jackets.
3.7 FIELD QUALITY CONTROL
A. Perform tests and inspections.
B. Tests and Inspections:
1. Inspect pipe, fittings, strainers, and valves, randomly selected by Architect, by removing field-applied jacket and insulation in layers in reverse order of their installation. Extent of inspection shall be limited to three locations of straight pipe, three locations of threaded fittings, three locations of welded fittings, two locations of threaded strainers, two locations of welded strainers, three locations of threaded valves, and three locations of flanged valves for each pipe service defined in the "Piping Insulation Schedule, General" Article.
C. All insulation applications will be considered defective Work if sample inspection reveals noncompliance with requirements.
3.8 PIPING INSULATION SCHEDULE, GENERAL Service Service Location Insulation Type Jacket Type Temperature Designation (oF) Non Potable Water Exterior Type1 Type 2 < 40 Interior Hot Water Interior Type 1 Type 1 100 to 200 Sodium Bisulfite Exterior Type2 Type 2 < 40
END OF SECTION 220719
WRCRWA PIPING INSULATION PLANT EXPANSION PROJECT 220719-8
SECTION 221030 – DUCTILE IRON PIPE
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall furnish and install all ductile iron pipe, fittings, transitions, connections and appurtenant work, complete and in accordance with the requirements of the Contract Documents.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Section 105000 – Pipeline Cathodic Protection B. Section 220050 – General Pipes and Fittings C. Section 221066 – Pipeline Testing D. Section 331400 – Hydraulic Structures Testing
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Commercial Standards:
ANSI/AWWA C104/A21.4 Cement-mortar lining for Ductile Iron and Gray Iron Pipe and Fittings for Water.
ANSI/AWWA C105/A21.5 Polyethylene Encasement for Gray and Ductile Cast Iron Piping for Water and Other Liquids.
ANSI/AWWA C110/A21.10 Fittings, 3-inch through 48-inch for Water and Other Liquids, Gray Iron and Ductile Iron.
ANSI/AWWA C111/A21.11 Rubber Gasket Joints for Ductile Iron and Gray Iron Pressure Pipe and Fittings.
ANSI/AWWA C115/A21.15 Flanged Ductile Iron and Gray Iron Pipe with Threaded Flanges.
ANSI/AWWA C150/A21.50 Thickness Design of Ductile Iron Pipe.
ANSI/AWWA C153/A21.53 Mechanical Joints (MJ), Push-on joints.
ANSI/AWWA C151/A21.51 Ductile Iron Pipe, Centrifugally Cast, in Metal Molds or Sand Lined Molds for Water and Other Liquids.
ANSI/AWWA C209 Cold Applied Coatings for the Exterior of Special Sections, Connections and Fittings for Steel Water Pipelines.
ANSI/AWWA C214 Tape Coating Systems for the Exterior of Steel Water Pipelines.
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-1 ANSI/AWWA C600 Water Mains and Appurtenances, Installation of Ductile Iron.
ANSI/ASTM D 1248 Polyethylene Lining Material for Ductile Iron Pipe and Fittings.
ASTM C 150 Specification for Portland Cement.
ASTM A 746 Installation of Ductile Iron Pipe for Gravity Sewers.
1.4 CONTRACTOR SUBMITTALS
A. The Contractor shall furnish a certified affidavit of compliance for all pipe and other products or materials furnished under this Section of the Specifications and as specified in the referenced standards. Certification shall include physical and chemical properties of pipe materials and hydrostatic test reports.
B. All expenses incurred in sampling and testing for certifications shall be borne by the Contractor.
1.5 QUALITY ASSURANCE
A. Ductile iron pipe shall be manufactured with the material, have the dimensions, be within the tolerances and meet the testing requirements set forth in ASTM A746 and ANSI A21.51. Ductile iron pipe shall be manufactured in nominal 18-foot or 20-foot laying lengths and shall have the lining called for in the Contract Documents.
B. All pipe shall be subject to inspection at the place of manufacture in accordance with the provisions of the referenced standards, as supplemented by the requirements herein.
C. In addition to those tests specifically required, the Engineer may request additional samples of any material including lining and coating samples for testing by the Owner. The additional samples shall be furnished at no additional cost to the Owner.
PART 2 - PRODUCTS
2.1 GENERAL
A. Mortar lined ductile iron pipe shall conform to ANSI/AWWA C151, C104, C105, C214 and D1248, subject to the following supplemental requirements. The pipe shall be of the diameter shown, shall be furnished complete with rubber gaskets as indicated in the Contract Documents and all specials and fittings shall be provided as required under the Contract Documents.
B. The pipe shall be handled by use of wide slings, padded cradles or other devices acceptable to the Engineer, designed and constructed to prevent damage to the pipe lining and/or coating. The use of chains, hooks or other equipment which might injure the pipe lining and coating will not be permitted. Stockpiled pipe shall be safely and properly supported to prevent accidental rolling. The Contractor shall be fully liable for the cost of replacement or repair of pipe which is damaged.
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-2
C. Maximum pipe laying lengths shall be 20-foot with shorter lengths provided as required by the Drawings.
D. The pipe shall have a smooth dense interior surface and shall be free from fractures, defects and roughness.
2.2 MATERIALS
A. Ductile iron pipe materials shall conform to the requirements of ANSI/AWWA C151/A21.51.
B. Fittings for ductile iron pipe shall conform to the requirements of ANSI/AWWA C110/A21.10 or AWWA C153 for diameters 3-inch through 48-inch. Ductile iron fittings larger than 48-inch shall conform to the above referenced standard with the necessary modifications for the larger size.
C. Cement for mortar lining shall conform to the requirements of ANSI/AWWA C104/A21.4; provided, that cement for mortar lining shall be Type II or V. A fly ash or pozzolan shall not be used as a cement replacement.
D. Glass lined ductile iron pipe and fittings shall be lined with a vitreous material which is hard, smooth, continuous and formulated to prevent the adherence of grease in sludge and scum lines, and to resist the adherence of crystalline metal salt deposits (struvite and vivionite) to sludge and centrate lines in sewage and wastewater treatment plants. It shall be applied to properly prepared pipe and fittings using accepted industry standards, and shall be tested per applicable ASTM, NACE and SSPC standards.
E. Material for the polyethylene encasement shall conform to the requirements of ANSI/AWWA C105/A21.5.
F. All elastomer gaskets used for ductile iron pipe shall be of neoprene or SBR elastomer material with a 1/8” thickness. For high temperature service (process air) gaskets shall be Viton. For high temperature water service gaskets shall be EPDM.
G. All bolts, nuts, and washers, which are buried, submerged or below the top of the wall inside any hydraulic structure used in the assembly of ductile iron pipe and fittings shall be of Type 316 Stainless Steel.
2.3 DESIGN OF PIPE
A. Ductile iron pipe shall be designed in accordance with the requirements of ANSI/AWWA C150/A21.50, as applicable and as modified in this Section. The pipe furnished shall be either mortar-lined or glass-lined as called out in the Contract Documents.
B. The pipe shall be designed, manufactured, tested, inspected and marked according to applicable requirements previously stated and except as hereinafter modified, shall conform to ANSI/AWWA C151.
C. The pipe and fittings shall be of the diameter shown and shall be of pressure Class 350 for pipe sizes twelve inches and below and pressure Class 250 for pipe fourteen inches to twenty inches and pressure class 200 for twenty four inch pipe and pressure class 150 for
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-3 thirty inch and above, except that where mechanical couplings are used and the pipe is grooved, the ductile iron pipe shall be of special thickness Class 53.
D. Ductile iron pipe and fittings shall be furnished with mechanical joints, push-on joints, flanged joints and restrained joints as required.
1. All Mechanical and push-on joints may conform to ANSI/AWWA C153/A21.53 or C110/A21.10.
2. Flanged joints shall conform to ANSI/AWWA C115/A21.15.
E. For bell-and-spigot ends with rubber gaskets, the clearance between the bells and spigots shall be such that when combined with the gasket groove configuration and the gasket itself, will provide watertight joints under all operating conditions when properly installed. The Contractor shall require the pipe manufacturer to submit details complete with significant dimensions and tolerances and also to submit performance data indicating that the proposed joint has performed satisfactorily under similar conditions. In the absence of a history of field performance, the results of a test program shall be submitted.
2.4 CEMENT-MORTAR LINING
A. Except as otherwise provided herein, interior surfaces of ductile iron pipe, fittings and specials to be furnished with cement-mortar lining shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with ANSI/AWWA C104. If lining is damaged or found faulty at delivery site, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications.
B. The minimum lining thickness shall be as follows:
Nominal Pipe Diameter Minimum Lining Thickness (inches) (inches) 3-12 1/8 14-24 3/16 30-54 1/4
C. For all pipe and fittings with plant-applied cement mortar linings, the Contractor shall provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special openings. All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed.
2.5 GLASS LINING
A. The lining material shall consist of vitreous and inorganic material applied to the internal surfaces that have been prepared by blasting. The lining shall be applied in a minimum of two (2) coats, separately applied and separately fired. The items shall be exposed to a maturing temperature of approximately 1400 degrees F., at which point the vitreous and inorganic materials melt and fuse to the base metal, forming an integral molecular bond with the base metal surface. Subsequent coatings will be processed in a similar manner, forcing an integral molecular bond with the base coat. The entire finished coating shall be a minimum of 10 mils (.010”) as tested with a micro test or other acceptable dry film thickness gauge. The finished lining shall be able to withstand a strain of 0.001 inch/inch
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-4 (the yield point of the base metal) without damage to the glass. The lining shall be of a light, bright color to allow visual detection of defects more easily prior to electronic holiday detection testing.
B. The lining shall have a hardness of 5-6 on the MOHS scale, and a density of 2.5-3.0 grams per cubic centimeter as measured by ASTM D-792. The glass lining shall be capable of withstanding an instantaneous thermal shock of 350 degrees F. differential without crazing, blistering or spalling. It shall be resistant to corrosion of between PH-3 and PH-10 at 125 degrees F. There shall be no visible loss of surface gloss to the lining after immersing a production sample in an 8% sulfuric acid solution at 148 degrees F. for a period of 10 minutes. When tested according to ASTM C-283, it shall show a weight loss of not more than 3 milligrams per square inch.
C. Per the recommended industry standards under ASTM D-5162-01, NACE RP 0188-99, and SSPC Coating Manual, Volume 1, Section XIV, the glass lining shall be tested by “low voltage, wet sponge, non-destructive holiday detection unit”, with only isolated voids permitted due to casting anomalies. Documentation shall be furnished with each shipment of material listing the test results by identifying “mark” or “tag” numbers.
D. The finished glass lined pipe shall not deviate more than 0.0125 inch per foot of length from a centerline perpendicular to the square pipe end or flange face.
E. The applicator shall have a minimum of 5 years of successful experience in the application of high temperature glass and porcelain coatings for the wastewater and sewage treatment industry. All glass lining of pipe and fittings should be from one manufacturer.
F. All handling and/or lifting of glass lined pipe and fittings must be done on the exterior only. Avoid lifting internally with hooks, forks or chains at any time.
2.5 EXTERIOR COATING OF PIPE
A. The exterior surfaces of ductile iron pipe which will be exposed to the atmosphere inside structures or above ground shall be thoroughly cleaned and then given a shop coat of rust-inhibitive primer conforming to the requirements of Section 098000 entitled, "Protective Coating." This exposed piping shall not be coated with the bituminous coating by the manufacturer prior to delivery.
B. Buried ductile iron pipe shall be pipe shall be epoxy-coated according to requirements of Section 098000 “Protective Coatings”.
C. Submerged ductile iron pipe shall be epoxy-coated according to requirements of Section 098000 “Protective Coatings”.
2.5 RESTRAINED JOINTS
A. Restrained joints shall conform to either ANSI/AWWA C111/A21.11 or ANSI/AWWA C153/A21.53.
B. Restraint devices for pipe sizes 3” – 48” shall consist of multiple gripping wedges incorporated into a follower gland meeting the applicable requirements of ANSI/AWWA C110/A21.10. The devices shall have a working pressure rating of 350 psi for 3”-16”
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-5 and 250 psi for 18”-48”. Ratings are for water pressure and must include a minimum safety factor of 2 to 1 in all sizes.
C. Gland body, wedges and wedge actuating components shall be cast from grade 65-45-12 ductile iron material in accordance with ASTM A536. For applications requiring restraint 30” and greater, an alternate grade of iron meeting the material requirements of ASTM A536 is acceptable, providing the device meets all end product performance requirements. Ductile iron gripping wedges shall be heat treated within a range of 370 to 470 BHN.
D. Three (3) test bars shall be incrementally poured per production shift as per UL specifications and ASTM A536. Testing for tensile, yield and elongation shall be done in accordance with ASTM E8. Chemical and nodularity tests shall be performed as recommended by the Ductile Iron Society, on a per ladle basis.
E. Mechanical joint restraint for ductile iron pipe shall be:
a. Megalug Series 1100 for Fittings b. Megalug Series 1700 for Joints c. Megalug Series 3800 for Couplings
produced by EBAA Iron Inc. or equal.
F. Finish shall be Megabond, or equal.
PART 3 - EXECUTION
3.1 INSTALLATION OF PIPE
A. All pipe, fittings, etc. shall be carefully handled and protected against damage, impact shocks and free fall. All pipe handling equipment shall be acceptable to the Engineer. Pipe shall not be placed directly on rough ground, but shall be supported in a manner which will protect the pipe against injury whenever stored at the trench site in accordance with Paragraph 2.1B, herein. All pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor.
B. The Contractor shall inspect each pipe and fitting prior to installation to ensure that there are no damaged portions of the pipe. No pipe shall be installed where the lining or coating show defects that may be harmful as determined by the Engineer. Such damaged lining or coating shall be repaired, or a new undamaged pipe shall be furnished and installed.
C. The pipe shall be installed in accordance with ANSI/AWWA C600. Before placement of the pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the Work. As pipe laying progresses, the Contractor shall keep the pipe interior free of all debris. The Contractor shall completely clean the interior of the pipe of all sand, dirt, rocks and any other debris following completion of pipe laying prior to testing and disinfecting the completed pipeline.
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-6 D. Pipe shall be laid directly on the imported bedding material. No blocking will be permitted and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent joint loading at the bells or couplings. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coating on field joints.
E. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the Engineer may change the alignment and/or the grades. Such change shall be made by the deflection of joints, by the use of bevel adapters or by the use of additional fittings. However, in no case shall the deflection in the joint exceed the maximum deflection recommended by the pipe manufacturer.
F. No pipe shall be installed upon a foundation into which frost has penetrated or at any time that there is a danger of the formation of ice or penetration of frost at the bottom of the excavation. No pipe shall be laid unless it can be established that the trench will be backfilled before the formation of ice and frost occurs.
G. The openings of all pipe and specials where the pipe and specials have been cement- mortar lined in the shop shall be protected with suitable bulkheads to prevent unauthorized access by persons, animals, water or any undesirable substance. At all times, means shall be provided to prevent the pipe from floating.
H. Immediately before jointing pipe, the bell end of the pipe shall be thoroughly cleaned and a clean rubber gasket lubricated with an approved vegetable-based lubricant shall be placed in the bell groove. The spigot end of the pipe shall be carefully cleaned and lubricated with a vegetable-based lubricant. The spigot end of the pipe section shall then be inserted into the bell of the previously laid joint and telescoped into its proper position. Tilting of the pipe to insert the spigot into the bell will not be permitted.
I. All valves shall be handled in a manner to prevent any injury to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation. The Contractor shall adjust all stem packing and operate each valve prior to installation to ensure proper operation. All valves shall be installed so that the valve stems are plumb and in the location shown.
J. All ductile iron pipes and fittings shall have cathodic protection, in accordance with Section 105000.
K. All buried bolts shall be coated with FM grease prior to applying the polyethylene wrap.
END OF SECTION 221030
WRCRWA DUCTILE IRON PIPE PLANT EXPANSION PROJECT 221030-7 SECTION 221040 - PLASTIC PIPE
PART 1 - GENERAL
1.1 THE REQUIREMENT:
A. The Contractor shall furnish and install all PVC and polyethylene plastic pipe, fittings, transitions, connections and appurtenant work, complete and in accordance with the requirements of the Contract Documents.
1.2 RELATED WORK SPECIFIED ELSEWHERE:
A. Earth Moving. Section 312000
B. Pipeline Testing. Section 221066
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS:
A. Commercial Standards:
ASTM D 1784 and ASTM D 1785 Specifications for Polyvinyl Chloride (PVC) Plastic Pressure Pipe and Solvents ASTM D 3034 Specifications for Polyvinyl Chloride (PVC) Plastic Gravity Sewer Pipe ASTM D 2321 Standard Practice for Underground Installation of Flexible Thermoplastic Sewer Pipe ASTM F894 Specification for Polyethylene (PE) Large Diameter Profile Wall Sewer and Drain Pipe. ASTM D3350 Specification for Polyethylene Plastics Pipe and Fittings Materials.
1.4 CONTRACTOR SUBMITTALS:
A. Contractor shall submit copies of the manufacturer's product specifications according to the requirements of Section 013300 entitled, "Contractor Submittals".
PART 2 - PRODUCTS
2.1 PVC (POLYVINYL CHLORIDE) PRESSURE PIPE, 24-INCH DIAMETER AND SMALLER - SOLVENT WELDED
A. PVC pressure pipe 24-inches and smaller shall be made from all new rigid un-plasticized polyvinyl chloride and shall be Normal Impact Class 12454-B, Schedule 80, to conform to ASTM D 1785, unless otherwise shown. Elbows and tees shall be of the same material and schedule as the pipe. Unless otherwise shown, joint design shall be for solvent-welded construction.
B. Solvent welded PVC and CPVC joints shall utilize heavy solvent welding glue, suitable for chemical exposure applications including sodium hypochlorite solution (up to 20% concentration) and sodium bisulfate solution (up to 50% concentration). Solvents shall meet
WRCRWA PLASTIC PIPE PLANT EXPANSION PROJECT 221040-1 ASTM F 493, ASTM D 2846, ASTM D 2564 standards and SCAQMD Rule 1168/316A. PVC solvent weld shall be WELD-ON brand as manufactured by IPS Corporation or equal. Installation shall conform to ASMT D-2855 and manufacturer instructions. The following solvents are provided for reference, Contractor shall confirm appropriate installation and application with the solvent supplier:
Up to 12” PVC (schedule 40 or 80): Weld-On 711 & 717 Up to 30” PVC (schedule 40 or 80): Weld On 719 Up to 12” CPVC (schedule 40 or 80): Weld-On 714 & 724 Up to 30” CPVC (schedule 40 or 80): Weld-On 729
C. Contractor shall apply primers (Weld-On P-70) and prepare the solvent welded joints as recommended by the manufacturer.
2.2 CPVC (CHORINATED POLYVINYL CHLORIDE) PRESSURE PIPE, 8-INCHES AND SMALLER – SOLVENT WELDED
D. All CPVC pipe shall be made from all new rigid, un-plasticized Type IV, Grade I Chlorinated Polyvinyl Chloride (CPVC) compound with a cell classification of 23447, Schedule 80, per ASTM D 1784. The pipe shall be manufactured in compliance to ASTM F441, meeting all requirements with regard to material, workmanship, burst pressure, flattening, and extrusion quality.
E. Solvent welded PVC and CPVC joints shall utilize heavy solvent welding glue, suitable for chemical exposure applications. Solvents shall meet ASTM F 493, ASTM D 2846, ASTM D 2564 standards and SCAQMD Rule 1168/316A. PVC solvent weld shall be WELD-ON brand as manufactured by IPS Corporation or equal. Installation shall conform to ASTM D- 2855 and manufacturer instructions. The following solvents are recommended by IPS Corporation
Up to 12” PVC (schedule 40 or 80): Weld-On 711 & 717 Up to 30” PVC (schedule 40 or 80): Weld-On 719 Up to 12” CPVC (schedule 40 or 80): Weld-On 714 & 724 Up to 24” CPVC (schedule 40 or 80): Weld-On 729
Contractor shall consult with solvent manufacturer to ensure proper use and application for each pipe size required in the design drawings. Contractor shall apply primers (Weld-On P- 70) and prepare the solvent welded joints as recommended by the manufacturer.
2.3 DOUBLE WALL CONTAINMENT PVC AND CPVC PIPING AND FITTINGS – SOLVENT WELDED
A. Contractor shall furnish a complete double-containment piping system including piping, fittings, anchors, terminations, and other appurtenances. Containment piping shall conform to the following standards:
ASTM D 1784 ASTM D 1970 ASTM F 437 ASTM F 439 ASTM F 441
WRCRWA PLASTIC PIPE PLANT EXPANSION PROJECT 221040-2
B. All double containment pipe for buried chemical service shall consist of an outer containment pipe of Schedule 80 PVC or CPVC by an inner product pipe of Schedule 80 PVC or CPVC pipe, material as specified in the design drawings and pipe schedules. Containment pipe shall be at least 2 sizes larger than product pipe. Transition to single wall piping must be above the finished grade or floor.
C. Where joining to existing below grade containment lines (pipe in a pipe style containment lines), contractor shall utilize CPVC couplers, bushings, or fittings as necessary to connect the new containment pipe to the existing containment pipe lines. Note that existing lines may utilize different containment line diameter sizes than that of the new containment pipe. Contractor shall coordinate couplings and tie-ins to existing containment pipe with the containment pipe supplier.
D. Containment PVC and CPVC pipe shall be:
1. Asahi/America – Pro-Lock 2. IPS Flow Systems - Duo-Safe 3. Or Equal
E. For transition from double containment below grade service to single wall above grade service, provide a cap to cover and prevent water, debris or other items from falling into the containment pipe.
F. Solvent welded PVC and CPVC joints shall utilize heavy solvent welding glue, suitable for chemical exposure applications. Solvents shall meet ASTM F 493, ASTM D 2846, ASTM D 2564 standards and SCAQMD Rule 1168/316A. PVC solvent weld shall be WELD-ON brand as manufactured by IPS Corporation or equal. Installation shall conform to ASTM D- 2855 and manufacturer instructions. The following solvents are recommended by IPS Corporation:
Up to 12” PVC (schedule 40 or 80): Weld-On 711 & 717 Up to 30” PVC (schedule 40 or 80): Weld-On 719 Up to 12” CPVC (schedule 40 or 80): Weld-On 714 & 724 Up to 24” CPVC (schedule 40 or 80): Weld-On 729
Contractor shall consult with solvent manufacturer to ensure proper use and application for each pipe size required in the design drawings. Contractor shall apply primers (Weld-On P- 70) and prepare the solvent welded joints as recommended by the manufacturer. Contractor shall also consult with the containment pipe supplier regarding solvent welding procedures.
2.4 AWWA C-900 PLASTIC PIPE (4”-12”)
A. Pipe shall meet the requirements of AWWA C900 “Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4-Inch through 12-Inch with maximum DR of 18 unless noted otherwise.
B. Provisions must be made for expansion and contraction at each joint with an elastomeric seal.
C. The bell shall consist of an integral thickened wall section with an elastomeric seal. The wall thickness in the bell section shall conform to the requirements of Section 6.2 of ASTM
WRCRWA PLASTIC PIPE PLANT EXPANSION PROJECT 221040-3 D3139, “Standard Specification for Joint for Plastic Pressure Pipes Using Flexible Elastomeric Seals.”
D. When used for potable water systems, pipe shall meet the requirements of ANSI/NSF 61 “Drinking Water System Components – Health Effects.”
E. The pipe shall be manufactured to cast iron outside diameters (CIOD) in accordance with AWWA C900.
F. The seal shall meet the requirement of ASTM F477 “Standard for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.”
G. All fittings shall be ductile iron fittings, as required in Section 221030.
2.5 AWWA C-905 PLASTIC PIPE (14”-42”)
A. Material: PVC compound shall meet Cell Class 12454 per ASTM D 1784 and shall be certified to ANSI/NSF Standard 61 for potability.
B. Pipe shall meet AWWA C905 with a maximum DR of 41 and shall be UL listed.
C. Elastomeric Seal: Integral bell pipe shall be provided with factory-installed gaskets, which meet the requirements of ASTM F 477.
D. Gasketed joint assembly shall meet the requirements of ASTM D 3139.
E. All fittings shall be ductile iron fittings, as required in Section 221030.
2.6 DRAIN WASTE VENT PIPE (PVC DR-35 ½” – 8”)
A. Pipe shall be extruded from PVC Compound having a minimum Cell Classification 12454B as defined in ASTM D 1784. Belled end shall conform to ASTM D 2672, “Joints for PVC Pipe Using Solvent Cements”, and shall conform to ASTM D 2855.
2.7 RESTRAINED JOINTS
A. Restrained joints shall conform to either ANSI/AWWA C111/A21.11 or ANSI/AWWA C153/A21.53.
B. Restraint devices for pipe sizes 3” – 48” shall consist of multiple gripping wedges incorporated into a follower gland meeting the applicable requirements of ANSI/AWWA C110/A21.10. The devices shall have a working pressure rating of 350 psi for 3”-16” and 250 psi for 18”-48”. Ratings are for water pressure and must include a minimum safety factor of 2 to 1 in all sizes.
C. Gland body, wedges and wedge actuating components shall be cast from grade 65-45-12 ductile iron material in accordance with ASTM A536. For applications requiring restraint 30” and greater, an alternate grade of iron meeting the material requirements of ASTM A536 is acceptable, providing the device meets all end product performance requirements. Ductile iron gripping wedges shall be heat treated within a range of 370 to 470 BHN.
WRCRWA PLASTIC PIPE PLANT EXPANSION PROJECT 221040-4
D. Three (3) test bars shall be incrementally poured per production shift as per UL specifications and ASTM A536. Testing for tensile, yield and elongation shall be done in accordance with ASTM E8. Chemical and nodularity tests shall be performed as recommended by the Ductile Iron Society, on a per ladle basis.
E. Mechanical join restraint for PVC pipe shall be:
1. Megalug Series 2000 or 2200 produced by EBAA Iron Inc. or equal for fittings. 2. Megalug Series 1900 or 2800 produced by EBAA Iron Inc. or equal for joints.
F. Finish coating shall be Megabond, or equal.
PART 3 - EXECUTION
3.1 INSTALLATION OF PIPE:
A. All pipe, fittings, etc. shall be carefully handled and protected against damage, impact shocks and free fall. All pipe handling equipment shall be acceptable to the Engineer. Pipe shall not be placed directly on rough ground, but shall be supported in a manner which will protect the pipe against injury whenever stored at the work site. All pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor.
B. The Contractor shall inspect each pipe and fitting prior to installation to ensure that there are no damaged portions of the pipe. Damaged pipe shall be replaced with new undamaged sections of pipe.
C. Before placement of the pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the Work. As pipe laying progresses, the Contractor shall keep the pipe interior free of all debris. The Contractor shall completely clean the interior of the pipe of all sand, dirt, rocks and any other debris following completion of pipe laying prior to testing, disinfecting and placing the completed pipeline in service.
D. Pipe shall be laid directly on the imported bedding material. No blocking will be permitted and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Bell holes shall be formed at the ends of the pipe to prevent joint loading at the bells or couplings.
E. Where necessary to raise or lower the pipe grade due to unforeseen obstructions or other causes, the Engineer may change the alignment and/or the grades. Such change shall be made by the deflection of joints or by the use of additional fittings. However, in no case shall the deflection in the joint exceed the maximum deflection recommended by the pipe manufacturer.
F. No pipe shall be installed upon a foundation into which frost has penetrated or any time that there is a danger of the formation of ice or penetration of frost at the bottom of the excavation.
WRCRWA PLASTIC PIPE PLANT EXPANSION PROJECT 221040-5 No pipe shall be laid unless it can be established that the trench will be backfilled before the formation of ice and frost occurs.
G. Immediately before jointing bell and spigot pipe, both the bell and spigot end of the pipe shall be thoroughly cleaned and lubricated with an approved vegetable-based lubricant. The spigot end of the pipe section shall then be inserted into the bell of the previously laid joint and telescoped into its proper alignment. Tilting of the pipe to insert the spigot into the bell will not be permitted.
H. Solvent-welded and heat-fused joints shall be carefully and thoroughly cleaned immediately before jointing the pipe. Particular care shall be taken in making solvent-welded joints to ensure a uniform, homogeneous and complete bond.
I. All buried PVC piping, 4” and greater, shall have both a marking tape placed 12” above the pipe, and a tracer wire placed on top of the pipe. Tracer wire shall be 12 gauge solid copper wire with a plastic coat to prevent corrosion. The tracer shall be secured to the pipe10 feet and at all bends. Tracer wire shall not be wrapped around a pipe. Tracer wire installation requires access points at least every 300 feet. At access points the tracer wire is brought up to grade with valve boxes, cleanouts, manholes, vaults, or other covered access devices. Splices in tracer wire should be made with split bolt or compression-type connectors. Wire nuts shall not be used. Testing of tracer wire continuity after installation shall be performed.
END OF SECTION 221040
WRCRWA PLASTIC PIPE PLANT EXPANSION PROJECT 221040-6 SECTION 221050 – HIGH DENSITY POLYETHYLENE PIPE AND FITTINGS
PART 1 – GENERAL
1.1 TERMS AND CONDITIONS
A. Scope. This specification covers requirements for high-density polyethylene pipe and fittings for general purpose applications. All work shall be performed in accordance with these specifications.
B. Referenced Standards. All standard specification, i.e., Federal, ANSI, ASTM, etc., made a portion of these Specifications by reference, shall be the latest edition and revision thereof.
1.2 CONTRACTOR SUBMITTALS
A. Contractor shall submit copies of the manufacture’s product specifications according to the requirements of section 013300 entitled, “Contractor Submittals”.
PART 2 – POLYETHYLENE PIPE AND FITTINGS
2.1 GENERAL REQUIREMENTS
A. Qualification of Manufacturers. The Manufacturer shall have manufacturing and quality control facilities capable of producing and assuring the quality of the pipe and fittings required by these Specifications. The Manufacturer’s production facilities shall be open for inspection by the Owner or his Authorized Representative. Qualified Manufacturers shall be approved by the Project Engineer.
B. Materials. Materials used for the manufacture of polyethylene pipe and fittings shall be PE3408 high density polyethylene meeting cell classification 345444C or 345444E per ASTM D 3350; and shall be listed in the name of the pipe and fitting Manufacturer in PPI1 TR-4, Recommended Hydrostatic Strengths and Design Stresses for Thermoplastic Pipe and Fittings Compounds, with a standard grade HDB rating of 1600 psi at 73¡F. The Manufacturer shall certify that the materials used to manufacture pipe and fittings meet these requirements.
1. Typical material properties shall be submitted to the project design engineer for analysis. These properties are to be used for engineering evaluation and are not to be misconstrued as specification minimums.
C. Gravity Lines (HDPE 18” up to and including 36”):
Unless noted otherwise the DR shall be a maximum of 21.
D. Pressure Lines (1 inch to 4 inches)
Unless noted otherwise the DR shall be a maximum of 11.
E. Interchangeability of Pipe and Fittings. Polyethylene pipe and fittings shall be supplied by the same Manufacturer. Pipe and fittings from different Manufacturers shall not be interchanged.
WRCRWA HIGH DENSITY POLYETHYLENE PIPE & FITTINGS PLANT EXPANSION PROJECT 221050-1
1. Polyethylene Pipe. Polyethylene pipe shall be manufactured in accordance with ASTM F 714, Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Outside Diameter, or ASTM D 3035, Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter and shall be so marked. Each production lot of pipe shall be tested for (from material or pipe) melt index, density, % carbon (from pipe), dimensions and either quick burst or ring tensile strength (equipment permitting).
2. Polyethylene Fittings & Custom Fabrications. Polyethylene fittings and custom fabrications shall be molded or fabricated by the pipe manufacturer. Butt fusion outlets shall be made to the same outside diameter, wall thickness, and tolerances as the mating pipe. All fittings and custom fabrications shall be fully rated for the same internal pressure as the mating pipe. Pressure de-rated fabricated fittings are prohibited.
a. Molded Fittings. Molded fittings shall be manufactured in accordance with ASTM D 3261, Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing, and shall be so marked. Each production lot molded fittings shall be subjected to the tests required under ASTM D 3261.
b. Fabricated Fittings. Fabricated fittings shall be made by heat fusion joining specially machined shapes cut from pipe, polyethylene sheet rock, or molded fittings. Fabricated fittings shall be rated for internal pressure service equivalent to the full service pressure rating of the mating pipe. Directional fittings 16” IPS and larger such as elbows, tees, crosses, etc., shall have a plain end inlet for butt fusion and flanged directional outlets. Part drawing shall be submitted for the approval of the Project Engineer.
c. Back-up Rings & Flange Bolts. Flange adapters shall be fitted with lap joint flanges pressure rated equal to or greater than the mating pipe. The lap joint flange bore shall be chamfered or radiused to provide clearance to the flange adapter radius. Flange bolts and nuts shall be stainless steel.
F. Manufacturer’s Quality Control. The pipe and fitting manufacturer shall have an established quality control program responsible for inspecting incoming and outgoing materials. Incoming polyethylene materials shall be inspected for density, melt flow rate, and contamination. The cell classification properties of the material shall be certified by the supplier, and verified by Manufacturer’s Quality Control. Incoming materials shall be approved by Quality Control before processing into finished goods.
Outgoing materials shall be checked for:
Outside diameter, wall thickness, and eccentricity as per ASTM D2122 at a frequency of at least once/hour or once/hour, whichever is less frequent. Out of Roundness at a frequency of at least once/hour or once/coil whichever is less frequent. Straightness, inside and outside surface finish, markings and end cuts shall be visually inspected as per ASTM F714 on every length of pipe.
Quality Control shall verify production checks and test for:
WRCRWA HIGH DENSITY POLYETHYLENE PIPE & FITTINGS PLANT EXPANSION PROJECT 221050-2 Density as per ASTM D1505 at a frequency of at least once per extrusion lot. Melt Index as per ASTM D1238 at a frequency of at least once per extrusion lot. Carbon content as per ASTM D1603 at a frequency of at least once per day per extrusion line. Quick burst pressure (sizes thru 4”0 as per ASTM D1599 at a frequency of at least once per day per line. Ring Tensile Strength (sizes above 4” equipment permitting) as per ASTM D2290 at a frequency of a least once per day per line. ESCR (size permitting) as per ASTM F1248 at a frequency of at least once per extrusion lot.
X-Ray inspection shall be used to inspect molded fittings for voids, and knit line strength shall be tested. All fabricated fittings shall be inspected for joint quality and alignment.
1. Permanent Records. The Manufacturer shall maintain permanent QC and QA records.
G. Compliance Tests – Manufacturer’s inspection and testing of the materials. In case of conflict with Manufacturer’s certification, the Contractor, Project Engineer, or Customer my request retesting by the Manufacturer or have retests performed by an outside testing service. All retesting shall be at the requestor’s expense, and shall be performed in accordance with the Specifications.
PART 3 – JOINING
3.1 REQUIREMENTS
A. Heat Fusion Joining. Joints between plain end pipes and fittings shall be made by butt fusion, and joints between the main and saddle branch fittings shall be made using only saddle fusion procedures that are recommended by the pipe and fitting Manufacturer. The Contractor shall ensure that persons making heat fusion joints have received training in the Manufacturer’s recommended procedure. The Contractor shall maintain records of trained personnel, and shall certify that training was received not more than 12 months before commencing construction. External and internal beads shall not be removed.
1. Heat Fusion Training Services. Upon request, the Manufacturer shall provide assistance in the Customer’s recommended butt fusion and saddle fusion procedures to the Contractor’s installation personnel, and to inspectors representing the Customer.
B. Mechanical Joining. Polyethylene pipe and fittings may be joined together or to other materials by means of flanged connections (flange adapters and back-up rings) or mechanical couplings designed for joining polyethylene pipe or for joining polyethylene pipe to another material. Mechanical couplings shall be fully pressure rated and fully thrust restrained such that when installed in accordance with manufacturer’s recommendations, a longitudinal load applied to the mechanical coupling will cause the pipe to yield before the mechanical coupling disjoins. External joint restraints shall not be used in lieu of fully restrained mechanical couplings.
WRCRWA HIGH DENSITY POLYETHYLENE PIPE & FITTINGS PLANT EXPANSION PROJECT 221050-3 C. Branch Connections. Branch connections to the main shall be made with saddle fittings or tees. Polyethylene saddle fittings shall be saddle fused to the main pipe.
D. Electro Fusion Couplings. Fittings shall be PE4710 or PE 3608, with a minimum Cell Classification to match the pipe. Electrofusion fittings shall have a manufacturing standard of ASTM F1055. Fittings shall have a pressure rating equal to the pipe. Joining shall be done in accordance with the manufacturers recommended procedure. Other sources of electrofusion joining information are ASTM F 1290 and PPI TN 34. Qualification of the fusion technician shall be demonstrated by evidence of electrofusion training within the past year on the equipment to be utilized for this project.
PART 4 – INSTALLATION
4.1 GENERAL REQUIREMENTS
A. General. The Manufacturer shall package products for shipment in a manner suitable for safe transport by commercial carrier. When delivered, a receiving inspection shall be performed, and any shipping damage shall be reported to the Manufacturer within 7 days. Installation shall be in accordance with Manufacturer’s recommendations, and this specification. All necessary precautions shall be taken to ensure a safe working environment in accordance with applicable codes and standards.
B. Large Diameter Fabricated Fittings. Fabricated directional fittings 16” IPS and larger shall be butt fused to the end of a pipe. The flanged directional outlet connections shall be made up in the trench.
C. Foundation & Bedding. Pipe shall be laid on grade and on a stable foundation. Unstable or mucky trench bottom soils shall be removed, and a 6” foundation or bedding of compacted Type 4 material shall be installed to pipe bottom grade. Excess groundwater shall be removed from the trench before laying the foundation or bedding and the pipe. A trench cut in rock or stony soil shall be excavated to 6” below pipe bottom grade, and brought back to grade with compacted Type 4 bedding. All ledge rock, boulders and large stones shall be removed.
D. Pipe Handling. When lifting with slings, only wide fabric choker slings capable of safely carrying the load, shall be used to lift, move, or lower pipe and fittings. Wire rope or chain shall not be used. Slings shall be of sufficient capacity for the load, and shall be inspected before use. Worn or defective equipment shall not be used.
PART 5 – TESTING
5.1 QUALITY ASSURANCE
A. Butt Fusion Testing. On every day butt fusions are to be made, the first fusion of the day shall be a trial fusion. The trial fusion shall be allowed to cool completely, then fusion test straps shall be cut out. The test strap shall be 12” (min) or 30 times the wall thickness in length with the fusion in the center, and 1” (min) or 1.5 times the wall thickness in width. Bend the test strap until the ends of the strap touch. If the fusion fails at the joint, a new trial fusion shall be made, cooled completely and tested. Butt fusion of pipe to be installed shall not commence until a trial fusion has passed the bent strap test.
WRCRWA HIGH DENSITY POLYETHYLENE PIPE & FITTINGS PLANT EXPANSION PROJECT 221050-4 Pressure Testing. The initial pressure test can be conducted before the line is backfilled. However, it is advisable to cover the pipe at intervals or particularly at curves to hold the pipe in place during pressure test. Flanged connections may be left exposed for visual leak inspection. The main shall be tested after the final installation is completed.
Test pressure should not exceed 1.5 times the rated operating pressure of the pipe or the lowest rated component in the system. The initial pressure test shall be applied and allowed to stand without make up pressure for a sufficient time to allow for diametric expansion or pipe stretching to stabilize. This usually occurs within 2 to 3 hours. After this equilibrium period, the test section can be returned to the 1.5 times operating pressure, the pump turned off, and a final test pressure held for 2 hours.
Allowable amounts of make-up water for expansion during pressure test is shown below. There shall be no visual leaks or pressure drops greater than 5 PSI during the final test period.
ALLOWANCE FOR EXPANSION UNDER TEST PRESSURE NOMINAL U.S. GALLONS/100 FEET OF PIPE PIPE SIZE 1 HOUR 2 HOURS 3 HOURS 2" 0.08 0.12 0.15 3" 0.10 0.15 0.25 4" 0.13 0.25 0.40 5" 0.21 0.41 0.63 6" 0.30 0.60 0.90 8" 0.50 1.00 1.50 10" 0.75 1.30 2.10 12" 1.10 2.30 3.40 14" 1.40 2.80 4.20 16" 1.70 3.30 5.00 18" 2.20 4.30 6.50 20" 2.80 5.50 8.00 22" 3.50 7.00 10.50 24" 4.50 8.90 13.30 28" 5.50 11.10 16.80 30" 6.20 12.60 19.10 32" 7.00 14.30 21.50 36" 9.00 18.00 27.00 42" 12.00 24.00 36.00 48" 15.00 27.00 43.00 54" 18.00 30.00 50.00
Under no circumstances shall the total time under test exceed 3 hours at 1 ½ times the pressure rating. If the test is not completed because of leakage, equipment failure, or other reason, the test section shall be permitted to ‘relax’ for 8 hours before the next testing sequence. Pneumatic pressure testing is NOT allowed.
END OF SECTION 221050
WRCRWA HIGH DENSITY POLYETHYLENE PIPE & FITTINGS PLANT EXPANSION PROJECT 221050-5 SECTION 221055 – HDPE STORM DRAIN PIPE
PART 1 - GENERAL
1.1 THE REQUIREMENT:
A. The Contractor shall furnish and install all HDPE storm drainage pipe, fittings, transitions where indicated in the drawings.
1.2 SCOPE:
A. This specification describes 12- through 30-inch ADS N-12 HP pipe for use in gravity-flow storm drainage applications.
PART 2 – PRODUCTS
2.1 Pipe shall be ADS N-12 HP pipe as manufactured by ADS, Inc., or Equal.
2.2 PIPE REQUIREMENTS:
A. 12- through 30-inch pipe shall have a smooth interior and annular exterior corrugations and meet or exceed ASTM F2736 and AASHTO MP-21-11. B. Pipe shall be joined with a gasketed integral bell & spigot joint meeting the requirements of ASTM F2736 and F2881, for the respective diameters. C. 12- through 30-inch shall be watertight according to the requirements of ASTM D3212. D. Spigots shall have gaskets meeting the requirements of ASTM F477. Gasket shall be installed by the pipe manufacturer and covered with a removable, protective wrap to ensure the gasket is free from debris. A joint lubricant available from the manufacturer shall be used on the gasket and bell during assembly. E. 12- through 30-inch diameters shall have a reinforced bell with a polymer composite band installed by the manufacturer.
2.3 FITTINGS:
A. Fittings shall conform to ASTM F2736, ASTM F2881 and AASHTO MP-21-11, for the respective diameters. B. Bell & spigot connections shall utilize a spun-on, welded or integral bell and spigot with gaskets meeting ASTM F477. Bell & spigot fittings joint shall meet the watertight joint performance requirements of ASTM D3212. C. Corrugated couplings shall be split collar, engaging at least 2 full corrugations.
PART 3 – EXECUTION
3.1 FIELD PIPE AND JOINT PERFORMANCE:
A. To assure watertightness, field performance verification may be accomplished by testing in accordance with ASTM F2487. Appropriate safety precautions must be used when field- testing any pipe material. Contact the manufacturer for recommended leakage rates.
WRCRWA HDPE STORM DRAIN PIPE PLANT EXPANSION PROJECT 221055-1 3.2 INSTALLATION:
B. Installation shall be in accordance with ASTM D2321 and ADS recommended installation guidelines, with the exception that minimum cover in traffic areas for 12- through 48-inch diameters shall be one foot.
END OF SECTION 221055
WRCRWA HDPE STORM DRAIN PIPE PLANT EXPANSION PROJECT 221055-2 SECTION 221060 – STAINLESS STEEL PIPING AND TUBING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: Stainless steel piping and tubing, and alloy steel pipe.
1.2 REFERENCES
A. American National Standards Institute (ANSI) B16.9 factory made wrought steel butt welded fittings.
B. American Society for Testing and Materials (ASTM) :
1. A 240 – Standard Specification for Heat-Resisting Chromium and Chromium –Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Stainless Steel Piping
1. General: a. Stainless steel piping 12 inches and smaller in nominal pipe size, with minimum wall thickness corresponding to schedules showing in the drawings.
b. Stainless steel piping larger than 12 inches in diameter shall be in accordance with ASTM A 409 – Specification for Welded Large Diameter Austenitic Steel Pipe for Corrosive or High-Temperature Service, of the schedules indicated in the drawings, with welded or flanged joints.
2. Pipe sizes specified in the Specifications and indicated on the Drawings are nominal. 3. Supply piping 12 inches and less in diameter in 10 foot and 20 foot lengths without intermediate butt-welds. 4. Make joints with stub ends and backing flanges, welded or flanged.
B. Design:
1. Piping: Suitable for a working internal pressure of 100 pounds per square inch, and a maximum temperature of 400 degrees Fahrenheit.
C. Materials:
WRCRWA STAINLESS STEEL PIPING AND TUBING PLANT EXPANSION PROJECT 221060-1
1. Stainless steel piping: ASTM A 240, type 316L stainless steel. 2. Piping stub ends: Nonporous cast Type 316L stainless steel: a. Alaskan Copper Works, Figure SK38P i. Machine gasket and wetted surfaces of stub ends free of crevices, pits, cracks and protrusions. 3. Backing Flanges: Cast stainless steel with stainless steel bolt sets. 4. Flexible couplings: One of the following or equal: a. Type 316 stainless steel middle ring. i. Dresser, Style 38 ii. Baker Industries, Style 201
D. Fabrication:
1. General: a. Provide stainless steel fabrications free from pits, cracks, crevices, oxidation, weld splatter, stains, and discoloration. i. Surfaces: Clean and of uniform appearance.
2. Pipe: a. Pipe larger than 12 inches in diameter – ASTM A 409. b. Pipe 12 inches and less in diameter: Automatically welded using gas tungsten arc procedures. c. Piping 4 inches through 12 inches in diameter: Double butt-welded d. Piping less than 4 inches in diameter: Single butt-welded.
3. Fittings: a. Welded with Type 316L filler material b. Fitting dimensions: In accordance with ANSI B 16.9 c. Elbows 24 inches and smaller in diameter: Die formed and automatically welded, using gas tungsten-arc procedures with inert gas backing. d. Tees, crosses, true Y’s and laterals: Nozzle welded, using manual shielded metal arc procedures and double welds. e. Reducers: Cone type. f. Where not otherwise indicated on the Drawings, terminate spools with stub ends, and determine face to face dimensions by pipe fabricator.
4. Welding a. Ensure that weld seams have full penetration and be free of oxidation, crevices, pits, cracks and protrusions. i. Weld seems without undercuts ii. Provide weld crowns of 1/16 inch with tolerance of plus 1/16 inch and minus 1/32 inch. b. Accomplish longitudinal welds on fittings, except elbows by the same procedures as for pipe. c. Manually weld pipe spools with Type 316L filler metal:
i. Where internal weld seams are not accessible, use gas tungsten-arc procedures with internal gas purge.
WRCRWA STAINLESS STEEL PIPING AND TUBING PLANT EXPANSION PROJECT 221060-2
ii. Where internal weld seams are accessible, weld seams inside and outside using manual shielded metal-arc procedures.
5. Following fabrication, pickle and passivated pipe, spools, fittings, and other shop fabricated pieces by immersion in sulfuric acid solution followed by immersion in a nitric-hydrofluoric bath and subsequent wash at the proper temperature and length to remove free iron, weld scale, and other impurities, and to obtain a passive finished surface.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Provide stainless steel piping at all locations indicated in the drawings.
B. All stainless steel pipe shall be installed in a neat and workmanlike manner, properly aligned and cut from measurements taken at the site to avoid interferences with structural members, architectural features, openings, and equipment. Where necessary all piping shall be installed with sufficient slopes for venting and drainage of liquids and condensate to low points. All installations shall be acceptable to the Engineer.
3.2 FIELD QUALITY CONTROL:
A. Testing of Stainless Steel Piping:
1. Perform leakage and pressure testing by the air method only, as specified below. a. Hydrostatic testing is not acceptable. 2. Test pressure: As indicated in piping schedule. 3. Leaks shall be repaired to the satisfaction of the Engineer and the system shall be re- tested until no leaks are found.
B. Welding Inspection of Stainless Steel Piping:
1. Conduct a visual inspection for crevices, pits, cracks, protrusions, or oxidation deposits.
3.3 PROTECTION
A. Preserve appearance and finish of stainless steel piping by providing suitable protection during handling and installation and until final acceptance of Work.
END OF SECTION 221060
WRCRWA STAINLESS STEEL PIPING AND TUBING PLANT EXPANSION PROJECT 221060-3
SECTION 221065 – STEEL PIPING AND FABRICATED STEEL PIPING
PART 1 - GENERAL
1.1 SUMMARY
A. The contractor shall furnish and install steel pipe and fabricated steel pipe fittings, complete with coatings, linings, fittings, and appurtenances as specified in the design drawings and technical specifications.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards: the following standards are listed for convenience only. All specified standards, whether listed or not, shall apply to work
ASTM A 53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
ASTM A 134 Pipe, Steel, Electric Fusion Welded (Sizes NPS 16 and Over
ASTM A 135 Electric-Resistance Welded Steel Pipe
ASTM A 139 Electric-Fusion Welded Steel Pipe (NPS 4 and Over)
ASTM A 211 Spiral-Welded Steel or Iron Pipe
AWWA C200 Steel Water Pipe 6 Inches or Larger
AWWA C203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines – Enamel and Tape Hot Applied
AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe 4 Inches or Larger – Shop Applied
AWWA C206 Field Welding of Steel Water Pipe
AWWA C207 Steel Pipe Flanges
AWWA C208 Dimensions for Fabricated Steel Water Pipe Fittings
AWWA C209 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 1
AWWA C210 Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
AWWA C214 Tape Coating Systems for The Exterior of Steel Water Pipelines
API Standard 1104 Welding Pipelines and Related Structures
AWWA M-11 Steel Water Pipe – A Guide for Design and Installation
1.3 CONTRACTOR SUBMITTALS
A. Shop Drawings: Submit shop drawings of pipe and fittings in accordance with the requirements in Section 013300 – Contractor Submittals, and the following supplemental requirements as applicable.
1. Fabrication Information a. Pipe/fitting wall construction details which indicate the type and thickness of cylinder; the position, type, size, and area of reinforcement; manufacturing tolerances; maximum angular joint deflection limitations; and other pertinent information required for the manufacture and installation of the product. b. Rubber gasket joint design and details complete with dimensions, tolerances, and performance or test data. c. Manufacturer’s Written Quality Assurance/Control Program. 2. Welding Information a. Information regarding location, type, size, and extent of all welds with reference called out for Welding Procedure Specifications (WPS) numbers shall be shown on the shop drawings. The shop drawings shall distinguish between shop and field welds. Shop drawings shall indicate by welding symbols or sketches the details of the welded joints, and the preparation of parent metal required to make them. b. Written welding procedures for shop and field welds, including Welding Procedure Specifications (WPS’s) and Procedure Qualification Records (PQR’s). c. Written nondestructive testing procedure specifications, and nondestructive testing personnel qualifications for shop and field welds. d. Current welder performance qualifications (WPQ’s) shall be submitted for each welder used prior to its performing any Work either in the shop or field. Qualification testing shall be as specified in Article 1.4 – Quality Assurance, Paragraph F, in this Section. 3. Field Lining a. Submit field lining Contractor’s credentials. b. Submit a description of lining equipment and personnel to be used. c. Submit written procedures for pipe surface preparation, lining application, and curing. d. Submit cement mortar mix design.
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 2
1.4 QUALITY ASSURANCE
A. Tests: Except as modified herein, all materials used in the manufacture of the pipe shall be tested in accordance with the requirements of ANSI/AWWA C200, C205, C206, and C602, as applicable.
PART 2 - PRODUCTS
2.1 GENERAL
A. Unless otherwise indicated, steel pipe, linings and coatings shall conform to the Standards listed in Paragraph 1.2 herein, as applicable, subject to the following supplemental requirements. The pipe shall be furnished complete with welded or gasket joints, as indicated in the Contract Documents. For pipe larger than 24 inches in diameter, the inside diameter after lining shall not be less than the nominal diameter indicated unless otherwise shown. Pipe 24 inches in diameter and smaller may be provided in standard outside diameters.
B. Handling and Storage: The pipe shall be handled by use of wide slings, padded cradles, or other devices, designed and constructed to prevent damage to the pipe coating/exterior. The use of chains, hooks, or other equipment which might injure the pipe coating/exterior will not be permitted. Stock piled pipe shall be suitably supported and shall be secured to prevent accidental rolling and to avoid contact with mud, water, or other deleterious materials. Stockpiled pipe shall be supported on sand or earth berms free of rock exceeding 3 inches in diameter. The ends of all pipe shall be securely bulkheaded or otherwise sealed during transport to the jobsite. All pipe handling equipment and methods shall be acceptable to the Engineer.
C. Pay the cost of replacement or repair of pipe which is damaged at not increased cost to the Owner.
D. Strutting: Adequate strutting (stulling) shall be provided on all specials, fittings, and straight pipe so as to avoid damage or distortion to the pipe and fittings during handling, storage, hauling, and installation. The following requirements shall apply. 1. The strutting shall be placed as soon as practicable after the pipe is fabricated or the mortar lining has been applied and shall remain in place while the pipe is loaded, transported, unloaded, installed and backfilled at the jobsite. 2. The strutting materials, size and spacing shall be the responsibility of the Contractor and shall be adequate to prevent deflection and support the earth backfill plus any greater loads which may be imposed by the backfilling and compaction equipment. One strut shall be placed vertical oriented with the top of pipe. One set of struts shall be set 2 feet from each end of each pipe section and at a maximum interval of 15 feet in-between. 3. Any pipe damaged during handling, hauling, storage, or installation due to improper strutting shall be repaired or replaced.
E. Lining: The pipe lining shall have smooth dense interior surfaces and shall be free from fractures, excessive interior surface crazing and roughness.
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 3
F. Closures and Correction Pieces: Closures and correction pieces shall be provided as required so that closures may be made due to different headings in the pipe laying operation and so that correction may be made to adjust the pipe laying to conform to pipe stationing indicated. The locations of correction pieces and closure assemblies shall be shown on the pipe layout diagrams and shall be subject to the Engineer’s review. Any change in location or number of said items shall be approved by the Engineer.
2.2 GENERAL MATERIAL REQUIREMENTS
A. Typical Steel Pipe: Steel pipe shall comply with ASTM A 53 (Type E or S), ASTM A 106 or AWWA C200; schedule 40 for pipe 10 inches diameter and smaller, and schedule 80 for pipe larger than 10 inches diameter unless indicated otherwise in the design drawings.
B. Fabricated Steel Pipe: Fabricated pipe shall comply with ASTM A 53 and ASTM A 106 pipe shall be grade B, straight or spiral seam with wall thickness of 7 gauge for pipe 24-inches in diameter and smaller, and minimum wall thickness of 1/4-inch for pipe larger than 24 inches in diameter except as noted otherwise in the design drawings. Fabricated fittings shall comply with AWWA C208.
C. For all buried applications, epoxy coating for the exterior of pipe is required per AWWA C210. In addition, all buried pipe shall be installed a cathodic protection system as described in Section 105000 – Cathodic Protection for Pipelines.
D. Cement: Cement for mortar shall conform to the requirements of ANSI/AWWA C205; provided, that cement for mortar coating shall be type V, and mortar lining shall be type II or V, per ASTM C150. Fly ash or pozzolan shall not be used as a cement replacement.
E. Steel: Provide steel coils for spiral welded steel pipe or steel plate for straight seam welded steel pipe per AWWA C200 and as follows: 1. Yield Strength: 40,000 psi minimum. Measured yield strength shall not exceed 85 % of measured tensile strength. 2. Minimum Tensile Strength: 60,000 psi. 3. Coils: Steel coils shall be made from the continuous cast process or continuous cast slabs, fully killed, fine-grain practice conforming to the physical and chemical characteristics of ASTM A1018/A1018M, SS Grade 40 Type 2. For sheet steel, the maximum allowable thickness variation shall be 0.010 inch under or over the nominal thickness. 4. Plate: Steel plate shall be fully killed, conform to ASTM A20, and be manufactured to fine-grain practice conforming to the physical and chemical characteristics of ASTM A572/A572M, Grade 50. For plate steel, the maximum allowable thickness variation shall be 0.010 inch under or over the nominal thickness.
F. Pipe shall be manufactured as fabricated pipe per AWWA C200 as modified herein. Pipe sections shall be fabricated by either of the following methods: 1. Pipe sections may be spirally welded or fabricated from short cylindrical courses joined circumferentially by complete penetration butt joint welds with not more than two longitudinal seams per course. Longitudinal seams shall be staggered on both sides of the pipe.
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 4
2. Pipe sections may be rolled or pressed from no more than three sheets the full length of the pipe and welded with no more than three longitudinal seams. Patching inserts, overlays, or pounding out of dents will not be permitted. Damaged ends shall be removed as a cylinder and the section end properly prepared. Distorted or flattened length shall be rejected. A buckled section shall be replaced as a cylinder.
G. Charpy Tests 1. General. Steel used in production manufacturing of pipe and specials shall be tested for notch toughness using Charpy V-Notch tests per ASTM A370. The test acceptance shall be 25 foot-pounds at a test temperature of 30 degrees F. 2. Charpy V-Notch tests shall be conducted on all steel used in fabricating pipe and reinforcement materials 0.5 inch or greater in thickness. Test outside diameter wrap of two coils minimum per heat lot.
2.3 FABRICATED SPECIALS AND FITTINGS
A. Unless otherwise required, all specials and fittings shall conform to the dimensions of ANSI/AWWA C208.
B. Fabricated steel pipe pieces shall be fabricated to meet requirements of AWWA C200 and shall conform tom ASTM A 53 grade B straight or spiral seam. All standards for fabricated and welded steel pipe fabrications and fittings.
C. Fabricated fittings are not required to be mortar lined, but shall be provided with interior linings that comply with a coal-tar protective lining per AWWA C203 or an epoxy coating system per AWWA C210.
D. All fabricated steel fittings shall be provided shall be coated with exterior protective coatings per AWWA C203 or AWWA C210.
E. Provide cathodic protection for all buried fabricated pipe fittings per Section 105000 – Cathodic Protection for Pipelines.
2.4 DESIGN OF PIPE
A. General: The pipe shall be steel pipe, mortar-lined as shown on the Drawings, with field welded joints or gasket as indicated. The pipe shall consist of a steel cylinder, lined with Portland cement-mortar as indicated, with an exterior coating as indicated in Section 098000 – Protective Coatings.
B. The pipe shall be manufactured, tested, inspected, and marked according to applicable requirements previously stated and except as hereinafter modified, shall conform to ANSI/AWWA C200.
C. Joint Design: Unless otherwise shown, the standard field joint for steel pipe shall be a double- welded (fully circumferential) lap joint. Mechanical couples or flanged joints shall be required where indicated on the Drawings. Butt-strap joints shall be used only where required for
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 5
enclosures or where indicated. The joints furnished shall have the same or higher pressure rating as the abutting pipe. Provide air test tapped holes for each double welded lap joint as defined in Section 221066 – Pipeline Testing.
D. Lap joints prepared for field welding shall be in accordance with ANSI/AWWA C200. The method used to form, shape and size bell ends shall be such that the physical properties of the steel are not substantially altered. Unless otherwise approved by the Engineer, bell ends shall be formed by an expanding press or by the pipe being moved axially over a die in such manner as to stretch the steel plate beyond its elastic limit to form a truly round bell of suitable diameter and shape. The ends shall not be rolled. Faying surfaces of the bell and spigot shall be essentially parallel, but in no case shall the bell slope vary more than 2 degrees from the longitudinal axis of the pipe.
E. Shop-applied interior linings and exterior coatings shall be held back from the ends of the pipe as indicated or as otherwise acceptable to the Engineer. Holdback areas shall be coated as hereinafter specified.
F. Joint Shop Coating: All holdback areas for welded joints, all butt straps, and all bell and spigot joint rings for rubber –gasket joints shall be thoroughly cleaned and given a shop coat of rust- inhibitive primer. The surface preparation and primer shall be compatible with the intended finish coating as specified in Section 098000 – Protective Coatings.
2.5 EXTERIOR COATINGS FOR STEEL PIPE
A. All AWWA C200 steel pipe shall be provided with an exterior protective coating per AWWA C205 or AWWA C210.
B. Buried steel pipe shall also be installed with cathodic protection per Section 1050000.
2.6 CEMENT-MORTAR LINING
A. Cement-Mortar Lining for Shop Application: Interior surfaces of all steel pipe, fittings, and specials shall be cleaned and lined with cement-mortar lining applied centrifugally in conformity with ANSI/AWWA C205. During the lining operation and thereafter, the pipe shall be maintained in a round condition by suitable bracing or strutting. The lining machines shall be of a type that has been used successfully for similar work and shall be approved by the Engineer. Every precaution shall be taken to prevent damage to the lining. If lining is damaged or found faulty at the delivery site, or after installation, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications at no additional cost to the Owner.
B. The minimum lining thickness shall be as follows, with a tolerance of plus 1/8-inch or minus 1/16-inch: Nominal Pipe Lining Thickness Diameter (in) (in) 4 - 10 ¼
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 6
11 - 23 5/16 24 - 36 3/8 Over 36 1/2
C. The pipe shall be left bare where field joints occur as indicated. Ends of the linings shall be left square and uniform. Feathered or uneven edges will not be permitted.
D. Defective linings, as determined by the Engineer, shall be removed from the pipe wall and shall be replaced to the full thickness required. Defective linings shall be cut back to a square shoulder in order to avoid feather edged joints. Temperature and shrinkage cracks in the mortar less than 1/16 inch wide need not be repaired. Pipe, specials, or fittings with cracks wider than 1/16 inch shall be rejected or repaired per C205 at the discretion of the Engineer.
E. The progress of the application of mortar lining shall be regulated in order that all hand work, including the repair of defective areas is cured in accordance with the provisions of ANSI/AWWA C205. Cement-mortar for patching shall be the same materials as the mortar for shop or machine lining, except that a finer grading of sand and mortar richer in cement shall be used when field inspection indicates that such mix will improve the finished lining of pipe.
F. Cement-Mortar Lining: Unless otherwise indicated, all steel pipe shall be mortar-lined. The materials and design of in-place cement-mortar lining shall be in accordance with ANSI/AWWA C602 and the following supplementary requirements: 1. Pozzolanic material shall not be used in the mortar mix. 2. Admixtures shall contain no calcium chloride. 3. The minimum lining thickness shall be as indicated for shop-applied cement-mortar lining and finished inside diameter after lining shall be as indicated. 4. Temperature and shrinkage cracks in the mortar less than 1/16 inch wide need not to be repaired. Pipe, specials, or fitting with mortar cracks wider than 1/16 inch shall be rejected to repaired at the discretion of the Engineer. 5. Field applied mortar lining shall meet the requirements of this Subparagraph F.
G. Protection of Pipe Lining/Interior: For all pipe and fittings with plant-applied cement-mortar linings, provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special openings to prevent drying out of the lining, All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed.
PART 3 - EXCUTION
3.1 INSTALLATION OF PIPE
A. Hanging and Storage: All pipe, fittings, and specials shall be carefully handled and protected against damage to lining and coating/interior and exterior surfaces, impact shocks and free fall. All pipe handling equipment shall be acceptable to the Engineer. Pipe shall not be placed directly on rough ground but shall be supported in a manner which will protect the pipe against injury whenever stored at the trench site or elsewhere. Pipe shall be handled and stored at the trench site in accordance with the requirements stated below. No pipe shall be installed when
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 7
the lining or coating/interior and exterior surfaces show cracks or other damage that may harmful as determined by the Engineer. Such damaged lining and coating/interior and exterior surfaces, shall be repaired to the satisfaction of the Engineer, or a new undamaged pipe shall be furnished.
B. All pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor at no additional cost to the Owner.
C. Inspect each pipe and fitting to insure that there are no damaged portions of the pipe. Remove or smooth out any burrs, gouges, weld splatter or other small defects prior to laying the pipe.
D. Before placement of pipe in the trench, each pipe in the trench or fitting shall be thoroughly cleaned of any foreign substance, which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the Work.
E. Lifting points shall be no closer than the 1/3 and 2/3 points along the length of the Section. Contractor shall be responsible for selecting lifting points that when used, do not result in damage to the pipe.
F. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coating on field joints.
G. For pipe backfilled with CLSM, the pipe shall be laid directly on moist sandbags or other suitable supports approved by the Engineer in preparation for CLSM pipe zone material. Sandbags shall be placed to provide at least 6 inches of CLSM below the bottom of the pipe. Sandbags shall be spaced at maximum interval of 8 feet and one set shall be placed within 3 feet on both sides of each joint. The Contractor shall provide additional sandbags as needed to support the pipe on line and grade. For pipe bedded in granular material, no blocking will be permitted, and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent point loading at the bells or couplings. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coating on field joints.
H. At all times, means shall be provided to prevent the pipe from floating. Take all necessary precautions to prevent the pipe from floating due to water entering the trench or from backfilling with CLSM. The Contractor shall assume full responsibility for any damage due to this cause and shall at its own expense restore and replace the pipe to its specifies condition and grade if it is displaced due to floating. Maintain the inside of the pipe free from foreign materials and in a clean and sanitary condition until its acceptance by the Owner.
I. Bulkheads
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 8
1. Prior to shipment of pipe with cement mortar lining the lining shall be wetted then a suitable bulkhead shall be attached to each end of pipe section. This bulkhead shall remain in place and in good condition through transit to the Project. 2. During construction the openings of all pipe and specials where the pipe and specials have been cement mortar lined in the shop shall be protected with suitable bulkheads to maintain a moist atmosphere and to prevent unauthorized access by persons, animals, water or any undesirable substance. The bulkheads shall be so designed to prevent drying out of the interior of the pipe. Introduce water into the pipe as needed to keep the mortar moist where moisture has been lost due to damaged bulkheads.
J. Pipe Cleanup: As pipe laying progresses, keep the pipe interior free of all debris. Completely clean the interior of the pipe of all sand, dirt, mortar splatter and any other debris following completion of pipe laying and any necessary interior repairs prior to testing and disinfecting the completed pipeline.
K. Installation Tolerances: Each section of pipe shall be laid in the order and position shown on the laying diagram and the following requirements: 1. Each section of pipe having a nominal diameter less than 48 inches shall be laid to line and grade, within plus or minus 2 inches horizontal deviation and plus or minus 1 inch vertical deviation 2. Each Section of pipe having nominal diameter 48 inches and larger shall be laid to line and grade, within plus or minus 5 percent of diameter horizontal deviation and plus or minus 2.5 percent of diameter vertical deviation. 3. In addition to the horizontal and vertical tolerances above, lay the pipe so that no high or low points other than those on the laying diagram are introduced. 4. Pipe deflection, after backfill but prior to installation of field-applied cement mortar lining, if applied, shall not exceed 2.25 percent for flexible coated pipe and 1.5 percent for cement mortar coated pipe. Deflection shall be measured by the difference in vertical inside diameter in the installed pipe and the manufactured pipe 5. Pipe not conforming to these criteria or which otherwise impact the ability to complete the Work shall be removed and reinstalled in full conformance with the Contract Documents at no additional cost to the Owner 6. For each section of pipe, record the invert elevation at the lower end and incorporate the data on the Record Drawings.
L. Protection of Pipe: At locations where the contractor proposes to cross the installed pipeline with heavy equipment, precautions as approved by the Engineer shall be taken to protect the pipe from damage. Acceptance precautions include: backfilling the pipe trench as necessary to protect the pipe, concrete encasing the pipe, and placing steel plating over the pipe. Any damage to the pipe caused by the Contractor’s operation or his equipment shall be repaired at no additional cost to the Owner.
3.2 WELDED JOINTS
A. Welded Procedures, Welding Qualifications, and Testing 1. Field welding procedures, welders, welding operators, and tackers shall be qualified in accordance with AWS D1.1 and as defined in Section 3 of ANSI/AWWA C206 or
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 9
ANSI/AWWA C200, as applicable. All qualifications shall be accordance with all- position pipe tests as defined in Section 5 of AWS D1.1. 2. For field welding, the welder qualification testing shall be performed at the site. Previous qualifications will not be accepted. The Contractor shall obtain the services of an independent testing laboratory to perform the welder qualification onsite. Copies of all test data and certifications shall be provided to the Engineer. All costs for welder qualification testing shall be at no increased cost to the Owner. 3. Upon completion of each field-welded joint, the welding operator shall mark his regularly assigned identification number and the last two numbers of the year in which the work was completed, or the Contractor may have a records system that traces a welder’s work completion to a specific joint. Steel stamping directly on piping will not be permitted unless “low stress” die stamps, such as interrupted dot or round nose types, are used. 4. All single welded lap joints will be inspected by the CONTRACTOR in the presence of the Engineer using magnetic particle or dye penetration methods. Field butt welds will be inspected by the CONTRACTOR in accordance with the requirements of API 1104 by the radiographic method and the acceptance criteria of API 1104. Magnetic particle testing is not required for seal welds. 5. The Contractor shall inform the Engineer before completed weld joints are to be backfilled so that the joint may be inspected. The Contractor shall assume all costs of exposing backfilled joints for inspection when backfilling preceded the inspection.
B. Where exterior welds are performed, adequate space shall be provided for welding and inspection of the joints.
C. Lap Welded joints: During installation of welded steel pipe in either straight alignment or on curves, the pipe shall be laid so that at any point around the circumference of the joint there is a minimum lap as required.
D. After the pipe and pipe joint are properly positioned in the trench, weld and provide external joint protection for all joints except the special temperature control lap joint hereinafter specified. The length of pipe between special temperature control joints shall be backfilled to at least one foot above the top of the pipe as hereinafter specified. The special temperature control joints shall be welded after the pipe is backfilled to at least one foot above the top of the pipe for the full distance between the temperature control joints upstream and downstream. Joint protection shall be provided for special temperature control joints after completion of the joint welds and tests as specified. Care shall be exercised during the initial backfilling to prevent movement of the pipe and to prevent any backfill material from being deposited on the special temperature control joint.
E. Testing of Joints: The pipeline joints shall be tested as specified herein and in Section 221066.
F. Following tests of the joint, the exterior joint spaces shall be coated in accordance with these Specifications after which backfilling may be completed.
G. Joints: The pipe ends shall be cut straight on joints where butt straps are used for realignment, adjustment, or deflection, and fillet welds shall be made as indicated.
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 10
H. Repair of Welds: all welds that are defective shall be repaired by the Contractor to meet the requirements of this Section at no additional cost to the Owner. Defects in welds or defective welds shall be removed, and that section of the joint shall then be rewelded. Only sufficient removal of defective material that is necessary to correct the defect is required. After the repair is made, the joint shall be checked by repeating the original test procedure. Welds deficient in size shall be repaired by adding weld metal.
3.3 JOINT COATING AND LINING
A. General: The interior and exterior joint recesses shall be thoroughly wiped clean and all water, loose scale, dirt and other foreign material shall be removed from the inside surface of the pipe. The grout for joint coating and lining shall be cement grout in accordance with Section 036000 - grout, except that composition shall be one part cement to two parts sand and sufficient water for dry pack consistency.
B. Joint Lining: 1. The grout for joint lining shall be cement grout in accordance with Section 036000, except that composition shall be one part of cement to two parts sand and sufficient water for dry pack consistency. 2. After the backfill has been completed to final grade, the interior joint recess of shop-lined pipe shall be filled with grout, tightly packed into the joint recess and troweled flush with the interior surface. All excess shall be removed. At no point shall there be an indentation or projection of the grout exceeding 1/16 inch. With pipe smaller than 24 inches in diameter, before the spigot is inserted into the bell, the bell shall be daubed with grout containing one part cement to two parts sand. The spigot end then shall be forced to the bottom of the bell and excess mortar on the inside of the joint shall be swabbed out.
3.4 CEMENT-MORTAR LINING, FIELD-APPLIED
A. Unless otherwise indicated, the Contractor shall construct the cement-mortar lining in-place after the pipeline is backfilled to approximate finished grade. The application of in-place cement-mortar lining shall be in accordance with ANSI/AWWA C602.
1. The lining machine shall be of a type that has been used successfully for a similar size of pipe. Perform all Work in a thorough and workmanlike manner by trained personnel, under the supervision of experienced personnel skilled in machine application of cement- mortar lining to pipelines of size comparable to this Work. 2. Curing of the in-place cement-mortar lining shall be in accordance with ANSI/AWWA C602, except the Contractor shall be responsible for curing and maintaining the lining unit final acceptance by the Owner. Provide a system to maintain a suitably moist environment within the pipe to properly cure and maintain the lining. Provide additional protective devices as required to ensure that the airtight covers, which maintain a moist condition in the pipeline, are not damaged. 3. Defective areas encompassing the full diameter of the pipe shall be replaced by machine wherever the length measured along the pipe centerline is greater than 5 feet.; otherwise defective areas may be replaced by hand.
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 11
3.5 INSTALLATION OF PIPE APPURTENANCES
A. Protection of Appurtenances: Where the joining pipe is concrete or coated with cement mortar, buried appurtenances shall be coated with a minimum thickness of one inch of cement mortar having one part cement to not more than two parts plaster sand. Following coating with cement mortar, the appurtenances shall be coated with a protective overcoat in accordance with the paragraph entitled “Protective Coating.”
B. Installation of Flanged Joints: Before the joint is assembled, the flange faces shall be thoroughly cleaned of all foreign material with a power wire brush. The gasket shall be centered and the connecting flanges drawn up watertight without unnecessarily stressing the flanges. All bolts shall be tightened in a progressive diametrically opposite sequence and torqued with a suitable, approved and calibrated torque wrench. All clamping torque shall be applied to the nuts only.
C. Wrenches used in bolting couplings shall be of a type and size recommended by the coupling manufacturer. Coupling bolts shall be tightened so as to secure a uniform annular space between the follower rings and the body of the pipe with all bolts tightened approximately the same amount. Diametrically opposite bolts shall be tightened progressively and evenly. Final tightening shall be done with a suitable, approved and calibrated torque wrench set for the torque recommended by the coupling manufacturer. All clamping torque shall be applied to the nut only.
D. Upon completion of the coupled joint, the coupling and bare metal of the pipe shall be cleaned, primed and protected in accordance with the requirements of Section 098000.
3.6 CORROSION CONTROL
A. Cathodic Protection: Corrosion mitigation and testing materials shall be provided where indicated and as detailed in Section 105000, “Cathodic Protection of Pipelines”.
3.7 PIPELINE TESTING
A. The steel pipe shall be hydrostatically tested as specified in Section 221066 Pipeline Testing
END OF SECTION 221065
WRCRWA STEEL PIPE PLANT EXPANSION PROJECT 221065 - 12
SECTION 221066 – PIPELINE TESTING
PART 1 - GENERAL
1.1. SUMMARY
A. The Contractor shall perform flushing and testing of all pipelines and appurtenant piping complete, including conveyance of test water from Owner-designated source to point of use and all disposal thereof, all in accordance with the requirements of the Contract Documents.
B. Section includes provisions for following piping testing:
a. Testing of alignment, grade, and deflection; b. Gravity flow piping testing; c. Hydrostatic High Head pressure testing; d. Hydrostatic Low Head pressure testing; e. Low pressure air testing; f. High pressure air testing.
1.2. RELATED SECTIONS
A. General Pipes and Fittings. Section 220050
B. Ductile Iron Pipe. Section 221030
C. Plastic Pipe. Section 221040
D. High Density Polyethylene Pipe and Fittings. Section 221060
E. HDPE Storm Drain Pipe. Section 221055
F. Stainless Steel Piping and Tubing. Section 221060
G. Steel Piping and Fabricated Steel piping. Section 221065
H. Domestic Water Piping. Section 221116
I. Sanitary Waste and Vent Piping. Section 221316
J. Hydraulic Structure Testing. Section 331400
1.3. SUBMITTALS
A. Schedule and Notification of tests:
a. Submit a list of scheduled piping tests by noon of working day preceding the date of scheduled tests.
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-1 b. Notification of readiness to test: Before testing notify the Engineer or Construction Manager in writing of readiness to test piping. c. Have personnel, materials, and equipment required for testing in place before submitting notification of readiness.
B. Provide a test report for each piping system tested. Include the following:
a. Date of Test; b. Description and identification of piping system tested; c. Results of alignment, grade, and deflection testing; d. Type of test performed; e. Test fluid; f. Test pressure; g. Type and location of leaks detected; h. Corrective action taken to repair leaks; i. Results of re-testing.
C. Submit test report in accordance with Specification Section 13300.
1.4. SEQUENCE
A. Test Piping Systems as follows:
a. Clean piping before pressure or leak tests. b. Test exposed, non-insulated piping systems upon completion of system (including supports, hangers, anchors, etc.) c. Test exposed, insulated piping systems upon completion of system but prior to application of insulation. d. Test concealed interior piping systems prior to concealment and, if system is insulated prior to application of insulation. e. Test buried piping (insulated and non-insulated) prior to backfilling and, if insulated, prior to application of insulation. f. Test buried piping before encasing piping in concrete or covering piping with slab, structure, or permanent improvement.
PART 2 - PRODUCTS
2.1. MATERIALS REQUIREMENTS
A. All test equipment, temporary valves, bulkheads or other water control equipment and materials shall be determined and furnished by the Contractor subject to the Engineer's review.
PART 3 - EXECUTION
3.1. GENERAL
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-2
A. Contractor shall make all necessary provisions for conveying the water from the Owner-designated source to the points of use.
B. All pipelines shall be tested. All testing operations shall be performed in the presence of the Construction Manager.
C. Provide air supply.
D. Plug pipe outlets with test plugs. Brace each plug securely to prevent blowouts.
E. Add test fluid slowly.
F. Include regulator set to avoid over-pressurizing and damaging piping.
G. Perform pressure testing in accordance with local, state, and federal requirements.
H. Correct leaks or defects at no additional cost to Owner and as approved by the Engineer.
I. Disposal or release of test water from pipelines after testing, shall be acceptable to the Engineer.
3.2. TESTING ALIGNMENT, GRADE, AND DEFLECTION
A. Alignment and grade:
a. Visually inspect the interior of gravity piping with artificial light, reflected light, or laser beam. b. Consider inspection complete when no broken or collapsed piping, no open or poorly made joints, no grade changes that affect the piping capacity, or no other defects are observed.
B. Deflection test:
a. Pull a mandrel through the clean piping section under test. b. Perform the test no sooner than 30 days after installation and not later than 60 days after installation or permanent surfacing. c. Use a full circle, solid cylinder, or a rigid non-adjustable, odd-numbered leg (9 leg minimum) steel cylinder mandrel approved by the Engineer as to design and manufacture. The circular cross section of the mandrel shall have a diameter of at least 95 percent of the specified average inside pipe diameter of the pipe and the minimum length of the circular portion of the mandrel shall be equal to the nominal diameter of the pipe. Obstructions encountered by the mandrel shall be corrected by the Contractor.
3.3. TESTING OF GRAVITY FLOW PIPING
A. Test gravity flow piping indicated with “G” in piping schedule, as follows:
a. Unless specified otherwise, subject gravity flow piping to the following tests:
i. Alignment and grade. ii. For plastic piping test for deflection.
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-3 iii. Visible leaks and pressure with maximum leakage allowance.
b. Inspect piping for visible leaks before backfilling. c. Provide temporary restraints when needed to prevent movement of piping. d. Pressure test piping with maximum leakage allowance after backfilling. e. With the lower end plugged, fill piping slowly with water while allowing air to escape from high points. Keep piping full under the head indicated in the piping schedule for the water at least 24 hours:
i. Examine piping for visible leaks. Correct any visible leaks. Consider examination complete when no visible leaks are observed. ii. Maintain piping with water, or allow a new water absorption period of 24 hours for the performance of the pressure test with maximum leakage allowance. iii. After successful completion of the test for visible leaks and after the piping has been restrained and backfilled, subject piping to the test pressure for minimum of 4 hours while accurately measuring the volume of water added to maintain the test pressure:
1. Consider the test completed when leakage is equal or less than the following maximum leakage allowance:
a) For concrete piping with rubber gasket joints: 80 gallons per day per inch of diameter per mile of piping under test. b) For HDPE Strom Drain Piping use manufacturer recommended leakage rates. c) Test sanitary waste and vent piping in accordance with section 221316 requirements. d) For other piping: 80 gallons per day per inch diameter per mile of piping under test.
B. Repair piping systems sections which fail required piping test, by disassembly and re-installation, using new materials to extent required to overcome leakage. Do not use chemicals, stop-leak compounds, mastics, or other temporary repair methods.
C. Test waste, drain and vent systems in accordance with local plumbing code and these specifications. Repair failed sections by disassembly and reinstallation.
3.4. HYDROSTATIC HIGH HEAD TESTING OF PIPELINES
A. Test piping indicated “HH” in the Piping Schedule with the high head pressure test method.
B. General:
a. The test pressure for yard piping shall be as shown or specified on the Piping Schedule measured at the lowest point of the pipeline section being tested. Where not indicated in the Piping Schedule, test piping systems at 150% of the operating pressure indicated, but not less than 25 psi. Observe each test section for leakage at the end of the test period. Test fails if leakage is observed or if there is any pressure drop in the system. All leaks shall be repaired in a manner acceptable to the Engineer. b. Prior to hydrostatic testing, all pipelines shall be flushed or blown out as appropriate. The Contractor shall be responsible for ascertaining that all test bulkheads are suitably restrained to resist the thrust of the test pressure without damage to, or movement of, the adjacent pipe.
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-4 Care shall be taken to see that all air vents are open during filling. Provide temporary equipment for testing, including pump and gages. Test piping system before insulation is installed, and remove control devices before testing. Test each natural section of each piping system independently but do not use piping system valves to isolate sections where test pressure exceeds valve pressure rating. Fill each section with water and pressurize for indicated pressure and time.
C. Testing Procedures:
a. The pipeline shall be filled at a rate which will not cause any surges or exceed the rate at which the air can be released through the air valves at a reasonable velocity and all the air within the pipeline shall be properly purged. After the pipeline or section thereof has been filled it shall be allowed to stand under a slight pressure for at least 24-hours to allow the concrete or mortar lining, as applicable, to absorb what water it will and to allow the escape of air from any air pockets. During this period, bulkheads, valves and connections shall be examined for leaks. If leaks are found, corrective measures satisfactory to the Engineer shall be taken. b. Use potable water for all potable water lines testing. c. Test piping for minimum 2 hours for visible leaks and minimum 2 hours for the pressure test with maximum leakage allowance. d. Raise pressure to the specified test pressure and inspect piping visually for leaks:
i. Correct any visible leaks,
ii. Consider visible leakage testing complete when no visible leaks are observed.
D. Pressure test with maximum leakage allowance:
a. Leakage allowance is zero for all exposed (insulated or non-insulated) piping and all piping systems using flanged, National Pipe Thread threaded and welded joints. b. Pressure test piping after completion of visible leaks test. c. Buried piping with mechanical joints or push-on joints, piping systems shall have maximum allowable leakage of
L= (NxDxP(1/2))/7,400 Where: L = Leakage, gallons per hour N = Number of joints under test D = Nominal diameter of piping, inches P = Average pressure during test, pounds per square inch x = multiplication symbol.
E. Pressure test HDPE pipe in accordance with the requirements of section 221050 “High Density Polyethylene Pipe and Fittings”.
F. Pressure test potable water piping in accordance with the requirements of section 221116 “Water Piping”.
G. Pressure test PEX piping systems in accordance with the requirements of section 238316.
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-5 H. Repair piping systems sections which fail required piping test, by disassembly and re-installation, using new materials to extent required to overcome leakage. Do not use chemicals, stop-leak compounds, mastics, or other temporary repair methods.
I. Drain and dispose of test water from piping systems as directed by the Construction Manager or Engineer after testing and repair work has been completed.
J. Test all pressure piping in accordance with ANSI B31.
3.5. HYDROSTATIC LOW HEAD TESTING OF PIPELINES
A. Test piping indicated “LH” in the Piping Schedule with the low head pressure test method.
B. General:
a. Test pressures shall be as noted in the pipe schedule. b. During the performance of the tests, test pressure shall not vary more than plus or minus 2 pounds per square inch gauge with respect to the specified test pressure. c. Test connections, blowoffs, vents closure pieces, and joints into structures including existing bell rings and other appurtances with the piping. d. Test piping for minimum 2 hours for visible leaks test and minimum 2 hours for the pressure test with maximum leakage allowance.
C. Visible Leaks Test:
a. Subject piping under test to the specified pressure measured at the lowest end. b. Fill piping under test slowly with water while venting air: i. Use potable water for all potable waterlines. c. Before pressurizing for the tests, retain water in piping under slight pressure for the water absorption period of minimum 24 hours. d. Raise pressure to the specified test pressure and inspect piping visually for leaks. Correct any visible leaks. Consider testing complete when no visible leaks are observed.
D. Pressure test with maximum leakage allowance.
a. Pressure test piping after completion of visible leaks test. b. Accurately measure the makeup water necessary to maintain the pressure in the piping section under test during the pressure test period: i. Consider the pressure test to be complete when makeup water added is less than the allowable leakage of 80 gallons per inch of nominal diameter, per mile of piping section under test and no damage to piping and appurtances has occurred. ii. Successful completion of the leakage test shall have been achieved when the observed leakage is equal or less than the allowable leakage and no damage to piping and appurtances has occurred.
3.6. LOW PRESSURE AIR TESTING
A. Perform low pressure air testing for gravity sewer and drainage piping systems where indicated “AL” in the Piping Schedule.
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-6 B. Test pipes between adjacent manholes. Test time for air pressure to drop 1.0 psi.
a. For pipes 4 in. through 36 in. diameter to comply with Table 1.
b. Pipe over 36 inch diameter shall not be tested by the low pressure air method.
C. Preparation:
a. Isolate pipe section to be tested by plugging each end with air tight plugs. Plug end of branches, laterals and wyes which are not to be included in the test section. b. Brace plugs to prevent slippage and blowout due to internal pressure. c. One plug shall have inlet tap or other provision for connecting air supply. d. Air control equipment shall consist of valves and pressure gauges to control rate at which air flows into test section and gauges to monitor air pressure inside pipe.
D. Testing: a. If pipe to be tested is submerged in water, determine height of water above spring line of pipe at each end of test section and compute average. For each foot of water above pipe’s spring line, increase test pressure by 0.43 psi. b. Add air slowly until pressure inside pipe is raised to 5.0 psi. greater than average back pressure of water that may be over pipe. c. After pressure of 5.0 psi is obtained, control supply of air so the internal pressure is maintained between 4.5 and 5.0 psi (above average water back pressure) for minimum of 2 minutes to allow temperature of air to come into equilibrium with temperature of pipe. d. In no case shall the test pressure exceed 9.0 psi or the maximum pressure allowed by the pipe manufacturer. e. Determine the rate of air lost by time pressure drop method. i. After temperature stabilized for a 2 minute period, disconnect air supply. Allow pressure to decrease to 4.6 psi. At this pressure, start stopwatch to determine time required for pressure to drop 1.0 psi. Time required for loss of 1.0 psi is then compared to Table 1. ii. If time is equal to or greater than time indicate din table, test shall be acceptable. iii. If time is less than time indicated in table, make appropriate repairs and retest.
Table 1. Low Pressure Air Test Times for 1.0 PSIg Pressure Drop. Pipe Minimum Time Pipe Test Time for Diameter for 1.0 PSIg Length for Pipe Length (in) Pressure Drop Minimum (L) in Excess (min:sec) Time of Minimum (ft.) (sec.) 4 03:47 597 .380L 6 05:40 398 .854L 8 07:33 298 1.520L 10 09:27 239 2.374L 12 11:20 199 3.418L 15 14:10 159 5.342L 18 17:00 133 7.692L 21 19:50 114 10.470L 24 22:40 99 13.674L 27 25:30 88 17.306L 30 28:20 80 21.366L 33 31:10 72 25.852L 36 34:00 66 30.768L
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-7 E. Repair piping systems sections which fail required piping test, by disassembly and re-installation, using new materials to extent required to overcome leakage. Do not use chemicals, stop-leak compounds, mastics, or other temporary repair methods.
3.7. HIGH PRESSURE AIR TESTING
A. Perform high pressure air testing for gravity sewer and drainage piping systems where indicated “AH” in the Piping Schedule.
B. Perform preliminary test at not greater than 25 psi. Examine for leakage at joints with soap solution and visual detection of soap bubbles. Correct visible leaks.
C. Perform final test at the pressure specified. Pressure in the system shall be gradually increased until the test pressure is reached. Test pressure shall be maintained for a minimum of 10 minutes and additional time conduct soap bubble test examination of each joint for leakage.
D. Piping system shall show no evidence of leakage. If leakage is evident, make appropriate repairs and retest.
END OF SECTION 221066
WRCRWA PIPELINE TESTING PLANT EXPANSION PROJECT 221066-8 SECTION 221094 – RUBBER HOSE
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes: Hose.
1.2 SUBMITTALS:
A. Product Data: Manufacturer’s data indicating service types, sizes, materials, and required accessories.
PART 2 – PRODUCTS
2.1 HOSE
A. Hose material: Neoprene or acceptable oil resistant material suitable for working pressure of minimum 150 pounds per square inch (psi), gauge. Verify existing plant utility water system pressure and provide hose adequate to handle existing pressure if greater than 150 psi, gauge. B. Size as indicated in the Drawings. Fit ends with appropriate combination clamped nipples and threaded ends as indicated on the Drawings. C. Hose larger than 1.5 inches in size: Industrial fire hose. Provide one 50-foot long hose for each utility station (hose bib and hose rack) provided. a. Manufacturers: One of the following or equal: i. Goodyear Rubber Products Corp. ii. Uniroyal, Inc. D. Hose ½ inch through 1.5 inch nominal diameter: General purpose hose. Provide one 75-foot long hose for each utility station (hose bib and hose rack) provided. a. Manufacturers: i. Goodyear Rubber Products Corp. ii. Uniroyal, Inc.
E. Equip and fit hose ends with appropriate combination clamped nipples and threaded ends to make up the assembly indicated on the Drawings.
PART 3 – EXECUTION
3.1 INSTALLATION:
A. Install hose in accordance with manufacturer’s instructions.
END OF SECTION 221094
WRCRWA RUBBER HOSE PLANT EXPANSION PROJECT 221094-1 SECTION 221116 - WATER PIPING
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes under-building-slab and aboveground potable and non-potable water pipes, tubes, and fittings inside buildings.
1.2 ACTION SUBMITTALS
A. Product Data: For transition fittings and dielectric fittings.
1.3 INFORMATIONAL SUBMITTALS
A. System purging and disinfecting activities report.
B. Field quality-control reports.
PART 2 - PRODUCTS
2.1 PIPING MATERIALS
A. Comply with requirements in "Piping Schedule" included in the drawings for applications of pipe, tube, fitting materials, and joining methods for specific services, service locations, and pipe sizes.
B. Potable-water piping and components shall comply with NSF 14 and NSF 61 Annex G. Plastic piping components shall be marked with “NSF-pw."
2.2 COPPER TUBE AND FITTINGS
A. Hard Copper Tube: ASTM B 88, Type L and ASTM B 88, Type M water tube, drawn temper.
B. Soft Copper Tube: ASTM B 88, Type K and ASTM B 88, Type L water tube, annealed temper.
C. Cast-Copper, Solder-Joint Fittings: ASME B16.18, pressure fittings.
D. Wrought-Copper, Solder-Joint Fittings: ASME B16.22, wrought-copper pressure fittings.
E. Bronze Flanges: ASME B16.24, Class 150, with solder-joint ends.
F. Copper Unions:
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 1 1. MSS SP-123. 2. Cast-copper-alloy, hexagonal-stock body. 3. Ball-and-socket, metal-to-metal seating surfaces. 4. Solder-joint or threaded ends.
G. Copper Pressure-Seal-Joint Fittings:
1. Fittings for NPS 2 and Smaller: Wrought-copper fitting with EPDM-rubber, O-ring seal in each end. 2. Fittings for NPS 2-1/2 to NPS 4: Cast-bronze or wrought-copper fitting with EPDM- rubber, O-ring seal in each end.
H. Copper Push-on-Joint Fittings:
1. Cast-copper fitting complying with ASME B16.18 or wrought-copper fitting complying with ASME B 16.22. 2. Stainless-steel teeth and EPDM-rubber, O-ring seal in each end instead of solder-joint ends.
2.3 DUCTILE-IRON PIPE AND FITTINGS
A. Mechanical-Joint, Ductile-Iron Pipe:
1. AWWA C151/A21.51, with mechanical-joint bell and plain spigot end unless grooved or flanged ends are indicated. 2. Glands, Gaskets, and Bolts: AWWA C111/A21.11, ductile- or gray-iron glands, rubber gaskets, and steel bolts.
B. Standard-Pattern, Mechanical-Joint Fittings:
1. AWWA C110/A21.10, ductile or gray iron. 2. Glands, Gaskets, and Bolts: AWWA C111/A21.11, ductile- or gray-iron glands, rubber gaskets, and steel bolts.
C. Compact-Pattern, Mechanical-Joint Fittings:
1. AWWA C153/A21.53, ductile iron. 2. Glands, Gaskets, and Bolts: AWWA C111/A21.11, ductile- or gray-iron glands, rubber gaskets, and steel bolts.
2.4 GALVANIZED-STEEL PIPE AND FITTINGS
A. Galvanized-Steel Pipe:
1. ASTM A 53/A 53M, Type E, Grade B, Standard Weight. 2. Include ends matching joining method.
B. Galvanized-Steel Pipe Nipples: ASTM A 733, made of ASTM A 53/A 53M or ASTM A 106/A 106M, Standard Weight, seamless steel pipe with threaded ends.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 2 C. Galvanized, Gray-Iron Threaded Fittings: ASME B16.4, Class 125, standard pattern.
D. Malleable-Iron Unions:
1. ASME B16.39, Class 150. 2. Hexagonal-stock body. 3. Ball-and-socket, metal-to-metal, bronze seating surface. 4. Threaded ends.
E. Flanges: ASME B16.1, Class 125, cast iron.
2.5 CPVC PIPING
A. CPVC Pipe: ASTM F 441/F 441M, Schedule 80.
1. CPVC Socket Fittings: ASTM F 439 for Schedule 80. 2. CPVC Threaded Fittings: ASTM F 437, Schedule 80.
B. CPVC Piping System: ASTM D 2846/D 2846M, SDR 11, pipe and socket fittings.
C. CPVC Tubing System: ASTM D 2846/D 2846M, SDR 11, tube and socket fittings.
2.6 PEX TUBE AND FITTINGS
A. PEX Distribution System: ASTM F 877, SDR 9 tubing.
B. Fittings for PEX Tube: ASTM F 1807, metal-insert type with copper or stainless-steel crimp rings and matching PEX tube dimensions.
C. Manifold: Multiple-outlet, plastic or corrosion-resistant-metal assembly complying with ASTM F 877; with plastic or corrosion-resistant-metal valve for each outlet.
2.7 PVC PIPE AND FITTINGS
A. PVC Pipe: ASTM D 1785, Schedule 40 and Schedule 80.
B. PVC Socket Fittings: ASTM D 2466 for Schedule 40 and ASTM D 2467 for Schedule 80.
C. PVC Schedule 80 Threaded Fittings: ASTM D 2464.
2.8 PIPING JOINING MATERIALS
A. Pipe-Flange Gasket Materials:
1. AWWA C110/A21.10, rubber, flat face, 1/8 inch thick or ASME B16.21, nonmetallic and asbestos free unless otherwise indicated. 2. Full-face or ring type unless otherwise indicated.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 3 B. Metal, Pipe-Flange Bolts and Nuts: ASME B18.2.1, carbon steel unless otherwise indicated.
C. Solder Filler Metals: ASTM B 32, lead-free alloys.
D. Flux: ASTM B 813, water flushable.
E. Brazing Filler Metals: AWS A5.8/A5.8M, BCuP Series, copper-phosphorus alloys for general- duty brazing unless otherwise indicated.
F. Solvent Cements for Joining CPVC Piping and Tubing: ASTM F 493.
G. Solvent Cements for Joining PVC Piping: ASTM D 2564. Include primer according to ASTM F 656.
H. Plastic, Pipe-Flange Gaskets, Bolts, and Nuts: Type and material recommended by piping system manufacturer unless otherwise indicated.
2.9 TRANSITION FITTINGS
A. General Requirements:
1. Same size as pipes to be joined. 2. Pressure rating at least equal to pipes to be joined. 3. End connections compatible with pipes to be joined.
B. Fitting-Type Transition Couplings: Manufactured piping coupling or specified piping system fitting.
C. Plastic-to-Metal Transition Fittings:
1. Description:
a. CPVC or PVC one-piece fitting with manufacturer's Schedule 80 equivalent dimensions. b. One end with threaded brass insert and one solvent-cement-socket end.
D. Plastic-to-Metal Transition Unions:
1. Description:
a. CPVC or PVC four-part union. b. Brass or stainless-steel threaded end. c. Solvent-cement-joint plastic end. d. Rubber O-ring. e. Union nut.
2.10 DIELECTRIC FITTINGS
A. General Requirements: Assembly of copper alloy and ferrous materials with separating nonconductive insulating material. Include end connections compatible with pipes to be joined.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 4 B. Dielectric Unions: 1. Basis-of-Design Product: Subject to compliance with requirements, provide product indicated on Drawings or comparable product by one of the following: a. Watts; a division of Watts Water Technologies, Inc. b. Or Equal.
2. Standard: ASSE 1079. 3. Pressure Rating: 125 psig minimum at 180 deg F. 4. End Connections: Solder-joint copper alloy and threaded ferrous.
C. Dielectric Flanges:
1. Standard: ASSE 1079. 2. Factory-fabricated, bolted, companion-flange assembly. 3. Pressure Rating: 125 psig minimum at 180 deg F. 4. End Connections: Solder-joint copper alloy and threaded ferrous; threaded solder-joint copper alloy and threaded ferrous.
D. Dielectric-Flange Insulating Kits:
1. Nonconducting materials for field assembly of companion flanges. 2. Pressure Rating: 150 psig. 3. Gasket: Neoprene or phenolic. 4. Bolt Sleeves: Phenolic or polyethylene. 5. Washers: Phenolic with steel backing washers.
E. Dielectric Nipples:
1. Standard: IAPMO PS 66. 2. Electroplated steel nipple complying with ASTM F 1545. 3. Pressure Rating and Temperature: 300 psig at 225 deg F. 4. End Connections: Male threaded or grooved. 5. Lining: Inert and noncorrosive, propylene.
PART 3 - EXECUTION
3.1 EARTHWORK
A. Comply with requirements in Section 312000 "Earth Moving" for excavating, trenching, and backfilling.
3.2 PIPING INSTALLATION
A. Drawing plans, schematics, and diagrams indicate general location and arrangement of domestic water piping. Indicated locations and arrangements are used to size pipe and calculate friction loss, expansion, and other design considerations. Install piping as indicated unless deviations to layout are approved on coordination drawings.
B. Install copper tubing under building slab according to CDA's "Copper Tube Handbook."
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 5 C. Install ductile-iron piping under building slab with restrained joints according to AWWA C600 and AWWA M41.
D. Install shutoff valve, hose-end drain valve, strainer, pressure gage, and test tee with valve inside the building at each domestic water-service entrance. Comply with requirements for pressure gages in Section 220519 "Meters and Gages for Plumbing Piping" and with requirements for drain valves and strainers in Section 221119 "Domestic Water Piping Specialties."
E. Install shutoff valve immediately upstream of each dielectric fitting.
F. Install water-pressure-reducing valves downstream from shutoff valves. Comply with requirements for pressure-reducing valves in Section 221119 "Domestic Water Piping Specialties."
G. Install domestic water piping level with 0.25 percent slope downward toward drain and plumb.
H. Rough-in domestic water piping for water-meter installation according to utility company's requirements.
I. Install seismic restraints on piping.
J. Install piping concealed from view and protected from physical contact by building occupants unless otherwise indicated and except in equipment rooms and service areas.
K. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.
L. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal, and coordinate with other services occupying that space.
M. Install piping to permit valve servicing.
N. Install nipples, unions, special fittings, and valves with pressure ratings the same as or higher than the system pressure rating used in applications below unless otherwise indicated.
O. Install piping free of sags and bends.
P. Install fittings for changes in direction and branch connections.
Q. Install PEX piping with loop at each change of direction of more than 90 degrees.
R. Install unions in copper tubing at final connection to each piece of equipment, machine, and specialty.
S. Install pressure gages on suction and discharge piping for each plumbing pump and packaged booster pump. Comply with requirements for pressure gages in Section 220519 "Meters and Gages for Plumbing Piping."
T. Install thermostats in hot-water circulation piping.
U. Install thermometers on outlet piping from each water heater.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 6 V. Install sleeves for piping penetrations of walls, ceilings, and floors. Comply with requirements for sleeves specified in Section 220517 "Sleeves and Sleeve Seals for Plumbing Piping."
W. Install sleeve seals for piping penetrations of concrete walls and slabs. Comply with requirements for sleeve seals specified in Section 220517 "Sleeves and Sleeve Seals for Plumbing Piping."
X. Install escutcheons for piping penetrations of walls, ceilings, and floors. Comply with requirements for escutcheons specified in Section 220518 "Escutcheons for Plumbing Piping."
3.3 JOINT CONSTRUCTION
A. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe.
B. Remove scale, slag, dirt, and debris from inside and outside of pipes, tubes, and fittings before assembly.
C. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows:
1. Apply appropriate tape or thread compound to external pipe threads. 2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged.
D. Brazed Joints for Copper Tubing: Comply with CDA's "Copper Tube Handbook," "Brazed Joints" chapter.
E. Soldered Joints for Copper Tubing: Apply ASTM B 813, water-flushable flux to end of tube. Join copper tube and fittings according to ASTM B 828 or CDA's "Copper Tube Handbook."
F. Pressure-Sealed Joints for Copper Tubing: Join copper tube and pressure-seal fittings with tools recommended by fitting manufacturer.
G. Flanged Joints: Select appropriate asbestos-free, nonmetallic gasket material in size, type, and thickness suitable for domestic water service. Join flanges with gasket and bolts according to ASME B31.9.
H. Joint Construction for Solvent-Cemented Plastic Piping: Clean and dry joining surfaces. Join pipe and fittings according to the following:
1. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent cements. Apply primer. 2. CPVC Piping: Join according to ASTM D 2846/D 2846M Appendix. 3. PVC Piping: Join according to ASTM D 2855.
I. Joints for PEX Piping: Join according to ASTM F 1807.
J. Joints for Dissimilar-Material Piping: Make joints using adapters compatible with materials of both piping systems.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 7 3.4 TRANSITION FITTING INSTALLATION
A. Install transition couplings at joints of dissimilar piping.
B. Transition Fittings in Underground Domestic Water Piping:
1. Fittings for NPS 1-1/2 and Smaller: Fitting-type coupling. 2. Fittings for NPS 2 and Larger: Sleeve-type coupling.
C. Transition Fittings in Aboveground Domestic Water Piping NPS 2 and Smaller: Plastic-to- metal transition fittings or unions.
3.5 DIELECTRIC FITTING INSTALLATION
A. Install dielectric fittings in piping at connections of dissimilar metal piping and tubing.
B. Dielectric Fittings for NPS 2 and Smaller: Use dielectric couplings or nipples.
C. Dielectric Fittings for NPS 2-1/2 to NPS 4: Use dielectric flanges.
D. Dielectric Fittings for NPS 5 and Larger: Use dielectric flange kits.
3.6 HANGER AND SUPPORT INSTALLATION
A. Comply with requirements for pipe hanger, support products, and installation in Section 220529 "Hangers and Supports for Plumbing Piping and Equipment."
1. Vertical Piping: MSS Type 8 or 42, clamps. 2. Individual, Straight, Horizontal Piping Runs:
a. 100 Feet and Less: MSS Type 1, adjustable, steel clevis hangers. b. Longer Than 100 Feet: MSS Type 43, adjustable roller hangers. c. Longer Than 100 Feet if Indicated: MSS Type 49, spring cushion rolls.
3. Multiple, Straight, Horizontal Piping Runs 100 Feet or Longer: MSS Type 44, pipe rolls. Support pipe rolls on trapeze. 4. Base of Vertical Piping: MSS Type 52, spring hangers.
B. Support vertical piping and tubing at base and at each floor.
C. Rod diameter may be reduced one size for double-rod hangers, to a minimum of 3/8 inch.
D. Install hangers for copper tubing with the following maximum horizontal spacing and minimum rod diameters:
1. NPS 3/4 and Smaller: 60 inches with 3/8-inch rod. 2. NPS 1 and NPS 1-1/4: 72 inches with 3/8-inch rod. 3. NPS 1-1/2 and NPS 2: 96 inches with 3/8-inch rod. 4. NPS 2-1/2: 108 inches with 1/2-inch rod. 5. NPS 3 to NPS 5: 10 feet with 1/2-inch rod.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 8 6. NPS 6: 10 feet with 5/8-inch rod. 7. NPS 8: 10 feet with 3/4-inch rod.
E. Install supports for vertical copper tubing every 10 feet.
F. Install hangers for steel piping with the following maximum horizontal spacing and minimum rod diameters:
1. NPS 1-1/4 and Smaller: 84 inches with 3/8-inch rod. 2. NPS 1-1/2: 108 inches with 3/8-inch rod. 3. NPS 2: 10 feet with 3/8-inch rod. 4. NPS 2-1/2: 11 feet with 1/2-inch rod. 5. NPS 3 and NPS 3-1/2: 12 feet with 1/2-inch rod. 6. NPS 4 and NPS 5: 12 feet with 5/8-inch rod. 7. NPS 6: 12 feet with 3/4-inch rod. 8. NPS 8 to NPS 12: 12 feet with 7/8-inch rod.
G. Install supports for vertical steel piping every 15 feet.
H. Install vinyl-coated hangers for CPVC piping with the following maximum horizontal spacing and minimum rod diameters:
1. NPS 1 and Smaller: 36 inches with 3/8-inch rod. 2. NPS 1-1/4 to NPS 2: 48 inches with 3/8-inch rod. 3. NPS 2-1/2 to NPS 3-1/2: 48 inches with 1/2-inch rod. 4. NPS 4 and NPS 5: 48 inches with 5/8-inch rod. 5. NPS 6: 48 inches with 3/4-inch rod. 6. NPS 8: 48 inches with 7/8-inch rod.
I. Install supports for vertical CPVC piping every 60 inches for NPS 1 and smaller, and every 72 inches for NPS 1-1/4 and larger.
J. Install vinyl-coated hangers for PEX piping with the following maximum horizontal spacing and minimum rod diameters:
1. NPS 1 and Smaller: 32 inches with 3/8-inch rod.
K. Install hangers for vertical PEX piping every 48 inches.
L. Install vinyl-coated hangers for PVC piping with the following maximum horizontal spacing and minimum rod diameters:
1. NPS 2 and Smaller: 48 inches with 3/8-inch rod. 2. NPS 2-1/2 to NPS 3-1/2: 48 inches with 1/2-inch rod. 3. NPS 4 and NPS 5: 48 inches with 5/8-inch rod. 4. NPS 6: 48 inches with 3/4-inch rod. 5. NPS 8: 48 inches with 7/8-inch rod.
M. Install supports for vertical PVC piping every 48 inches.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 9 N. Support piping and tubing not listed in this article according to MSS SP-69 and manufacturer's written instructions.
3.7 CONNECTIONS
A. Drawings indicate general arrangement of piping, fittings, and specialties.
B. When installing piping adjacent to equipment and machines, allow space for service and maintenance.
C. Connect domestic water piping to exterior water-service piping. Use transition fitting to join dissimilar piping materials.
D. Connect domestic water piping to water-service piping with shutoff valve; extend and connect to the following:
1. Domestic Water Booster Pumps: Cold-water suction and discharge piping. 2. Water Heaters: Cold-water inlet and hot-water outlet piping in sizes indicated, but not smaller than sizes of water heater connections. 3. Plumbing Fixtures: Cold- and hot-water-supply piping in sizes indicated, but not smaller than that required by plumbing code. 4. Equipment: Cold- and hot-water-supply piping as indicated, but not smaller than equipment connections. Provide shutoff valve and union for each connection. Use flanges instead of unions for NPS 2-1/2 and larger.
3.8 IDENTIFICATION
A. Identify system components. Comply with requirements for identification materials and installation in Section 220553 "Identification for Plumbing Piping and Equipment."
B. Label pressure piping with system operating pressure.
3.9 FIELD QUALITY CONTROL
A. Perform the following tests and inspections:
1. Piping Inspections:
a. Do not enclose, cover, or put piping into operation until it has been inspected and approved by authorities having jurisdiction. b. During installation, notify authorities having jurisdiction at least one day before inspection must be made. Perform tests specified below in presence of authorities having jurisdiction:
1) Roughing-in Inspection: Arrange for inspection of piping before concealing or closing in after roughing in and before setting fixtures. 2) Final Inspection: Arrange for authorities having jurisdiction to observe tests specified in "Piping Tests" Subparagraph below and to ensure compliance with requirements.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 10 c. Reinspection: If authorities having jurisdiction find that piping will not pass tests or inspections, make required corrections and arrange for reinspection. d. Reports: Prepare inspection reports and have them signed by authorities having jurisdiction.
2. Piping Tests:
a. Fill domestic water piping. Check components to determine that they are not air bound and that piping is full of water. b. Test for leaks and defects in new piping and parts of existing piping that have been altered, extended, or repaired. If testing is performed in segments, submit a separate report for each test, complete with diagram of portion of piping tested. c. Leave new, altered, extended, or replaced domestic water piping uncovered and unconcealed until it has been tested and approved. Expose work that was covered or concealed before it was tested. d. Cap and subject piping to static water pressure of 50 psig above operating pressure, without exceeding pressure rating of piping system materials. Isolate test source and allow it to stand for four hours. Leaks and loss in test pressure constitute defects that must be repaired. e. Repair leaks and defects with new materials, and retest piping or portion thereof until satisfactory results are obtained. f. Prepare reports for tests and for corrective action required.
B. Domestic water piping will be considered defective if it does not pass tests and inspections.
C. Prepare test and inspection reports.
3.10 ADJUSTING
A. Perform the following adjustments before operation:
1. Close drain valves, hydrants, and hose bibs. 2. Open shutoff valves to fully open position. 3. Open throttling valves to proper setting. 4. Adjust balancing valves in hot-water-circulation return piping to provide adequate flow.
a. Manually adjust ball-type balancing valves in hot-water-circulation return piping to provide hot-water flow in each branch. b. Adjust calibrated balancing valves to flows indicated.
5. Remove plugs used during testing of piping and for temporary sealing of piping during installation. 6. Remove and clean strainer screens. Close drain valves and replace drain plugs. 7. Remove filter cartridges from housings and verify that cartridges are as specified for application where used and are clean and ready for use. 8. Check plumbing specialties and verify proper settings, adjustments, and operation.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 11 3.11 CLEANING
A. Clean and disinfect potable domestic water piping as follows:
1. Purge new piping and parts of existing piping that have been altered, extended, or repaired before using. 2. Use purging and disinfecting procedures prescribed by authorities having jurisdiction; if methods are not prescribed, use procedures described in either AWWA C651 or AWWA C652 or follow procedures described below:
a. Flush piping system with clean, potable water until dirty water does not appear at outlets. b. Fill and isolate system according to either of the following:
1) Fill system or part thereof with water/chlorine solution with at least 50 ppm of chlorine. Isolate with valves and allow to stand for 24 hours. 2) Fill system or part thereof with water/chlorine solution with at least 200 ppm of chlorine. Isolate and allow to stand for three hours.
c. Flush system with clean, potable water until no chlorine is in water coming from system after the standing time. d. Repeat procedures if biological examination shows contamination. e. Submit water samples in sterile bottles to authorities having jurisdiction.
B. Prepare and submit reports of purging and disinfecting activities. Include copies of water- sample approvals from authorities having jurisdiction.
C. Clean interior of domestic water piping system. Remove dirt and debris as work progresses.
3.12 PIPING SCHEDULE
A. Transition and special fittings with pressure ratings at least equal to piping rating may be used in applications below unless otherwise indicated.
B. Flanges and unions may be used for aboveground piping joints unless otherwise indicated.
C. Fitting Option: Extruded-tee connections and brazed joints may be used on aboveground copper tubing.
D. Under-building-slab, domestic water, building-service piping, NPS 3 and smaller, shall be the following:
1. PVC, Schedule 80; socket fittings; and solvent-cemented joints.
E. Under-building-slab, domestic water, building-service piping, NPS 4 to NPS 8 and larger, shall be one of the following:
1. Plain-end, ductile-iron pipe; grooved-joint, ductile-iron-pipe appurtenances; and grooved joints. 2. PVC, Schedule 80; socket fittings; and solvent-cemented joints.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 12 F. Under-building-slab, combined domestic water, building-service, and fire-service-main piping, NPS 6 to NPS 12, shall be the following:
1. Plain-end, ductile-iron pipe; grooved-joint, ductile-iron-pipe appurtenances; and grooved joints.
G. Under-building-slab, domestic water piping, NPS 2 and smaller, shall be the following:
1. PVC, Schedule 80; socket fittings; and solvent-cemented joints.
H. Aboveground domestic water piping, NPS 2 and smaller, shall be one of the following:
1. Galvanized-steel pipe and nipples; galvanized, gray-iron threaded fittings; and threaded joints. 2. Hard copper tube, ASTM B 88, Type L; cast- or wrought-copper, solder-joint fittings; and brazed joints. 3. Hard copper tube, ASTM B 88, Type L; copper pressure-seal-joint fittings; and pressure- sealed joints. 4. Hard copper tube, ASTM B 88, Type L; copper push-on-joint fittings; and push-on joints. 5. CPVC, Schedule 80; socket fittings; and solvent-cemented joints. 6. CPVC, Schedule 80 pipe; CPVC, Schedule 80 threaded fittings; and threaded joints. 7. PEX tube, NPS 1 and smaller; fittings for PEX tube; and crimped joints. 8. PVC, Schedule 80; socket fittings; and solvent-cemented joints.
I. Aboveground domestic water piping, NPS 2-1/2 to NPS 4, shall be one of the following:
1. Hard copper tube, ASTM B 88, Type L; cast- or wrought-copper, solder-joint fittings; and brazed joints. 2. Hard copper tube, ASTM B 88, Type L; copper pressure-seal-joint fittings; and pressure- sealed joints. 3. Hard copper tube, ASTM B 88, Type L; grooved-joint, copper-tube appurtenances; and grooved joints. 4. Galvanized-steel pipe and nipples; galvanized, gray-iron threaded fittings; and threaded joints. 5. CPVC, Schedule 80; socket fittings; and solvent-cemented joints. 6. CPVC, Schedule 80 pipe; CPVC, Schedule 80 threaded fittings; and threaded joints. 7. PVC, Schedule 80; socket fittings; and solvent-cemented joints.
J. Aboveground domestic water piping, NPS 5 to NPS 8, shall be one of the following:
1. Hard copper tube, ASTM B 88, Type L; cast- or wrought-copper, solder-joint fittings; and brazed joints. 2. Hard copper tube, ASTM B 88, Type L; grooved-joint, copper-tube appurtenances; and grooved joints. 3. Galvanized-steel pipe and nipples; galvanized, gray-iron threaded fittings; and threaded joints. 4. CPVC, Schedule 80; socket fittings; and solvent-cemented joints. 5. CPVC, Schedule 80 pipe; CPVC, Schedule 80 threaded fittings; and threaded joints. 6. PVC, Schedule 80; socket fittings; and solvent-cemented joints.
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 13 K. Aboveground, combined domestic water-service and fire-service-main piping, NPS 6 to NPS 12, shall be one of the following:
1. Plain-end, ductile-iron pipe; grooved-joint, ductile-iron-pipe appurtenances; and grooved joints. 2. Galvanized-steel pipe and nipples; galvanized, gray-iron threaded fittings; and threaded joints.
END OF SECTION 221116
WRCRWA WATER PIPING PLANT EXPANSION PROJECT 221116 - 14 SECTION 221119 - WATER PIPING SPECIALTIES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Backflow Preventers. 2. Hose bibs. 3. Yard hydrants. 4. Water Filters.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
PART 2 - PRODUCTS
2.1 GENERAL REQUIREMENTS FOR PIPING SPECIALTIES
A. Potable-water piping and components shall comply with NSF 61 and NSF 14.
2.2 PERFORMANCE REQUIREMENTS
A. Minimum Working Pressure for Domestic Water Piping Specialties: 125 psig unless otherwise indicated.
2.3 BACKFLOW PREVENTERS
A. Intermediate Atmospheric-Vent Backflow Preventers. Backflow preventers shall be tested by a certified Backflow Prevention Assembly Tester following installation. Products shall be as follows:
WRCRWA WATER PIPING SPECIALTIES PLANT EXPANSION PROJECT 221119 - 1 B. Reduced Pressure Zone Assemblies: A reduced pressure zone assembly shall be installed at each cross-connection to prevent back siphonage and backpressure of hazardous materials into the potable water supply. The assembly shall consist of a pressure differential relief valve located in a zone between two positive seating check valves. Backsiphonage protection shall include provision to admit air directly into the reduced pressure zone via a separate channel from the water discharge channel, or directly into the supply pipe via a separate vent. The assembly shall be constructed using lead free cast copper silicon materials. The lead free reduced pressure zone assembly shall comply with state codes and standards, where applicable, requiring reduced lead content. The assembly shall include two tightly closing shutoff valves before and after the assembly, test cocks and a protective strainer upstream of the No. 1 shutoff valve. The assembly shall have a maximum pressure loss of 12 psig through the middle third of the flow range. The assembly shall meet the requirements of ASSE std. 1013; AWWA Std. C- 511-92 CSA B64.4; FCCCHR of USC Manual Section 10. The assembly shall be a Watts LF909 or equal.
2.4 HOSE BIBBS
A. Hose Bibbs:
1. Standard: ASME A112.18.1 for sediment faucets. 2. Body Material: Bronze. 3. Seat: Bronze, replaceable. 4. Supply Connections: NPS 1/2 or NPS 3/4 threaded or solder-joint inlet. 5. Outlet Connection: Garden-hose thread complying with ASME B1.20.7. 6. Pressure Rating: 125 psig. 7. Vacuum Breaker: Integral or field-installation, nonremovable, drainable, hose- connection vacuum breaker complying with ASSE 1011. 8. Finish for Equipment Rooms: Rough bronze, or chrome or nickel plated. 9. Finish for Service Areas: Chrome or nickel plated. 10. Finish for Finished Rooms: Chrome or nickel plated. 11. Operation for Equipment Rooms: Wheel handle or operating key. 12. Operation for Service Areas: Operating key. 13. Operation for Finished Rooms: Operating key. 14. Include operating key with each operating-key hose bib. 15. Include wall flange with each chrome- or nickel-plated hose bib. 16. Manufacturer: Watts Water Technologies Co., or equal.
2.5 YARD HYDRANTS
A. Yard Hydrants 1. Standard: ASME A112.21.3.M for exposed-outlet, self-draining wall hydrants. 2. 1” Female Inlet 3. Galvanized pipe casing 4. 1/8” Drain Hole 5. Removable Nozzle 6. Adjustable Link 7. Long life packing 8. Maximum working pressure 125 psi 9. Manufacturer: Watts Water Technologies Co., or equal
WRCRWA WATER PIPING SPECIALTIES PLANT EXPANSION PROJECT 221119 - 2 2.6 NON-POTABLE WATER FILTERS
A. Water filters shall consist of a housing containing a single liquid filtering bag. The housing shall be constructed of 304 stainless steel, with flanged inlet and outlets, and shall be rated for 150 psi at 300¡F. The filtering bag shall be a stainless steel 316 wire mesh basket with a minimum mesh size of 20 and shall be capable of treating up to 220 gpm. The water filter shall be by Krystil Klear Filtration or equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install backflow preventers in each water supply to mechanical equipment and systems and to other equipment and water systems that may be sources of contamination. Comply with authorities having jurisdiction.
1. Locate backflow preventers in same room as connected equipment or system. 2. Install drain for backflow preventers with atmospheric-vent drain connection with air-gap fitting, fixed air-gap fitting, or equivalent positive pipe separation of at least two pipe diameters in drain piping and pipe-to-floor drain. Locate air-gap device attached to or under backflow preventer. Simple air breaks are unacceptable for this application. 3. Do not install bypass piping around backflow preventers.
B. Install water regulators with inlet and outlet shutoff valves. Install pressure gages on inlet and outlet.
C. Install balancing valves in locations where they can easily be adjusted.
D. Install temperature-actuated, water mixing valves with check stops or shutoff valves on inlets and with shutoff valve on outlet.
1. Install cabinet-type units recessed in or surface mounted on wall as specified.
E. Install Y-pattern strainers where indicated.
F. Set yard hydrants with riser pipe in concrete or pavement. Do not encase canister in concrete.
G. Install water-hammer arresters in water piping according to PDI-WH 201.
H. Install supply-type, trap-seal primer valves with outlet piping pitched down toward drain trap a minimum of 1 percent, and connect to floor-drain body, trap, or inlet fitting. Adjust valve for proper flow.
I. Install drainage-type, trap-seal primer valves as lavatory trap with outlet piping pitched down toward drain trap a minimum of 1 percent, and connect to floor-drain body, trap, or inlet fitting.
WRCRWA WATER PIPING SPECIALTIES PLANT EXPANSION PROJECT 221119 - 3 3.2 CONNECTIONS
A. Comply with requirements for ground equipment in Section 260526 "Grounding and Bonding for Electrical Systems."
B. Fire-retardant-treated-wood blocking is specified in Section 260519 "Low-Voltage Electrical Power Conductors and Cables" for electrical connections.
3.3 FIELD QUALITY CONTROL
A. Testing shall be according to authorities having jurisdiction, and according to the device’s reference standard. Domestic water piping specialties will be considered defective if they do not pass tests and inspections. Any defective equipment shall be replaced at the Contractor’s expense.
B. Test and inspection reports shall be prepared by a certified tester for each given specialty above. Test reports shall be delivered to the Engineer.
3.4 ADJUSTING
A. Set field-adjustable pressure set points of water pressure-reducing valves.
B. Set field-adjustable flow set points of balancing valves.
C. Set field-adjustable temperature set points of temperature-actuated, water mixing valves.
END OF SECTION 221119
WRCRWA WATER PIPING SPECIALTIES PLANT EXPANSION PROJECT 221119 - 4 SECTION 221245 – HIGH DENSITY CROSS-LINKED POLYETHYLENE CHEMICAL STORAGE TANKS
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall furnish and install integrally molded flanged outlet, high density cross- linked polyethylene tank(s) and accessories, complete and in place, in accordance with the Contract Documents. Contractor and supplier shall provide tank and all of its accessories including nozzles, flange connections, ladders, access ports, man ways, anchors, tie downs, restraints, and all other appurtenances for a complete storage tank system as indicated in the design drawings and as recommended by the manufacturer.
B. Contractor and tank supplier are responsible to furnish all tie down, restraint, and seismic restraints required for each tank in accordance with all local building and mechanical code requirements. Tank supplier shall furnish calculations and design criteria for each tank supplied.
1.2 REFERENCE, CODES AND STANDARDS
A. American Society of Testing Materials (ASTM):
1. D638 Tensile Properties of Plastics 2. D883 Standard Definitions of Terms Relating to Plastics 3. D1505 Density of Plastics by the Density Gradient Technique 4. D1525 Test Method for Vicat Softening Temperature of Plastics 5. D1693 ESCR Specification Thickness 0.125” F50-10% Igepal 6. F412 Standard Terminology Relation got Plastic Piping Systems
B. ANSI Standards: B-16.5. Pipe Flanges and Flanged Fittings
C. ARM: Low Temperature Impact Resistance (Falling Dart Test Procdure)
D. ASTM D-1998: Standard Specification for Polyethylene Upright Storage Tanks
E. The latest edition of all other applicalbe codes that are enforced by local authorities including: 2012 IBC (2013 CBC), 2012 IMC, are applicable unless earlier editions are specifically listed in the general design criteria of the design drawings.
1.3 SUBMITTALS
A. Shop Drawings: Shop Drawings: Shop drawings shall be approved by the engineer or contractor prior to the manufacturing of the integrally molded flanged outlet, tank(s). Submit the following as a single complete initial submittal. Sufficient data shall be included to show that the product conforms to Specification requirements. Provide the following additional information:
1. Integrally molded flanged outlet IMFO tank and fitting material a. Resin manufacturing data sheet b. Fitting material
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-1 c. Gasket style and material d. Bolt material 2. Dimensioned Tank Drawings a. Location and orientation of molded in fitting, openings, fittings, accessories, restraints, and supports. b. Details of inlet and molded outlet fitting, manways, flexible conneciton, vents, ladders, supports, and other items attached to or directly related to the tank. 3. Factory Test Report including: a. Material, specific gravity rating at 600 psi and 100 degrees F. b. Wall thickness verification. c. Fitting placement verificaiton d. Ipact test, gel test, and hydrostatic test results. 4. Calculations shall be stamped and signed by a registered, third party engineer in the State of installation. a. Hoop stress shall be calculated using 600 psi @ 100 degress F. b. Include seismic and wind criteria for tank restrain system.
1.4 DELIVERY, STORAGE AND HANDLING:
A. Contractor shall be responsible to arrange delivery, unloading, handling, storage, and installation of the tank. Contractor shall follow all guideliens and recommendations from the manufacturer.
1.5 QUALITY ASSURANCE
A. The Contractor shall provide a vertical, high desntiy cross-linked polyethylene tank with full drain capability and molded fittings.
B. Tanks shall be of the size, capacity, and nominal dimensions indicated in the design drawings. Even minor variations from the design drawings must be approved by the Engineer.
C. Tanks shall be of the make and model indicated in mechanical schedule as supplied by Poly Processing Company or equal. Any supplier must have at least 10-years expereince in manufacturing and supplying chemical storage tanks.
D. Tanks shall be manufactured from virgin materials.
1. Welding: Qualify welding procedures, welders and operators in accordance with ASME B31.1, or ASME B31.9, as applicable, for shop and project site welding of piping work.
2. Brazing: Certify brazing procedures, brazers, and operators in accordance with ASME Boiler and Pressure Vessel Code, Section IX, for shop and job-site brazing of piping work.
1.6 WARRANTY
A. Manufactuere shall include a 5 year full replacement warranty.
PART 2 - PRODUCTS
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-2 2.1 GENERAL:
A. Tanks shall be rotationally-molded, integrally molded flanged outlet IMFO¨, high density cross-linked polyethylene, one-piece seamless construction, cylindrical in cross-section and vertical with flat / sloping bottoms in axis. Tanks shall be adequately vented as prescribed in Poly Processing Company’s Technical Bulletin, Venting-Design for ACFM (air cubic feet per minute). Where indicated, tanks shall be provided with ancillary mechanical fittings and accessories. Tanks shall be marked to identify the manufacturer, date of manufacture and serial numbers must be permanently embossed into the tank.
B. Refer to the design drawings for specific details on each storage tank application including capacity, dimensions, fittings, accessories, and other application-specific requirements. Note that the chemical being stored in each individual tank may vary – refer to the design drawings and the following sections for details regarding the media to be stored in each application.
2.2 POLYETHYLENE STORAGE TANKS
A. High Density Cross-linked Polyethylene resin used in the tank manufacture shall be Poly CL™ or equal and shall contain ultraviolet stabilizer as recommended by resin manufacturer. Where black tanks are indicated, the resin shall have a carbon black compounded into it. The tank material shall be rotationally molded and be a resin that is commercially available at the time of tank manufacture.
B. For sodium hypochlorite and sulfuric acid storage, resin shall include additional medium density polyethylene (OR-1000) with four times the antioxidant properties of a standard polyethylene bonded to the interior surface during the manufacturing process.
C. Wall thickness for a given hoop stress is to be calculated in accordance with ASTM D 1998. Tanks shall be designed using a hoop stress no greater than 600 psi. In NO case shall the tank thickness be less than design requirements per ASTM D 1998.
The minimum wall thickness shall be sufficient to support its own weight in an upright position without external support but shall not be less than 0.187” thick.
D. On closed top tanks the top head shall be integrally molded with the cylindrical wall. Its minimum thickness shall be equal to the thickness of the top of the straight sidewall. In most cases, flat areas shall be provided for attachment of large fittings on the dome of the tank. The bottom head shall be integrally molded with the cylindrical wall. Knuckle radius shall be a minimum of 1-inch for tank diameters ≤ 6-feet and 1.5-inches for tank diameters larger than 6- feet.
E. Tanks with 3000 gal capacity or larger shall have at least 3 lifting lugs. Lugs shall be designed for lifting the tank when empty.
1. Unless otherwise indicated by Contract drawings, for indoor pneumatic fill, manways shall be 24-in diameter or greater and equipped with an emergency pressure relief device or SAFE-Surge™ Manway with pressure relief at 6” water column to prevent over- pressurization. The SAFE-Surge manway shall be chemically compatible with the chemical being stored. Gaskets shall be closed cell, cross-linked polyethylene foam, Viton, or EPDM materials.
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-3 2. Unless otherwise indicated by Contract drawings, for outdoor pneumatic fill, manways shall be 24-in diameter or greater and equipped with Poly Processing Company’s F.S.2650¨ combined manway and vent to prevent over pressurization of tank. Manway must be capable of relieving a volume flow rate of up to 2650 ACFM. Gaskets shall be closed cell, cross-linked polyethylene foam, Viton, or EPDM materials.
3. Unless otherwise indicated, tanks less than 2000 gallons in non-pneumatic applications shall have a manway cover 17-in or smaller of Polyethylene material with a coarse thread. Gaskets shall be closed cell, cross-linked polyethylene foam, viton or EPDM materials.
F. Tanks must be vented to allow for performance at atmospheric pressure, in accordance with the following matrix and per manufacturer’s recommendations:
G. The following Tank Shedule summarizes the tanks associated with this project. Confirm all aspects of this schedule with the Design Drawings.
Chemical Tank capacity Material Diameter Height Heat Insulation Fitting materials Stored tracing
Sodium HDXLPE 10,300 gallons 12’0” 14’4” No No PVC/Titan/EPDM Hypochlorite w/OR1000
Sodium 3,000 gallons HDXLPE 8’2” 9’4” No* No* PVC/SS/EPDM Bisulfite
Alum 4,000 gallons HDXLPE 8’2” 12’10” No No PVC/SS/EPDM
Polymer 3,000 gallons HDXLPE 8’0” 8’6” No* No* PVC/SS/EPDM *Provisions shall be in place to add heat tracing and insualation in-field for these tanks as a future option.
H. Tank colors shall be natural (un-pigmented), or black (compounded), and shall be approved by Owner and Engineer prior to manufacturer.
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-4
2.3 TANK ACCESSORIES
A. Ladder:
1. Ladder shall be fiberglass, and shall be provided with the polyethylene chemical storage tanks at locations as shown. Safety cages shall be added to ladders as required, per OSHA. 2. Ladders must be secured to the tank and secured to the concrete to allow for tank expansion/ contraction due to temperature and loading changes. Use proper chemical resistant materials when anchoring to tank dome or sidewall. Follow all manufacturer requiremetns regarding ladder installation requirements. 3. All ladders shall be designed to meet applicable OSHA standards. Reference OSHA 2206; 1910.27; fixed ladders
B. Restraint System: Metal components to be stainless steel edge softeners, and tension ring with stainless steel cables and clamps. Tank restraint system shall be supplied and the design of same certified by a Structural Engineer registered in the State of tank installation. Design shall conform to the most recent edition of the IBC code (or CBC as applicable) for seismic and wind load. Anchor bolts as required by the calculations shall be supplied by the tank manufacturer and shall be fabricated from stainless steel.
C. Heat Tracing and Insulation: The storage tank for sodium bisulfite is not required to be provided with heat tracing and insulation at the time of installation. However, the tank supplied must allow for in-field installation of insulation and heat tracing in the future.
Insulation used shall be polyurethane foam with a density of 2.5 lb/ft3 with a minimum an “R” value of 6.3/in. The foam shall be applied with a nominal thickness of 2” to the external tank surfaces except the tank bottom. Upon completion of application and curing of the insulation, 2 full coverage coats of latex mastic coating shall be applied to the surface of the insulation in such manner as to seal the insulation from the outside environment. Tank supplier shall provide information on how the insulation would be installed in-field in the future.
D. Tank fittings shall be according to the fittings indicated in the design drawings. Threaded fittings shall use American Standard Pipe Threads. If tanks are insulated, fittings shall be installed at the factory prior to application of the insulation.
Integrally Molded Flanged Outlet Fittings (IMFO¨). These outlets must be an integral part of the tank, molded from the same material as the tank and provide complete drainage of liquid through the sidewall of the tank. Metal and alloy inserts shall not be used.
Bolted flange fittings shall be constructed of one 150 lb. flange with ANSI bolt pattern, one flange gasket and stud bolts with gaskets. Stud bolts to have chemical resistant polyethylene injection molded heads and gaskets to provide a sealing surface between the bolt head and the interior tank wall. Stud bolt heads are to be color coded for visual ease of identifying the bolt material by onsite operators. Green- 316 Stainless Steel, Black- Titanium, Red- Alloy C-276, Blue- Monel. All materials shall be compatible with chemical service and as indicated in the fitting schedule above. For NSF/ANSI 61 certification, EPDM or Viton GF gaskets shall be supplied.
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-5 For sodium hypochlorite and sulfuric acid storage, Bolted One-Piece Sure Seal (B.O.S.S.), double flange fittings constructed of virgin polyethylene shall be supplied. Bolts will be welded to a common backing ring and encapsulated with polyethylene preventing fluid contact with the metal material. Flange will have one full face gasket to provide a sealing surface against inside tank wall. All materials shall be compatible with chemical service and as indicated in the fitting schedule above
E. Down Pipes and Fill Pipes: Down pipes and fill pipes shall be supported at 6-ft max intervals. Down pipes and fill pipes shall be PVC or material compatible with the chemical stored.
F. U-Vents: Each tank must be vented for the material and flow and withdrawal rates expected. Vents should comply with OSHA 1910.106(F) (iii)(2)(IV)(9). U-vents shall be sized by the tank manufacturer and be furnished complete with insect screen if required (Insect screen lessens the vent capacity by 1/3) in accordance with the venting schedule listed above.
G. Provide ultrasonic level indicators in the location indicated in the design drawings.
PART 3 - EXECUTION
3.1 FACTORY TESTING
A. Perform gel and low temperature impact tests in accordance with ASTM D 1998 on condition samples cut from each polyethylene chemical storage tank.
B. Degree of Cross-linking. Use Method C of ASTM D 1998- Section11.4 to determine the ortho- xylene insoluble fraction of cross-linked polyethylene gel test. Samples shall test at no less than 60 percent.
C. Dimensions: Take exterior dimensions with the tank empty, in the vertical position. Outside diameter tolerance, including out-of-roundness, shall be per ASTM D 1998. Fitting placement tolerance shall be +/- 1/2-in vertical and +/- 1 degree radial.
D. Visual: Inspect for foreign inclusions, air bubbles, pimples, crazing, cracking.
E. Hydrostatic test: Following fabrication, the bottom tanks, including inlet and outlet fittings, shall be hydraulically tested with water by filling to the top sidewall for a minimum of 1 hour and inspected for leaks. Following successful testing, the tank shall be emptied and cleaned prior to shipment.
3.2 DELIVERY, STORAGE, AND HANDLING
A. The tank shall be shipped upright or lying down on their sides with blocks and slings to keep them from moving. AVOID sharp objects on trailers.
B. All fittings shall be installed and, if necessary, removed for shipping and shipped separately unless otherwise noted by the contractor.
C. Upon arrival at the destination, inspect the tank(s) and accessories for damage in transit. If damage has occurred, Poly Processing Company shall be notified immediately
3.3 INSTALLATION
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-6 A. Install the tanks in strict accordance with Poly Processing Company’s Tank Installation Manual and shop drawings.
B. Installation will be inspected by manufacturer to verify system flexible connections, venting and fittings are properly installed. In addition to on-sight inspection tank system(s) to be reviewed using tank manual check list as supplied by manufacture as listed below.
C. Manufacturer to provide 1 hour training session to prepare operators to service and maintain the tank system. Included in training session will be (#) training manuals.
D. Manufacturer’s trained technician to do an onsite inspection of installation. Inspection will verify chemical application, plumbing connections, venting, and applicable ancillary equipment such as ladders, restraints, etc. A verification of proper installation certificate will be supplied when equipment passes installation checklist.
E. Tank manuals will consist of installation check lists, tank drawing(s) as built, fitting drawings referencing nozzle schedule on tank drawing, materials of construction, and recommended maintenance program.
3.4 FIELD TESTING
A. All tanks shall be hydro-tested in field for 24 hours prior to commissioning. Test should include the tank and all attached pipelines that will handle fluid (feed pipe, discharge pipe). All nozzels and connections shall be field tested to verify water tightness.
END OF SECTION 221245
WRCRWA HDXLP CHEMICAL STORAGE TANKS PLANT EXPANSION PROJECT 221245-7
SECTION 221316 - SANITARY WASTE AND VENT PIPING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Pipe, tube, and fittings. 2. Specialty pipe fittings.
1.2 PERFORMANCE REQUIREMENTS
A. Seismic Performance: Soil, waste, and vent piping and support and installation shall withstand the effects of earthquake motions determined according to ASCE/SEI 7.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.4 INFORMATIONAL SUBMITTALS
A. Seismic Qualification Certificates: For waste and vent piping, accessories, and components, from manufacturer.
1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation. 2. Detailed description of piping anchorage devices on which the certification is based and their installation requirements.
B. Field quality-control reports.
1.5 QUALITY ASSURANCE
A. Piping materials shall bear label, stamp, or other markings of specified testing agency.
B. Comply with NSF/ANSI 14, "Plastics Piping Systems Components and Related Materials," for plastic piping components. Include marking with "NSF-dwv" for plastic drain, waste, and vent piping and "NSF-sewer" for plastic sewer piping.
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 1 PART 2 - PRODUCTS
2.1 PIPING MATERIALS
A. Comply with requirements in "Piping Schedule" Article for applications of pipe, tube, fitting materials, and joining methods for specific services, service locations, and pipe sizes.
2.2 ABS PIPE AND FITTINGS
A. Solid-Wall ABS Pipe: ASTM D 2661, Schedule 40.
B. Cellular-Core ABS Pipe: ASTM F 628, Schedule 40.
C. ABS Socket Fittings: ASTM D 2661, made to ASTM D 3311, drain, waste, and vent patterns.
D. Solvent Cement: ASTM D 2235.
2.3 PVC PIPE AND FITTINGS
A. Solid-Wall PVC Pipe: ASTM D 2665, drain, waste, and vent.
B. Cellular-Core PVC Pipe: ASTM F 891, Schedule 40.
C. PVC Socket Fittings: ASTM D 2665, made to ASTM D 3311, drain, waste, and vent patterns and to fit Schedule 40 pipe.
D. Adhesive Primer: ASTM F 656.
E. Solvent Cement: ASTM D 2564.
2.4 SPECIALTY PIPE FITTINGS
A. Transition Couplings:
1. General Requirements: Fitting or device for joining piping with small differences in OD's or of different materials. Include end connections same size as and compatible with pipes to be joined. 2. Fitting-Type Transition Couplings: Manufactured piping coupling or specified piping system fitting. 3. Unshielded, Nonpressure Transition Couplings:
a. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1) Fernco Inc. 2) Or Equal.
b. Standard: ASTM C 1173.
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 2 c. Description: Elastomeric, sleeve-type, reducing or transition pattern. Include shear ring and corrosion-resistant-metal tension band and tightening mechanism on each end. d. Sleeve Materials:
1) For Cast-Iron Soil Pipes: ASTM C 564, rubber. 2) For Plastic Pipes: ASTM F 477, elastomeric seal or ASTM D 5926, PVC. 3) For Dissimilar Pipes: ASTM D 5926, PVC or other material compatible with pipe materials being joined.
4. Shielded, Nonpressure Transition Couplings:
a. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1) Cascade Waterworks Mfg. Co. 2) Or Equal.
b. Standard: ASTM C 1460. c. Description: Elastomeric or rubber sleeve with full-length, corrosion-resistant outer shield and corrosion-resistant-metal tension band and tightening mechanism on each end.
PART 3 - EXECUTION
3.1 EARTH MOVING
A. Comply with requirements for excavating, trenching, and backfilling specified in Section 312000 "Earth Moving."
3.2 PIPING INSTALLATION
A. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on coordination drawings.
B. Install piping in concealed locations unless otherwise indicated and except in equipment rooms and service areas.
C. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise.
D. Install piping above accessible ceilings to allow sufficient space for ceiling panel removal.
E. Install piping at indicated slopes.
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 3 F. Install piping free of sags and bends.
G. Install fittings for changes in direction and branch connections.
H. Install seismic restraints on piping. Comply with requirements for seismic-restraint devices specified in Section 220548 "Vibration and Seismic Controls for Plumbing Piping and Equipment."
I. Make changes in direction for soil and waste drainage and vent piping using appropriate branches, bends, and long-sweep bends. Sanitary tees and short-sweep 1/4 bends may be used on vertical stacks if change in direction of flow is from horizontal to vertical. Use long-turn, double Y-branch and 1/8-bend fittings if two fixtures are installed back to back or side by side with common drain pipe. Straight tees, elbows, and crosses may be used on vent lines. Do not change direction of flow more than 90 degrees. Use proper size of standard increasers and reducers if pipes of different sizes are connected. Reducing size of drainage piping in direction of flow is prohibited.
J. Lay buried building drainage piping beginning at low point of each system. Install true to grades and alignment indicated, with unbroken continuity of invert. Place hub ends of piping upstream. Install required gaskets according to manufacturer's written instructions for use of lubricants, cements, and other installation requirements. Maintain swab in piping and pull past each joint as completed.
K. Install soil and waste drainage and vent piping at the following minimum slopes unless otherwise indicated:
1. Building Sanitary Drain: Unless noted otherwise, 2 percent downward in direction of flow for piping NPS 3 and smaller; 1 percent downward in direction of flow for piping NPS 4 and larger. 2. Horizontal Sanitary Drainage Piping: 2 percent downward in direction of flow. 3. Vent Piping: 1 percent down toward vertical fixture vent or toward vent stack.
L. Install aboveground ABS piping according to ASTM D 2661.
M. Install aboveground PVC piping according to ASTM D 2665.
N. Install underground ABS and PVC piping according to ASTM D 2321.
O. Plumbing Specialties: 1. Install cleanouts at grade and extend to where building sanitary drains connect to building sanitary sewers in sanitary drainage gravity-flow piping. Comply with requirements for cleanouts specified in Section 221319 "Sanitary Waste Piping Specialties." 2. Install drains in sanitary drainage gravity-flow piping. Comply with requirements for drains specified in Section 221319 "Sanitary Waste Piping Specialties."
P. Do not enclose, cover, or put piping into operation until it is inspected and approved by authorities having jurisdiction.
Q. Install sleeves for piping penetrations of walls, ceilings, and floors. Comply with requirements for sleeves specified in Section 220517 "Sleeves and Sleeve Seals for Plumbing Piping."
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 4 R. Install sleeve seals for piping penetrations of concrete walls and slabs. Comply with requirements for sleeve seals specified in Section 220517 "Sleeves and Sleeve Seals for Plumbing Piping."
S. Install escutcheons for piping penetrations of walls, ceilings, and floors. Comply with requirements for escutcheons specified in Section 220518 “Escutcheons for Piping.”
3.3 JOINT CONSTRUCTION
A. Flanged Joints: Align bolt holes. Select appropriate gasket material, size, type, and thickness. Install gasket concentrically positioned. Use suitable lubricants on bolt threads. Torque bolts in cross pattern.
B. Plastic, Nonpressure-Piping, Solvent-Cement Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following:
1. Comply with ASTM F 402 for safe-handling practice of cleaners, primers, and solvent cements. 2. ABS Piping: Join according to ASTM D 2235 and ASTM D 2661 Appendixes. 3. PVC Piping: Join according to ASTM D 2855 and ASTM D 2665 Appendixes.
3.4 SPECIALTY PIPE FITTING INSTALLATION
A. Transition Couplings:
1. Install transition couplings at joints of piping with small differences in OD's. 2. In Drainage Piping: Shielded, nonpressure transition couplings.
3.5 VALVE INSTALLATION
A. Backwater Valves: Install backwater valves in piping subject to backflow.
1. Horizontal Piping: Horizontal backwater valves. Use normally closed type unless otherwise indicated. 2. Floor Drains: Drain outlet backwater valves unless drain has integral backwater valve. 3. Install backwater valves in accessible locations. 4. Comply with requirements for backwater valve specified in Section 221319 "Sanitary Waste Piping Specialties."
3.6 HANGER AND SUPPORT INSTALLATION
A. Comply with requirements for pipe hanger and support devices and installation specified in Section 220529 "Hangers and Supports for Plumbing Piping and Equipment."
1. Install carbon-steel pipe hangers for horizontal piping in noncorrosive environments. 2. Install stainless-steel pipe hangers for horizontal piping in corrosive environments. 3. Install carbon-steel pipe support clamps for vertical piping in noncorrosive environments. 4. Install stainless-steel pipe support clamps for vertical piping in corrosive environments.
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 5 5. Vertical Piping: MSS Type 8 or Type 42, clamps. 6. Install individual, straight, horizontal piping runs:
a. 100 Feet and Less: MSS Type 1, adjustable, steel clevis hangers. b. Longer Than 100 Feet: MSS Type 43, adjustable roller hangers. c. Longer Than 100 Feet if Indicated: MSS Type 49, spring cushion rolls.
7. Multiple, Straight, Horizontal Piping Runs 100 Feet or Longer: MSS Type 44, pipe rolls. Support pipe rolls on trapeze. 8. Base of Vertical Piping: MSS Type 52, spring hangers.
B. Support horizontal piping and tubing within 12 inches of each fitting, valve, and coupling.
C. Support vertical piping and tubing at base and at each floor.
D. Rod diameter may be reduced one size for double-rod hangers, with 3/8-inch minimum rods.
E. Install hangers for ABS and PVC piping with the following maximum horizontal spacing and minimum rod diameters:
1. NPS 1-1/2 and NPS 2: 48 inches with 3/8-inch rod. 2. NPS 3: 48 inches with 1/2-inch rod. 3. NPS 4 and NPS 5: 48 inches with 5/8-inch rod. 4. NPS 6 and NPS 8: 48 inches with 3/4-inch rod.
F. Install supports for vertical ABS and PVC piping every 48 inches.
G. Support piping and tubing not listed above according to MSS SP-69 and manufacturer's written instructions.
H. Install supports for ABS and PVC piping every 48 inches.
3.7 CONNECTIONS
A. Drawings indicate general arrangement of piping, fittings, and specialties.
B. Connect soil and waste piping to exterior sanitary sewerage piping. Use transition fitting to join dissimilar piping materials.
C. Connect drainage and vent piping to the following:
1. Plumbing Fixtures: Connect drainage piping in sizes indicated, but not smaller than required by plumbing code. 2. Plumbing Fixtures and Equipment: Connect atmospheric vent piping in sizes indicated, but not smaller than required by authorities having jurisdiction. 3. Plumbing Specialties: Connect drainage and vent piping in sizes indicated, but not smaller than required by plumbing code. 4. Install test tees (wall cleanouts) in conductors near floor and floor cleanouts with cover flush with floor. 5. Install horizontal backwater valves with cleanout cover flush with floor.
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 6 6. Comply with requirements for backwater valves cleanouts and drains specified in Section 221319 "Sanitary Waste Piping Specialties." 7. Equipment: Connect drainage piping as indicated. Provide shutoff valve if indicated and union for each connection. Use flanges instead of unions for connections NPS 2-1/2 and larger.
D. Where installing piping adjacent to equipment, allow space for service and maintenance of equipment.
E. Make connections according to the following unless otherwise indicated:
1. Install unions, in piping NPS 2 and smaller, adjacent to each valve and at final connection to each piece of equipment. 2. Install flanges, in piping NPS 2-1/2 and larger, adjacent to flanged valves and at final connection to each piece of equipment.
3.8 IDENTIFICATION
A. Identify exposed sanitary waste and vent piping. Comply with requirements for identification specified in Section 220553 "Identification for Plumbing Piping and Equipment."
3.9 FIELD QUALITY CONTROL
A. During installation, notify authorities having jurisdiction at least 24 hours before inspection must be made. Perform tests specified below in presence of authorities having jurisdiction.
1. Roughing-in Inspection: Arrange for inspection of piping before concealing or closing-in after roughing-in and before setting fixtures. 2. Final Inspection: Arrange for final inspection by authorities having jurisdiction to observe tests specified below and to ensure compliance with requirements.
B. Reinspection: If authorities having jurisdiction find that piping will not pass test or inspection, make required corrections and arrange for reinspection.
C. Reports: Prepare inspection reports and have them signed by authorities having jurisdiction.
D. Test sanitary drainage and vent piping according to procedures of authorities having jurisdiction or, in absence of published procedures, as follows:
1. Test for leaks and defects in new piping and parts of existing piping that have been altered, extended, or repaired. If testing is performed in segments, submit separate report for each test, complete with diagram of portion of piping tested. 2. Leave uncovered and unconcealed new, altered, extended, or replaced drainage and vent piping until it has been tested and approved. Expose work that was covered or concealed before it was tested. 3. Roughing-in Plumbing Test Procedure: Test drainage and vent piping except outside leaders on completion of roughing-in. Close openings in piping system and fill with water to point of overflow, but not less than 10-foot head of water. From 15 minutes
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 7 before inspection starts to completion of inspection, water level must not drop. Inspect joints for leaks. 4. Finished Plumbing Test Procedure: After plumbing fixtures have been set and traps filled with water, test connections and prove they are gastight and watertight. Plug vent- stack openings on roof and building drains where they leave building. Introduce air into piping system equal to pressure of 1-inch wg. Use U-tube or manometer inserted in trap of water closet to measure this pressure. Air pressure must remain constant without introducing additional air throughout period of inspection. Inspect plumbing fixture connections for gas and water leaks. 5. Repair leaks and defects with new materials and retest piping, or portion thereof, until satisfactory results are obtained. 6. Prepare reports for tests and required corrective action.
3.10 CLEANING AND PROTECTION
A. Clean interior of piping. Remove dirt and debris as work progresses.
B. Protect drains during remainder of construction period to avoid clogging with dirt and debris and to prevent damage from traffic and construction work.
C. Place plugs in ends of uncompleted piping at end of day and when work stops.
D. Exposed ABS and PVC Piping: Protect plumbing vents exposed to sunlight with two coats of water-based latex paint.
END OF SECTION 221316
WRCRWA SANITARY WASTE AND VENT PIPING PLANT EXPANSION PROJECT 221316 - 8 SECTION 221319 - SANITARY WASTE PIPING SPECIALTIES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: 1. Cleanouts. 2. Trench drains. 3. Floor drains. 4. Miscellaneous sanitary drainage piping specialties. 5. Flashing materials.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated. Include rated capacities, operating characteristics, and accessories for grease interceptors.
1.3 QUALITY ASSURANCE
A. Drainage piping specialties shall bear label, stamp, or other markings of specified testing agency.
PART 2 - PRODUCTS
2.1 CLEANOUTS
A. Exposed Cast-Iron Cleanouts:
1. Standard: ASME A112.36.2M for cast iron for cleanout test tee. 2. Size: Same as connected drainage piping 3. Body Material: Hub-and-spigot, cast-iron soil pipe T-branch as required to match connected piping. 4. Closure: Countersunk, brass plug. 5. Closure Plug Size: Same as or not more than one size smaller than cleanout size.
2.2 TRENCH DRAINS
A. Pre-sloped Channel Drains
1. Description: 6-inch wide trench drain system. NDS Dura Slope Trench Drain, ACO USA, or equal. a. Material: Molded, structural-foam polyethylene with UV inhibitor. b. Built-In Slope: 0.7 percent.
WRCRWA SANITARY WASTE PIPING SPECIALTIES PLANT EXPANSION PROJECT 221319 - 1 c. Inside Diameter: 4 inches. d. Bottom Radius: 2 inches. e. Pre-Installed Locking System: Locks grate to integral frame. f. Rebar Supports: Located at 24-inch intervals along each side of channel contain internal protruding knob to grip No.4 rebar to provide channel height adjustment during installation. g. Tongue-and-Groove Ends: Connect to allow for precise fit and straight channel runs.
2. Channel Grate
a. Description: 2-foot, structural-foam polyolefin, secured channel grate with UV inhibitor. b. Grate Openings: 1/2 inch by 3-13/16 inches. c. Open Surface Area: 20.61 square inches per foot. d. Inlet Capacity: 27.00 gpm per foot. e. Load: Class E
2.3 FLOOR DRAINS
A. Cast-Iron Floor Drains: 1. Zurn Z-520 , Adjustable Heavy-Duty Drain, Or Equal 2. Standard: ASME A112.6.3. 3. Pattern: Area drain. 4. Body Material: Galvanized Cast Iron 5. Seepage Flange: Not required. 6. Anchor Flange: Not required. 7. Clamping Device: Not required. 8. Outlet: Bottom. 9. Backwater Valve: Not required. 10. Coating on Interior and Exposed Exterior Surfaces: Not Required 11. Sediment Bucket: Yes 12. Top or Strainer Material: Cast Iron 13. Top of Body and Strainer Finish: Galvanized Cast Iron 14. Top Shape: Round. 15. Funnel: Not required. 16. Inlet Fitting: Not required. 17. Trap Material: Bronze. 18. Trap Pattern: Standard P-trap. 19. Trap Features: Not required.
2.4 MISCELLANEOUS SANITARY DRAINAGE PIPING SPECIALTIES
A. Vent Caps:
1. Description: Cast-iron body with threaded or hub inlet and vandal-proof design. Include vented hood and setscrews to secure to vent pipe. 2. Size: Same as connected stack vent or vent stack.
WRCRWA SANITARY WASTE PIPING SPECIALTIES PLANT EXPANSION PROJECT 221319 - 2 PART 3 - EXECUTION
3.1 INSTALLATION
A. Install backwater valves in building drain piping. For interior installation, provide cleanout deck plate flush with floor and centered over backwater valve cover, and of adequate size to remove valve cover for servicing.
B. Install cleanouts in aboveground piping and building drain piping according to the following, unless otherwise indicated:
1. Size same as drainage piping up to NPS 4. Use NPS 4 for larger drainage piping unless larger cleanout is indicated. 2. Locate at each change in direction of piping greater than 45 degrees. 3. Locate at minimum intervals of 50 feet for piping NPS 4 and smaller and 100 feet for larger piping. 4. Locate at base of each vertical soil and waste stack.
C. For floor cleanouts for piping below floors, install cleanout deck plates with top flush with finished floor.
D. For cleanouts located in concealed piping, install cleanout wall access covers, of types indicated, with frame and cover flush with finished wall.
E. Install floor and trench drains at low points of surface areas to be drained. Set grates of drains flush with finished floor, unless otherwise indicated.
1. Position floor drains for easy access and maintenance. 2. Set floor drains below elevation of surrounding finished floor to allow floor drainage. Set with grates depressed according to the following drainage area radii:
a. Radius, 30 Inches or Less: Equivalent to 1 percent slope, but not less than 1/4-inch total depression. b. Radius, 30 to 60 Inches: Equivalent to 1 percent slope. c. Radius, 60 Inches or Larger: Equivalent to 1 percent slope, but not greater than 1- inch total depression.
3. Install floor-drain flashing collar or flange so no leakage occurs between drain and adjoining flooring. Maintain integrity of waterproof membranes where penetrated. 4. Install individual traps for floor drains connected to sanitary building drain, unless otherwise indicated.
F. Install roof flashing assemblies on sanitary stack vents and vent stacks that extend through roof.
G. Install flashing fittings on sanitary stack vents and vent stacks that extend through roof.
H. Install vent caps on each vent pipe passing through roof.
I. Install floor-drain, trap-seal primer fittings on inlet to floor drains that require trap-seal primer connection.
WRCRWA SANITARY WASTE PIPING SPECIALTIES PLANT EXPANSION PROJECT 221319 - 3 1. Exception: Fitting may be omitted if trap has trap-seal primer connection. 2. Size: Same as floor drain inlet.
J. Install air-gap fittings on draining-type backflow preventers and on indirect-waste piping discharge into sanitary drainage system.
K. Install sleeve flashing device with each riser and stack passing through floors with waterproof membrane.
L. Install traps on plumbing specialty drain outlets. Omit traps on indirect wastes unless trap is indicated.
3.2 CONNECTIONS
A. Comply with requirements in Section 221316 "Sanitary Waste and Vent Piping" for piping installation requirements. Drawings indicate general arrangement of piping, fittings, and specialties.
B. Install piping adjacent to equipment to allow service and maintenance.
3.3 FLASHING INSTALLATION
A. Fabricate flashing from single piece unless large pans, sumps, or other drainage shapes are required. Join flashing according to the following if required:
B. Install sheet flashing on pipes, sleeves, and specialties passing through or embedded in floors and roofs with waterproof membrane.
1. Pipe Flashing: Sleeve type, matching pipe size, with minimum length of 10 inches, and skirt or flange extending at least 8 inches around pipe. 2. Sleeve Flashing: Flat sheet, with skirt or flange extending at least 8 inches around sleeve. 3. Embedded Specialty Flashing: Flat sheet, with skirt or flange extending at least 8 inches around specialty.
C. Set flashing on floors and roofs in solid coating of bituminous cement.
D. Secure flashing into sleeve and specialty clamping ring or device.
E. Install flashing for piping passing through roofs with counterflashing or commercially made flashing fittings, according to Section 076200 "Sheet Metal Flashing and Trim."
F. Extend flashing up vent pipe passing through roofs and turn down into pipe, or secure flashing into cast-iron sleeve having calking recess.
3.4 LABELING AND IDENTIFYING
A. Distinguish among multiple units, inform operator of operational requirements, indicate safety and emergency precautions, and warn of hazards and improper operations, in addition to
WRCRWA SANITARY WASTE PIPING SPECIALTIES PLANT EXPANSION PROJECT 221319 - 4 identifying unit. Nameplates and signs are specified in Section 220553 "Identification for Plumbing Piping and Equipment."
3.5 PROTECTION
A. Protect drains during remainder of construction period to avoid clogging with dirt or debris and to prevent damage from traffic or construction work.
B. Place plugs in ends of uncompleted piping at end of each day or when work stops.
END OF SECTION 221319
WRCRWA SANITARY WASTE PIPING SPECIALTIES PLANT EXPANSION PROJECT 221319 - 5 SECTION 227100 – PROGRESSIVE CAVITY PUMPS
PART 1 - GENERAL
1.1 DESCRIRTION
A. This section specifies positive displacement progressing cavity pumps, complete with electric motors, and all specified appurtenances, as shown on the plans and specified herein.
B. The pumping units shall be of the self-priming, positive displacement, progressing cavity type specifically designed for pumping bulk liquid or polymer solutions, as specified, and/or waste water sludges.
1.2 PERFORMANCE AND DESIGN REQUIREMENTS
A. Sludge handling pumps shall be specifically designed and selected for continuous duty pumping for the following services:
Location Material Fluid Temperature Primary Clarifiers Primary Sludge (3-5%) Ambient Thickener Building Thickened WAS (5-6%) Ambient Solids Handling Building Emulsified Polymer, 48% active Ambient
B. The pumps shall be of the compact, close-coupled design. The gear reducer shall be sized for a minimum service factor of 1.5 and designed with a thrust load capability of 150 percent of the actual thrust load.
C. The pumps, along with associated drive appurtenances, shall be mounted on common fabricated steel baseplates.
D. Manufacturers must currently have installations for the same liquids and of the same model pump unit, in service for a minimum of three years.
E. All equipment shall be designed and built for 24-hour continuous service at any and all points within the specified range of operation, without overheating, without cavitation, and without excessive vibration or strain.
F. The pumping units required under this section shall be complete. All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness and to be especially adapted for the service to be performed. Ample room for inspection, repairs and adjustment shall be provided.
G. Stainless steel nameplates giving the name of the Manufacturer, the pump serial number and material code and all other pertinent data shall be attached to each pump, motor, and control panel.
WRCRWA PROGRESSIVE CAVITY PUMPS PLANT EXPANSION PROJECT 227100 - 1
H. All working parts of the pumps and motors, such as bearings, wearing rings, shaft, sleeves, etc., shall be standard dimensions built to limit gauges or formed to templates, such that parts will be interchangeable between like units and such that the Owner may, at any time in the future, obtain replacement and repair parts for those furnished in the original machines.
I. The nameplate ratings of the motors shall not be exceeded, nor shall the design service factor be reduced when the pump is operating at any point on its characteristic curve at maximum speed.
J. Mechanical equipment, including drives and electric motors shall be supplied and installed in accordance with applicable OSHA regulations. The noise level of motors, unless otherwise noted, shall not exceed 85 dBA measured 3 meters from the unit under free field conditions while operating on utility power.
K. All lubrication fittings shall be brought to the outside of all equipment so that they are readily accessible from the outside without the necessity of removing covers, plates, housings, or guards.
PART 2 - SUBMITTALS
2.1 GENERAL
A. Product Data: Submit manufacturer's technical product data, including installation instructions.
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list. Include this data, product data, and shop drawings in maintenance manual; in accordance with requirements of Division 1.
D. Performance Curves: Submit predicted performance curves developed for the specific application. Performance curves shall plot speed, capacity, head, and horsepower required for the specified operating range.
E. Anchorage: The manufacturer shall provide anchor bolt design calculations in accordance with the latest edition of CBC, stamped and signed by a licensed professional engineer in the State of California.
2.2 QUALITY ASSURANCE
A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of progressive cavity pumps, of types and sizes required, whose products have been in satisfactory use in similar service.
2.3 REFERENCES
A. This section contains references to the following documents. They are part of this section as specified and modified. In case of conflict between the requirements of the section and those of the listed documents, the requirements of this section shall prevail.
WRCRWA PROGRESSIVE CAVITY PUMPS PLANT EXPANSION PROJECT 227100 - 2
Reference Title
AGMA 6010-E-88 Spur, Helical, Herringbone, and Bevel Enclosed Drive AGMA 6019-E-89 Gear Motors Using Spur, Helical, Herringbone, Straight Bevel, or Spiral Bevel Gears AGMA 6023-A88 Design Manual for Enclosed Epicyclic Gear Drives
PART 3 - PRODUCTS
3.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with requirements, provide products by one of the following:
1. Seepex (Basis-of-Design) 2. Or equal.
3.2 MATERIALS
Component Material - Sludge Pumps Rotor D6 air hardened tool steel Stator Buna N Pump Body Cast iron Shaft Sealing Burgmann MG1 Q1Q1VGG
3.3 EQUIPMENT
A. Rotor and stator: Each pump shall be a one stage design employing a convoluted rotor operating in a similarly convoluted stator. The convolutions shall be configured to form a cavity between the rotor and stator, which shall progress from the pump's inlet to discharge port with the operation of the rotor. The fit between the rotor and stator at the point of contact shall compress the stator material sufficiently to form a seal and to prevent leakage from the discharge back to the inlet end of the pumping chamber. The stator shall be molded with a seal integral to the stator elastomer preventing the metal stator tube and the bonding agent from the elastomer from contacting the pumped liquid. Gaskets or "O" rings may not be used to form this seal. Stators for sludge pumps shall have Buna elastomer. The sludge pump rotors shall be constructed of D 6 air hardened tool steel. Hard chrome plating or ceramic coatings are not acceptable due to the ease at which this coating will crack and the lack of diffusion into the rotor base metal.
B. Rotor and drive train: The rotor drive train shall be warranted for a minimum of one (1) year from acceptance and shall consist of the following:
1. Each pump rotor shall be driven through a positively sealed and lubricated pin joint. The
WRCRWA PROGRESSIVE CAVITY PUMPS PLANT EXPANSION PROJECT 227100 - 3
pin joint shall have replaceable bushings, constructed of air-hardened tool steel of 57-60 HRc, in the rotor head and coupling rod. The pin shall be constructed of high speed steel, air hardened to 60-65 HRc. The joint shall be grease lubricated with a high temperature (450 F), PTFE filled synthetic grease, covered with Buna N sleeve and positively sealed with hose clamps constructed of 304 stainless steel. A stainless steel shell shall cover the rotor side universal joint assembly to protect the elastomer sleeve from being damaged by tramp metals or glass. The universal joints shall carry a separate warranty of 10,000 operating hours. This warranty shall be unconditional in regards to damage or wear. 2. Stators shall be replaceable without dismantling the pump suction or discharge flanges or any associated piping. Pumps that require additional space for axial/horizontal removal of the stator shall not be allowed. Stator designs shall additionally incorporate a retensioning feature to compensate for wear in lieu of increasing pump speed. Stator designs shall permit inspection of and access to the cavities for the removal blockages without removing the rotor from the pump. 3. Rotors shall be replaceable without dismantling the pump suction or discharge flanges or associated piping. Pumps that require additional space for axial/horizontal removal of the rotor shall not be allowed. The rotor design shall include provisions so that the rotor replacement does not require the disassembly of either universal joint.
C. Casing: A 150-pound (ANSI B16.5) flanged connection shall be provided at both the inlet and discharge ports. The suction and discharge casings shall each be provided with a 3/8-inch (or larger) tap to permit installation of pressure instruments.
D. Bearings: Each pump shall be provided with oil lubricated thrust and radial bearings, located in the gearmotor, designed for all loads imposed by the specified service.
E. Shaft sealing: Shaft shall be sealed using a double internal mechanical seal as specified. The shaft shall be solid through the sealing area, but of a two part design which allows the rotating unit to be removed from the pump without disassembly of the gearmotor bearings. Seal materials shall be solid silicon carbide faces with 316 stainless steel metal parts and viton elastomers.
1. Where required, a double mechanical seal shall be provided to maintain a seal at the minimum suction head, as indicated in Section 1.2.
F. Motor and Drive Unit:
1. Gear motors or gear reducers shall be designed in accordance with AGMA 6019-E (Class II). Unless otherwise noted, motors shall be energy-efficient, TEFC motors.
2. The pumps shall be variable frequency drive (VFD) controlled. The pump supplier shall be responsible for the provision of the fixed reduction between the motor and pump. The reduction ratio shall be that required to operate the pump at its maximum operating speed when the motor is operating at its nominal rated full speed as specified.
G. Run dry protection: The stator shall be fitted with a sensor sleeve and thermistor sensor. A controller shall also be provided and shall be installed by the contractor in the motor control center. The controller shall monitor the stator temperature and activate a shutdown and alarm sequence if the stator temperature reaches the adjustable limit on the controller. The controller
WRCRWA PROGRESSIVE CAVITY PUMPS PLANT EXPANSION PROJECT 227100 - 4
shall include a manual local and be capable of providing a future remote reset function. Input to the controller shall be 1x115VAC/60 Hz.
H. Over pressure protection: Each pump unit shall be supplied with a silicone-filled isolation ring with a dual mounted gauge and single point pressure switch. The pressure ranges for the switch and gauge shall be selected specifically for each specified service. The isolation ring shall be mounted between ANSI flanges, be sized according to the discharge pipe as shown on the plans, and be constructed with a carbon steel body and fittings with a Buna sleeve. The switch shall be SPDT, NEMA 4X.
3.4 PRODUCT DATA
A. The following information shall be provided in accordance with Section 13000.
1. Mill certifications confirming hardness of rotor. 2. Applicable operation and maintenance information. 3. Motor data. 4. Installation certification form. 5. Training certification form.
3.5 SPARE PARTS
A. One set of special tools shall be provided to service the pumps. In addition, the following shall be provided for each pump size (as appropriate for type of drive provided):
1 - stator assembly with TSE sensor sleeve 1 - rotor 1 - set universal joint assemblies 1 - TSE controller 1 – mechanical seal (packing)
B. Standby components shall be tagged and stored.
PART 4 - EXECUTION
4.1 INSTALLATION
A. The pumps shall be installed as specified and in accordance with manufacturer's written recommendations.
B. Install in strict accordance with the MANUFACTURER’S instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the MANUFACTURER’S recommendations. Anchor bolts shall be set in accordance with the MANUFACTURER’S recommendations.
WRCRWA PROGRESSIVE CAVITY PUMPS PLANT EXPANSION PROJECT 227100 - 5
C. Upon completion of the installation, the CONTRACTOR shall submit a certificate from the MANUFACTURER stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
4.2 TESTING
A. After completion of installation, the pumps shall be completely tested to demonstrate compliance with operating requirements as specified. The services of the pump manufacturer’s field service representative shall be provided for one (1) 8-hour day at site and at no additional cost to the owner for inspection, startup, acceptance and training.
B. Prior to startup, each pump shall be contractor tested by bumping the motor to check for rotation and the incoming voltage shall be verified to comply with pump nameplate rating and motor requirements.
C. After equipment has been contractor tested and the start-up has been successfully completed, the manufacturer’s field service representative shall instruct the owner’s personnel in the care, operation and adjustment of the equipment furnished.
4.3 STARTUP AND TRAINING
A. Following completion of the installation the pump manufacturer shall provide the service of qualified representatives to verify proper installation and assist in the pump startup.
B. Pump manufacturer shall provide qualified training and maintenance instruction to the Owner’s maintenance personnel.
4.4 SUPPLIER QUALIFICATIONS AND QUALITY ASSURANCE
A. The progressive cavity pumps shall be of a standard catalog product of a manufacturer regularly engaged in the production of this type of equipment that can show not less than five years of satisfactory performance for pumps of this type and size. The manufacturer shall have a factory authorized representative and repair facility in close proximity to the project site and which has been designated as such for at least ten years prior to project bid date and located within the state of California.
B. The authorized manufacturer’s representative shall have both in-house and field service technicians located within the state of California, factory qualified to work on supplied equipment with a minimum of ten years’ experience in pump and control repair. No exceptions.
END OF SECTION 227100
WRCRWA PROGRESSIVE CAVITY PUMPS PLANT EXPANSION PROJECT 227100 - 6
SECTION 227200 – SUBMERSIBLE RECIRCULATOR CHOPPER PUMPS
PART 1 - GENERAL
1.1 CONDITIONS OF OPERATION
A. Each pump shall be capable of pumping at the hydraulic conditions shown in the pump schedule or on the drawings.
1.2 WORK INCLUDED
A. The Contractor shall provide and install submersible recirculating chopper pumps as indicated in the contract drawings.
1.3 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation.
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings for each type of pump, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of pump. Include this data, product data, shop drawings in maintenance manual in accordance with requirements of Section 017823 – Operation and Maintenance Manuals.
D. Fasteners: The pump manufacturer shall provide anchor bolt design calculations in accordance with the latest edition of CBC, stamped and signed by a licensed professional engineer in the State of California.
1.4 WARRANTY
A. Each pump shall be supplied with manufacturer’s standard warranty of no less than one (1) year from date of shipment.
1.5 QUALITY ASSURANCE
A. The pump manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with requirements, provide products by one of the following:
1. Vaughan, Inc. (Basis-of-Design)
WRCRWA SUBMERSIBLE RECIRCULATOR CHOPPER PUMPS PLANT EXPANSION PROJECT 227200-1 2. Or equal.
B. All products, whether named as “acceptable”: or proposed as “equal” must fully comply with these specifications. Standard product must be modified, if required, for compliance.
2.2 GENERAL CONDITIONS
A. The pump manufacturer shall ensure that the pumps can operate in the following general conditions:
1. Operation: Intermittent 2. Drive: Constant Speed 3. Ambient Environment: Outdoors 4. Ambient Temperature: 30 to 105 ¡F 5. Fluid Service: Primary Clarifier Scum
2.3 PUMP REQUIREMENTS
A. Casing and Back Pull-Out Plate: The pump casing shall be of volute design, spiraling outward to the 125 lb. flanged centerline discharge. Back pull-out design shall incorporate jacking bolts for accurate adjustment of impeller-to-cutter bar clearance. Casing and backplate shall be ductile cast iron with all water passages to be smooth, and free of blowholes and imperfections for good flow characteristics. A pressure tap shall be included on or near the discharge flange. Backplate shall include a replaceable Rockwell C 60 steel cutter adjustable for 0.005-0.015” clearance to cut against the rotating impeller pumpout vanes for removing fiber and debris.
B. Impeller: Shall be semi-open type with pump out vanes to reduce seal area pressure. Chopping of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter bar at the intake openings, with a maximum set clearance between the impeller and cutter bar of 0.015-0.025” cold. Impeller shall be cast alloy steel heat treated to minimum Rockwell C 60 and dynamically balanced. The impeller shall be keyed to the shaft and shall have no axial adjustments and no set screws.
C. Cutter Bar Plate: Shall be recessed into the pump bowl and shall contain at least 2 shear bars extending diametrically across the intake opening to within 0.010-0.020” of the rotating cutter nut tooth, for the purpose of preventing intake opening blockage and wrapping of debris at the shaft area. Chopper pumps utilizing individually mounted shear bars shall not be acceptable. Cutter bar shall be alloy steel heat-treated to minimum Rockwell C 60.
D. Cutter Nut: The impeller shall be secured to the shaft using a cutter nut, designed to cut stringy materials and prevent binding using a raised, rotating cutter tooth. The cutter nut shall be cast steel heat treated to minimum Rockwell C 60.
E. Upper Cutter: Shall be threaded into the back pull-out adapter plate behind the impeller, designed to cut against the pump-out vanes and the impeller hub, reducing and removing stringy materials from the mechanical seal area. Upper cutter shall be cast steel heat treated to minimum Rockwell C 60. The upper cutter teeth are positioned as closely as possible to the center of shaft rotation to minimize cutting torque and nuisance motor tripping. The ratio of upper cutter cutting diameter to shaft diameter in the upper cutter area of the pump shall be 3.0 or less.
WRCRWA SUBMERSIBLE RECIRCULATOR CHOPPER PUMPS PLANT EXPANSION PROJECT 227200-2 F. Shafting: Pump shafting shall be heat-treated alloy steel. The pump shaft shall directly couple to the motor shaft, with a bolt and keyway.
G. Submersible Electric Motor: Shall be U/L LISTED EXPLOSION PROOF for Class 1, Group D, Division 1 hazardous locations, with a 1.15 service factor and Class F insulation. Motor shall be equipped with tandem independently mounted mechanical seals in oil bath and with dual moisture sensing probes. The inner and outer seals shall be separated by an oil-filled chamber. The oil chamber shall act as a barrier to trap moisture and provide sufficient time for a planned shutdown. The oil shall also provide lubrication to the internal seal. The inner seal shall be a standard UL listed John Crane Type 21 or equal, with carbon rotating faces and ceramic stationary faces. The outer seal construction shall be designed for easy replacement. Outer mechanical seal shall be 316 stainless steel metal bellows type with silicon carbide or tungsten carbide faces. Seal shall be positively driven by set screws. Motor shall include two normally closed automatic resetting thermostats connected in series and imbedded in adjoining phases. Motor frame shall be cast iron, and all hardware and shaft shall be stainless steel.
H. Stainless Steel Nameplates: Shall be attached to the pump and drive motor giving the manufacturer’s model and serial number, rated capacity, head, speed and all pertinent data.
I. Recirculation Nozzle Assembly: The pumps shall be fitted with a recirculation nozzle assembly to permit recirculation of the pit contents prior to discharge. The recirculation nozzle shall be adjustable minimum 180 degrees horizontally and 45 degrees vertically. A valve assembly shall be connected to the pump discharge to adjust pump flow either to the nozzle or the pump discharge flange. Valve shall be ductile cast iron, with SS valve disk. The operating levers shall be located above at a mounting plate for easy access.
J. Automatic Valve Actuator: An electrically operated valve actuator shall position the valve for pumpout or mixed operation. A ball screw linear actuator shall be supplied to provide valve positioning. Unit shall operate on 110V or 220V AC, single-phase power with 25% duty cycle, and shall be capable of producing 500lb. of actuation force, with a freewheeling feature to prevent overtravel at the end of stroke. External timers, housed in a separate control unit, shall be supplied to determine valve position. A capacitor for single phase-motor starting shall be included in the design. All components shall be housed in an enclosure suitable for outdoor operation.
K. Surface Preparation: SSPC-SP5 commercial sandblast, primed with 3 MDFT zinc-filled primer and finish coated with 3 MDFT epoxy.
2.4 MOUNTING AND REMOVAL
A. Spark Proof Guide Rail System: Provide a non-sparking guide rail system consisting of two stainless steel guide rails, cast aluminum bronze pump guide bracket, cast ductile iron discharge elbow with mounting feet and 125 lb. flanges, upper guide rail mounting bracket, and intermediate guide brackets every 10 feet. System design shall prevent spark ignition of explosive gases during pump installation and removal.
B. Guide Rail System: Provide a guide rail system consisting of two stainless steel guide rails, cast ductile iron pump guide bracket and discharge elbow with mounting feet and 125 lb. flanges, an upper guide rail mounting bracket and intermediate guide brackets every 10 feet.
C. Provide a pump which connects to a permanently mounted discharge connection by simple downward motion, without rotation, guided by at least two non-load-bearing guide pipes. Final connection shall insure zero leakage between pump and discharge connection flange. WRCRWA SUBMERSIBLE RECIRCULATOR CHOPPER PUMPS PLANT EXPANSION PROJECT 227200-3 D. Provide a discharge connection/guide system so that no part of the pump bears directly on the floor of the wet well.
E. Provide Type 316 stainless steel cable of sufficient length to properly and safely lift pumps from the wet well using a portable hoist mounted crane above the wet well. Provisions shall be made to allow the cable from either pump to be spooled around the hoist..
2.5 SPARE PARTS
A. The contractor shall supply manufacturer recommended spare parts, including the following:
1. Three (3) ¾” x 4” stainless steel bolts with nuts. 2. One (1) spare cutter bar. 3. One (1) spare impeller. 4. One (1) spare upper cutter. 5. One (1) spare cutter nut. 6. One (1) spare mechanical seal. 7. One (1) seal spanner wrench.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Installation in strict accordance with the MANUFACTURER’S instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the MANUFACTURER’S recommendations. Anchor bolts shall be set in accordance with the MANUFACTURER’S recommendations.
B. Upon completion of the installation, the CONTRACTOR shall submit a certificate from the MANUFACTURER stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
3.2 STARTUP AND TRAINING
A. Following completion of the installation the pump manufacturer shall provide the service of qualified representative to verify proper installation and assist in pump startup.
B. Pump manufacturer shall provide qualified training and maintenance instruction to the Owner’s maintenance personnel.
3.3 VERIFICATION OF PERFORMANCE
A. The Contractor shall field test all pumps after installation to demonstrate satisfactory operation without excessive noise, vibration, cavitation or over-heating. Any pump which fails to meet any of the contract specifications will be modified, repaired or replaced by the Contractor at no additional cost to the owner.
END OF SECTION 227200 WRCRWA SUBMERSIBLE RECIRCULATOR CHOPPER PUMPS PLANT EXPANSION PROJECT 227200-4 SECTION 227300 – ARCHIMEDES SCREW PUMP
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall furnish, install and place in satisfactory operating condition open screw pump assemblies and appurtenances as shown on the Drawings and described in the Speci- fications.
1.2 REFERENCES
A. American Gear Manufacturers Association (AGMA)
B. American Institute of Steel Construction (AISC)
C. American Society of Testing and Materials (ASTM)
D. American Society of Civil Engineers (ASCE)
E. American Welding Society (AWS)
F. International Electrotechnical Commission (IEC)
G. Steel Structures Painting Council (SSPC)
1.3 SYSTEM DESCRIPTION
A. Each screw pump shall be furnished complete with spiral steel flighted screw, upper and lower stub shafts, upper and lower support bearings, flow deflection plates, shaft-mounted speed reducer, V-belts and sheaves, drive motor, automatic lower bearing lubrication system, and all necessary anchorage parts.
B. Design Parameters For Each Unit:
1. Pump Capacity, gal/min – As indicated in the equipment schedule. 2. Lift, feet - As indicated in the equipment schedule. 3. Angle of Inclination, degrees - 30 4. Pump Diameter, inches - 42 5. Number of Flights - 3 6. Flight Thickness, inches - 0.25 7. Torque Tube Diameter, inches - 26 8. Torque Tube Wall Thickness, inches - 0.5 9. Minimum Lower Bearing Diameter, inches - 4.5 10. Minimum Upper Bearing Diameter, inches - 4.5 11. Maximum Rotational Speed, rev/min - 48 12. Motor Size, hp – 50, including Variable Frequency Drive WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 1
13. Electrical Power Characteristics, VAC – Hertz – Phase - 460 – 60 – 3 14. Motor and Solenoid Valve Electrical Classification - Non-Hazardous
1.4 PERFORMANCE
A. Each screw pump shall be able to pump at the lift and angle of inclination as specified. Additionally, each screw pump shall be capable of operating as described herein and as indicated in the schedule submerged up to 16 feet depth.
1.5 MATERIALS QUALITY
A. All steel components including the screw pump body, flow deflection plates, upper bearing and stub shaft, lower bearing and stub shaft and drive-bearing mounting plates shall be fabricated in the United States.
B. All fabricated components shall be manufactured in the United States.
1.6 QUALITY ASSURANCE
A. In order to assure uniform quality, ease of maintenance and minimal parts storage, it is the intent of these Specifications that all equipment called for under this Section shall be supplied by a single manufacturer.
B. The pump manufacturer shall have a minimum of ten (years) experience and shall provide a list of at least twenty (20) installations of identical (42-inch diameter) or larger size units as noted above.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with requirements, provide product by one of the following:
1. Lakeside Equipment Corporation (Basis-of-Design) 2. Or equal
2.2 SPIRAL SCREW
A. Spiral screw shall be fabricated of ASTM A36 steel. Flights shall be die formed with a 1:1 pitch-to-diameter ratio and shall have a minimum thickness as noted. Flights shall be helical shaped and continuously welded on both sides to the torque tube. There shall be no more than one flight butt welds per pitch, and all flight butt welds shall be full penetration joints. The screw shall be designed to rotate counter-clockwise when viewed from the lower bearing end up toward the drive assembly.
WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 2
B. Each torque tube shall have a minimum diameter and wall thickness as noted so that screw deflection shall not be greater than the bearing center distance divided by 2,000. Calculations for deflection and bearing loads shall be based on the dead weight of the screw plus the full weight of liquid being pumped. Decreased loading from buoyance effects shall not be considered in the design calculations.
C. The torque tube shall be sealed watertight with a welded steel plate at each end. All surfaces of the end plates mating with the bolted stub shafts shall be finish machined while the pump is supported between centers in a lathe after welding to the support tube and after all flight welding is complete to assure alignment and parallelism.
D. A solid steel upper drive shaft and lower stub shaft fitted with machine faced steel plate flange shall be fastened to the upper and lower ends of the fabricated spiral screw with ASTM A325 high-strength bolts.
E. The screw shall be placed in a lathe and the flights shall be ground to a true radius after fabrication.
2.3 LOWER BEARING ASSEMBLY
A. The lower bearing assembly shall be a cam-type with a pressure grease lubricated bronze sleeve bearing pressed onto the shaft and shall carry the radial load of the screw. Lower bearing nominal diameter shall be as noted. No thrust load shall be carried by the lower bearing.
B. The bronze sleeve shall rotate with the lower stub shaft in a bearing housing containing a minimum of two (2) spring loaded lip seals at the top of the bearing assembly. The seals shall be arranged so that one seal excludes wastewater and contaminants from the bearing and the other holds the grease in the bearing. The use of less than two lip seals will not be acceptable. The seals shall ride on an AISI Type 304 replaceable wear sleeve.
C. The bearing assembly shall permit precise angular (vertical) and lateral (horizontal) field adjustment to eliminate misalignment between the upper and lower bearings without the use of shims. Bearing assembly shall accommodate all static and operating deflections of the screw. Bearings with fixed or rigid shafts and housings shall not be acceptable.
D. The bearing assembly shall be supplied with a split non-rotating shield installed between the housing and rotating screw for operation of the shaft and seals.
E. The bearing assembly shall accommodate thermal expansion and contraction of the screw within the bearing housing on fully lubricated surfaces not subject to corrosion or seizure.
F. The bottom of the bearing housing shall be fitted with an inspection plate that can be removed for inspection of the lower bearing without disassembly of the lower stub shaft or bearing housing.
G. The use of roller or ball bearings will not be acceptable.
H. There shall be a flow through grease system with grease entering the lower part of the housing and passing across the full face of the bearing sleeve to the upper seals, then to a grease collection container for confirmation the bottom bearing is receiving grease from the automatic lubrication system. WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 3
2.4 UPPER BEARING ASSEMBLY
A. The upper stub shaft shall be a one-piece fabricated steel or forged steel design. Two-piece stub shaft designs (shaft and mating flange) will not be acceptable for this project.
B. The upper stub shaft shall extend through a grease lubricated upper bearing assembly which shall consist of a split housing fitted with dual bearings, lower spring loaded lip seal, bearing spacer and upper spring loaded lip seal. Upper bearing nominal diameter shall be as noted.
C. All of the thrust load from the pump shall be carried by a spherical thrust-type bearing assembly and the upper screw pump radial load shall be carried by a spherical roller bearing. A single dual-purpose bearing will not be acceptable.
D. The two bearings (radial and thrust) shall be positioned in the bearing housing so that the pressure center of the thrust bearing and radial bearing intersects the axis of the screw at the same point to provide true self-alignment in all planes.
E. Both radial and thrust bearings shall be rated at a minimum of 100,000 hours AFBMA L10 theoretical design life, based on the dead weight of the screw plus the full weight of the liquid being pumped.
F. Upper stub shaft shall be grooved and positively locked into the upper bearing assembly by a split collar and locking halter ring. Use of threaded nuts to lock bearings and shafts for support of thrust loading will not be acceptable.
G. A split bearing housing shall be provided to allow removal of the cover for inspection of the bearings without removal of the stub shaft or the entire bearing assembly.
2.5 DRIVE ASSEMBLY
A. The drive assembly shall be designed and constructed for a maximum screw rotational speed as noted. The drive assembly shall consist of a shaft-mounted speed reducer, belts and sheaves, and motor.
B. A shaft-mounted, double-reduction reducer in a cast iron housing with alloy steel high hardness helical gearing, positive splash-type lubrication, and double lip oil seals, shall be keyed to the screw pump stub shaft. Speed reducer manufacturer shall be a member of the AGMA and the reducer shall be designed in accordance with the latest AGMA standards.
C. The screw pump stub shaft shall be supported by the upper bearing and extended through the reducer hollow bore and centered and held firmly in place by tapered bushings on each side of the reducer. The use of set screws and collar to lock gear reducer to shaft will not be acceptable.
D. The speed reducer shall be designed with a service factor of not less than 1.5 based on the torque requirements of the screw or 1.0 based on the motor horsepower, whichever is greater. The speed reducer shall have a minimum torque rating as noted.
E. Reducer shall be held in position by a torque arm and torque arm bracket. Torque arm bracket shall be fastened with cast-in-place anchors. Expansion anchors will not be acceptable.
WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 4
F. A visual oil level gauge and oil filler tube for the reducer shall be mounted on the reducer.
G. A backstop shall be provided with the reducer to prevent reverse rotation of the screw.
2.6 BELTS AND SHEAVES
A. Power transmission from the motor to the reducer shall be by means of a set of V-belts and sheaves. Belts and sheaves shall be designed with a 1.5 service factor based on full motor horsepower.
B. Sheaves shall be two section units for both drive and driven sheaves and shall consist of a tapered split shaft bushing with three tapped holes to which the sheave is attached by three cap screws. Changing sheaves shall not require a wheel puller.
C. Belts and sheaves shall be covered with a fabricated steel belt guard in accordance with OSHA standards. Belt guard shall be designed with the expanded metal front hinged to the main enclosure for ease of inspection and access. Hinged front panel shall be held in place via stainless steel captive fasteners.
2.7 MOTOR
A. Each unit shall be driven by an 1,800 rev/min, 1.15 service factor, horizontal, ball bearing, continuous duty, constant speed, Design B, normal starting torque, totally-enclosed fan-cooled, premium-efficiency, foot-mounted motor with leads to gasketed conduit box for outdoor operation.
B. Motor size and electrical and environment ratings shall be as noted.
C. Motor shall be mounted on a fabricated steel plate, which provides adjustment of belt slack.
2.8 DEFLECTION PLATES
A. A flow deflection plate shall be provided to curve around the upper section on the uptake side of the screw to deflect the liquid as the screw rotates.
B. The flow deflection plate shall be fabricated of not less than 3/16-inch thick A36 carbon steel plate complete with stiffeners where required and stainless steel anchors on 2-foot centers at the bottom edge.
C. The deflection plate top edge shall have adjustable stainless steel anchors at not more than 8-foot centers.
2.9 AUTOMATIC LUBRICATION SYSTEM
A. Each screw pump shall be furnished with a positive pressure, automatic lubrication pump with stainless steel grease reservoir, and 3/8-inch minimum diameter stainless steel grease line.
WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 5
B. The automatic lubrication pump shall provide grease lubricant to the lower bearing assembly with provisions at the pump to manually charge the grease line.
C. Each lubrication pump shall be adjustable and shall provide 6 ounces per day at the minimum setting and 17 ounces per day at the maximum setting (nominal). Grease reservoir shall hold a minimum of 15 pounds of lubricant.
D. The lubricant pump shall consist of an eccentric piston pumping element, a check valve and shall have a one-third (1/3) horsepower, TEFC, ball bearing, gear motor connected to the lubricator by a flexible coupling. Grease pump motor shall be rated for electrical power characteristics and electrical environment as noted.
E. A centrifugal switch shall be furnished as an integral component of the grease pump and interlocked with the screw pump drive system. When the screw pump is required to operate, the lubrication pump motor shall switch on. As the lubrication pump motor reaches full speed, the centrifugal switch shall close, energizing the screw pump drive motor. If the grease pump motor stops the centrifugal switch shall open, de-energizing the screw pump drive motor. The centrifugal switch shall be rated for not less than 3 Amps at 120 VAC, resistive.
F. The lubrication system shall be factory assembled on a steel base plate. The coupling shall have a removable metal coupling guard in accordance with OSHA standards.
G. To protect the environment from contamination and to provide visual indication that the lower bearing is receiving a steady supply of lubricant, spent grease that has passed through the lower bearing shall be recovered in a stainless steel collection container with two (2) 1/4-inch holes located 1-inch from the top of the container to allow liquid to drain out of the container.
2.10 GROUTING MATERIALS
A. Equipment manufacturer shall furnish a radius screed for the Contractor to place the finishing grout in the trough with the screw after the unit has been installed.
B. Equipment manufacturer shall loan to the Contractor additional sheave(s) and belts as required to operate the screw at a reduced speed for grouting the trough with the screw pump drive.
2.11 ANCHOR BOLTS
A. Equipment manufacturer shall submit calculations for sizing of all anchor bolts. Anchor bolts, hex nuts, and washers shall be AISI Type 304 stainless steel unless noted otherwise. Anchor bolts shall be J-type embedded, or L-type embedded. Expansion-type anchors will not be acceptable.
B. Anchor bolts shall be set by the Contractor. Equipment shall be placed on the foundations, leveled, shimmed, bolted down, and grouted with a non-shrinking grout.
2.12 SPARE PARTS
A. The following spare parts shall be provided:
WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 6
1. One (1) set of lower bearing seals 2. One (1) grease pump pumping element kit
B. Spare parts shall be individually boxed with the project name and part number clearly identified on each individual box. All spare parts shall be shipped in a separate crate and clearly labeled. Spare parts shall be stored indoors by the Contractor in a temperature-controlled environment.
2.13 SHOP SURFACE PREPARATION AND PAINTING
A. All fabricated carbon steel or cast iron components for submerged service shall be near-white blast cleaned per SSPC-SP10 and given a 2.5 to 3.5-mil dry film thickness (DFT) coat of Tnemec Series 1 Omnithane Primer.
B. All fabricated carbon steel or cast iron components for non-submerged service shall be commercial blast cleaned per SSPC-SP6 and given a 2.5 to 3.5-mil dry film thickness (DFT) coat of Tnemec Series 1 Omnithane Primer.
C. Electric motors, speed reducers, and other self-contained or enclosed components shall be supplied with the manufacturer's standard finish coating.
D. Rust preventative compound shall be applied to all machined, polished, and nonferrous surfaces, which are not to be painted.
2.14 SOURCE QUALITY CONTROL
A. All structural steel components shall be fabricated in the United States and shall conform to the requirements of the "Specification for the Design, Fabrication and Erection of Structural Steel for Buildings" published by the American Institute of Steel Construction. Except where specifically indicated otherwise, all plates and structural members shall have a minimum thickness of 1/4-inch.
B. The equipment manufacturer's shop welds and welding procedures shall be in accordance with the requirements of the latest edition of ANSI/AWS D1.1 "Structural Welding Code - Steel" published by the American Welding Society.
C. Design and fabrication of structural steel members shall be in accordance with AISC and AWS Standards. The manufacturer shall comply with the American Welding Society (AWS) and the American Institute of Steel Construction (AISC) most current listed standards and qualifications in 2004 D1.1, the criteria per the requirements of Section 6 - Inspection - Structural Welding Code. Evidence of such AWS and AISC compliance shall be submitted with shop drawing submittals as follows:
1. AWS Certified Welding Inspectors (minimum 2 on staff) shall conform to all standards, current or previous as listed in section 6.1.4 AWS QC1, Standard and Guide for Qualification and Certification of Welding Inspectors. 2. AWS Non Destructive Testing Inspectors (Level I, II, III) for Magnetic Particle and Ultra-Sonic testing (minimum 2 on staff) shall conform to all standards, current or previous as listed in and in conformance with The American Society for Non-Destructive Testing (ASNT-TC-1A).
WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 7
PART 3 - EXECUTION
3.1 FIELD PREPARATION AND PAINTING
A. Finish field preparation and painting shall be performed by the Contractor as specified in Section 098000.
B. The Contractor shall touch-up all shipping damage to the paint as soon as the equipment arrives on the job site.
C. Prior to assembly the Contractor shall coat all stainless steel bolts and nut threads with a non-seizing compound.
3.2 INSTALLATION
A. Install in strict accordance with the MANUFACTURER’S instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the MANUFACTURER’S recommendations. Anchor bolts shall be set in accordance with the MANUFACTURER’S recommendations.
B. Upon completion of the installation, the CONTRACTOR shall submit a certificate from the MANUFACTURER stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
C. The manufacturer shall schedule two (2) trips to the project site for equipment start-up assistance as noted in paragraph 3.2.B. for the Contractor and for operating training as noted in paragraph 3.3.A. for Owner personnel.
D. After the Contractor has installed the screen and the equipment is capable of being operated, the equipment manufacturer shall furnish a qualified representative for a minimum of four (4) days (up to 32 hours) to inspect the equipment and to supervise field-testing and start-up for the Contractor.
E. After the equipment has been placed into operation, the manufacturer's representative shall make all final adjustments for proper operation.
3.3 OPERATOR TRAINING
A. Provide operator training for Owner’s personnel after system is operational. Training will take place while manufacturer's representative is at the job site for inspection.
END SECTION 227300
WRCRWA ARCHIMEDES SCREW PUMPS PLANT EXPANSION PROJECT 227300 - 8
SECTION 227400 – SUBMERSIBLE AXIAL FLOW PUMP
PART 1 - GENERAL
1.1 SUMMARY
A. The CONTRACTOR shall furnish and install submersible axial flow pumps as shown and specified according to the project drawings. Pump unit shall be approved according to UL standards.
B. All parts shall be designed and proportioned for ample strength, stability, and stiffness for their intended purposes.
C. Pumps shall be designed for continuous-duty operation in a mixed liquor wastewater.
D. Pumps shall be submersible with motors and gear boxes as specified under Part 3.
E. The guide rail arrangement shall permit the propeller pump to be easily lifted out of the liquid for inspection without the need for personnel to enter the tank.
F. Pump selection shall be based on the manufacturer’s recommendation, to provide the best possible, most economical performance and mechanical solutions, which meet or exceed specified application data.
1.2 SUBMITTALS
A. Provide submittals in accordance with specification section 013300.
1.3 QUALITY ASSURANCE
A. All pumping equipment furnished under this Section shall be of a design and manufacture that has been used in similar applications, and it shall be demonstrated to the satisfaction of the Owner that the quality is equal to equipment made by that manufacturer specifically named herein.
B. The pump manufacturer shall have at least five (5) similar installations in the US with a minimum of 5 years of continuous operation.
C. Unit responsibility. Pump(s), complete with motor, intermediate shafting, necessary guards and all other specified accessories and appurtenances shall be furnished by the pump manufacturer to insure compatibility and integrity of the individual components, and provide the specified warranty for all components.
D. The pump(s) specified in this section shall be furnished by and be the product of one manufacturer.
WRCRWA SUBMERSIBLE AXIAL FLOW PUMP PLANT EXPANSION PROJECT 227400 - 1 PART 2 - PRODUCTS
2.1 DESIGN CRITERIA:
A. Pumps shall meet the requirements outlined herein, at the design conditions given in the schedule.
2.2 PUMP DESIGN DATA
A. Maximum motor shaft, HP 9.0
B. Propeller material SS 304
C. Maximum weight, lbs 251
2.3 MANUFACTURER:
A. Subject to compliance with requirements, provide products by one of the following:
1. Landia, Inc. (Basis-of-Design) 2. Or equal
PART 3 - CONSTRUCTION
3.1 PUMP:
A. Each pump shall be of the integral-gear, closed-coupled submersible type with a maximum propeller speed of 499 rpm. All components of the pump, including the motor and gearbox, shall provide continuous underwater operation while the pump is completely submerged.
B. The pump shall be capable of handling typical domestic or industrial raw, screened sewage with normal concentrations of rags, strings, and sand/grit. The pump shall be designed to be easily raised and lowered for inspection without requiring personnel to enter the tank. A suspension bracket and sliding bracket shall be an integral part of the pump unit. The entire weight of the pump unit shall be guided by the guide bracket, which shall handle all thrust created by the pump. The propeller pump, with its appurtenances and cable, shall be capable of continuous submergence without loss of watertight integrity to the depth shown on the drawings.
C. Each pump shall be provided with a grease chamber in the propeller hub for the shaft sealing system and a second separate oil chamber for the gearbox. Drain and inspection plugs shall be provided with positive anti-leak seal and shall be accessible from the outside.
WRCRWA SUBMERSIBLE AXIAL FLOW PUMP PLANT EXPANSION PROJECT 227400 - 2 3.2 MOTOR:
A. The motor shall be submersible of the asynchronous speed type, housed in an air-filled, watertight chamber. The stator winding shall be insulated with moisture resistant Class F insulation, which shall resist temperatures of 315 ¡F. The stator shall be dipped and baked three times in Class F varnish. The motor shall meet the requirements of IEC, class N. The motor shall be designed for continuous-duty, capable of sustaining a maximum of ten (10) evenly spaced starts per hour. The rotor bars and short circuit rings shall be made of aluminum. At the design point, the motor shall not draw more than the maximum kW of energy listed under paragraph B on page 1 of these specifications. The motor shaft, delivered with the rotor as an integral part, shall be shafting steel AISI 4340. The stator housing shall be of gray cast iron AISI A48-40B.
B. Bimetallic thermal sensors, mounted in the stator windings and wired into the pump control, shall monitor temperature. These shall supplement the external motor overload protection wired into the control panel. The thermal sensors are of the normally closed type rated at 248 ¼F.
C. The pump motor shaft shall rotate on two permanently lubricated bearings. The inner and outer bearing shall be single row, deep-groove ball bearings calculated for an L-10 life of 100,000 hours at full load. The motor shall be manufactured under ISO 9001 certification.
D. The cable entry shall be an integral part of the stator casing. The cable entry shall be composed of a conical cable holder with a flange bearing against a shoulder in the stator casing opening. The cable entry cone shall be of gray cast iron AISI A48-40B. Sealing shall be accomplished by metal-to-metal contact between machined surfaces resulting in compression of the O-ring. The cable shall be cast into the cable entry cone providing a leak-proof, torque-free seal at the cable entrance. No terminal board in the motor is required.
3.3 SEALING SYSTEM:
A. Each pump shall be equipped with a sealing system consisting of three seals separating the var- ious parts. The propeller hub shall include a grease chamber to lubricate the seals and protect the seals from the mixed liquid. Pumps without a grease chamber in the propeller hub shall not be accepted. B. The outer seal in the propeller hub shall be a Nitrile rubber seal with a stainless steel spring, which isolates the propeller shaft and hub grease chamber from the mixed liquid. The seal shall rotate on a stainless steel wear bushing. The wear bushing and seal shall be easily exchangea- ble without the use of special tools. C. The intermediate seal shall be a mechanical seal mounted on the propeller shaft. The mechani- cal seal shall efficiently separate the grease chamber from the oil-filled gearbox and oil cham- ber. D. The inner seal shall be a mechanical seal mounted on the motor shaft. The mechanical seal shall efficiently separate the gearbox oil chamber from the dry motor stator housing. E. Mechanical seals shall include one Silicon Carbide stationary seal face and one Silicon Carbide rotating seal face. The seals shall be manufactured under ISO 9001 certification.
WRCRWA SUBMERSIBLE AXIAL FLOW PUMP PLANT EXPANSION PROJECT 227400 - 3 F. A seal leak detection system shall be provided consisting of a moisture sensor located in the oil chamber. A moisture sensor relay shall be included for installation in the control panel and shall be wired to detect the presence of water in the oil chamber.
3.4 GEARBOX:
A. The gearbox shall be a one-stage planetary reduction gear, equipped with high precision, low- loaded gears designed for infinitive live and shall have a service factor of not less than 1.5.
B. The motor shaft shall be provided with spline to attach to the gear reducer. The reduction stage shall consist of an integral toothed ring gear to which three planet wheels are mounted on the planet carriers, engaging with the sun pinion. The gear shaft shall be high-tensile-strength carbon steel AISI 9840 and be identical with the propeller shaft. Gear casing shall be gray cast iron AISI A48-40B.
C. All bearings incorporated in the gearbox shall have a rated life expectancy of 100,000 hours. Gearbox shall be manufactured under ISO 9001certification.
3.5 PROPELLER:
A. The propeller shall consist of three blades welded to the side of the hub. The blades shall be fabricated of stainless steel. It shall be selected to the requirements of capacity and total dynamic head as specified under Paragraph B. The lip seal and grease chamber shall be in the propeller hub.
B. The blade shape shall be a non-clogging, backward curved design that starts at the flange. The propeller shall be capable of handling solids, fibrous materials, heavy sludge, and other matter found in normal sewage applications.
3.6 PROPELLER PUMP ASSEMBLY:
A. All mating surfaces where watertight sealing is required shall be machined and fitted with nitrile rubber O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between machined surfaces, resulting in compression of the O-rings without secondary sealing compounds, rectangular gaskets, O-rings, grease, or other devices. The entire pump unit shall be assembled using AISI stainless steel bolts.
3.7 GUIDE RAIL SYSTEM:
A. The pump shall be provided with a coupling system which consists of two parts: (1) a volute insert of an optimum hydraulic design mounted on the pump and (2) a coupling flange which is mounted to the wall or supported by a special bottom footing for Y-wall installations. A counter flange or extension piece shall be welded onto the coupling flange, if further connection with another pipe system is designed. The installation shall be equipped with a 2 inch round guide pipe extending from the top of the coupling flange to a fixing bracket mounted at the top of the tank wall. A recess in the guide pipe shall be fabricated just below the upper fixing
WRCRWA SUBMERSIBLE AXIAL FLOW PUMP PLANT EXPANSION PROJECT 227400 - 4 bracket making it easy to remove the pump for inspection without requiring the loosening or removing of any bolts.
B. All components of the mounting system shall be constructed of stainless steel. The manufacturer of the wall pump shall provide the mounting system, which shall include the coupling flange.
3.8 REMOVABLE CRANE ARM ASSEMBLY:
A. One portable crane arm assembly shall be provided to easily raise and lower the wall pump for installation and inspection. It shall consist of a crane arm with telescopic capabilities, rotatable at 360¼, a hand winch with brake for load control with stainless steel wire and a hook. It shall be suitable for swinging the pump over the rail and placing it safely on the platform/gangway. When the crane arm is not in use, it shall be stored indoors out of the weather.
B. Each pump shall have its own cable capable of attaching to the spool on the hoist/wench.
3.9 FASTENERS:
A. All fasteners shall be AISI 316 stainless steel.
B. All anchor bolts securing the pump components to the concrete structure shall be provided by the pump manufacturer.
C. The pump manufacturer shall provide anchor bolt design calculations in accordance with the latest addition of CBC, stamped and signed by a licensed professional engineer in the State of California.
3.10 MATERIALS:
A. Major pump components shall be gray cast iron, class 40, with smooth surfaces devoid of blow holes and other irregularities. All surfaces coming into contact with sewage, other than stainless steel, shall be protected by an epoxy coating of a minimum thickness of 250 μm. All stainless steel components shall be electro polished or passivated to obtain maximum corrosion resistance.
3.11 PIPE SLEEVE
A. The pump shall be supplied with a ductile pipe sleeve, with a seep ring. The sleeve shall be provided by the pump manufacturer to connect to the pump on one end and to be able to connect to the required yard piping on the other, as indicated in the drawings and pipe schedule.
3.12 SPARE PARTS
A. Each pump shall be supplied with a set of manufacturer recommended spare parts.
WRCRWA SUBMERSIBLE AXIAL FLOW PUMP PLANT EXPANSION PROJECT 227400 - 5 PART 4 - QUALITY ASSURANCES
4.1 INSTALLATION:
A. Install in strict accordance with the manufacturer’s instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations.
B. Upon completion of the installation, the contractor shall submit a certificate from the manufacturer stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
4.2 FACTORY TESTS:
A. The wall pump manufacturer shall perform the following inspections and tests on each pump before shipment:
1. An insulation test of the windings, 2. A balancing of the motor (rotor). 3. A test of the pump motor (run dry for 5 minutes at full load) to verify electrical data measurements. All electrical data shall be registered as part of documentation, 4. A submerged test where pump casing is exposed to an over pressure of 15 lb/in2, 5. A motor and cable insulation test for moisture content and insulation defects, 6. A dry run pump test to verify correct rotation and mechanical integrity. The entire unit is checked for vibrations, 7. A final inspection of propeller, motor rating, and electrical connections for compliance with purchase order.
B. The above inspections and tests shall be executed under ISO 9001 certification.
4.3 STARTUP AND TRAINING:
A. Following completion of the installation the pump manufacturer shall provide the service of qualified representative to verify proper installation and assist in pump startup.
B. Pump manufacturer shall provide qualified training and maintenance instruction to the Owner’s maintenance personnel.
END OF SECTION 227400
WRCRWA SUBMERSIBLE AXIAL FLOW PUMP PLANT EXPANSION PROJECT 227400 - 6 SECTION 227500 - HORIZONTAL DRY-PIT PUMP
PART 1 - GENERAL
1.1 SUMMARY
A. This specification includes the supply of horizontal dry-pit solids-handling angleflow pump(s). Each unit shall be furnished with a pump, driver, and motor high ring base with guard. Pumps are to be connected to drivers by suitably sized flexible coupling and coupling guard.
1.2 SUBMITTALS
Provide submittals in accordance with specification section 013300.
1.3 QUALITY ASSURANCE
A. All pumping equipment furnished under this Section shall be of a design and manufacture that has been used in similar applications, and it shall be demonstrated to the satisfaction of the Owner that the quality is equal to equipment made by that manufacturer specifically named herein.
B. The pump manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
C. Unit responsibility. Pump(s), complete with motor, intermediate shafting, necessary guards and all other specified accessories and appurtenances shall be furnished by the pump manufacturer to insure compatibility and integrity of the individual components, and provide the specified warranty for all components.
D. The horizontal dry-pit solids-handling angleflow pump(s) specified in this section shall be furnished by and be the product of one manufacturer.
E. Pumps are to be engineered and manufactured under a written Quality Assurance program. The Quality Assurance program is to be in effect for at least ten years, to include a written record of periodic internal and external audits to confirm compliance with such program.
F. Pump(s) are to be engineered and manufactured under the certification of ISO-9001:2000.
1.4 PERFORMANCE
A. The pump(s) shall be designed for continuous operation under normal service.
B. Operation Criteria – As Indicated in the Pump Schedule
WRCRWA HORIZONTAL DRY PIT PUMP PLANT EXPANSION PROJECT 227500 - 1
C. Liquid pump is Activated Sludge with a maximum temperature of 70 deg. F.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Manufacturer shall have installations of like or similar application with a minimum of 5 years’ service for this pump size.
B. Subject to compliance with requirements, provide pump(s) of the following:
1. Fairbanks Nijhuis, a company of Pentair, Inc. (Basis-of-Design) 2. Or equal.
2.2 DESIGN
A. Rotation
1. The pump will be counterclockwise rotation when viewed from the driver end looking at the pump. Final rotation shall be verified by the engineer during the submittal process.
B. Impeller
1. The impeller shall of close-grained cast iron conforming to ASTM A48 CL30 and be of the enclosed mixed-flow design, single suction, solids-handling type designed to pass a minimum sphere size of 3” diameter. 2. The impeller is to be dynamically balanced and secured to the shaft by means of a key, and impeller capscrew, and matched to the volute/casing. The arrangement shall be such that the impeller cannot be loosened from torque in either forward or reverse rotation. 3. Wiper vanes on the back impeller shroud are not allowed.
C. Volute/Casing
1. The volute shall be matched to the impeller and made of close-grained cast iron conforming to ASTM A48 CL30. The volute is to be of one-piece design (split volute on 42” and larger) with smooth fluid passages large enough to pass any size solid that can pass through the impeller. 2. The volute shall be flanged tangential discharge and capable of rotation in 45 degree increments to accommodate piping orientation. The volute shall be designed to permit front or back impeller removal. Diffusion vanes are not permitted. 3. The volute shall be furnished with a large contoured inspection and cleanout opening located at the cutwater, to allow access to the impeller. Discharge flange 125 lb. ANSI drilling. 4. The volute shall be designed to permit front or back impeller removal and to permit the removal of the rotating assembly without disturbing the suction or discharge piping. The casing shall be hydrostatically tested to 1.5 times the design head or 1.25 times the shutoff head whichever is greater.
WRCRWA HORIZONTAL DRY PIT PUMP PLANT EXPANSION PROJECT 227500 - 2
D. Wear Rings
1. Axial-type removable wear rings are to be provided on both the impeller and suction head for reduction of recirculation. 2. Wear rings shall be stainless steel. The impeller wear ring shall be approximately 50 Brinell softer than the fronthead wear ring.
E. Fronthead
1. The fronthead shall be made of close-grained cast iron conforming to ASTM A48 CL30. It shall be cast separately of the volute. Fronthead suction flange shall be 125 lb. ANSI drilling. 2. Fronthead shall incorporate a hand hole for inspection.
F. Backhead
1. A separately cast close-grained cast iron backhead with large access openings and integral sealing box conforming to ASTM A48 CL30 shall be provided. The sealing box shall be cast integrally with the backhead and be designed to accommodate either packing or mechanical seal without re-machining. The sealing box shall be drilled and tapped for external flushing with seal cage. 2. A ¾” minimum backhead drain tap shall be provided. Sealing box leakage will be collected by the backhead drain trough and piped directly to drain, eliminating any drippage to the floor. 3. Graphite-impregnated synthetic packing and a split Teflon water seal ring shall be furnished. Glands shall be two-piece split interlocking, made of cast iron (bronze), held in place by studs and nuts.
G. Bearing Frame Assembly
1. The bearing housing shall be close-grained cast iron conforming to ASTM A48 CL30 and of heavy, rugged design for carrying the bearings and machined for accurate and permanent bearing alignment completely enclosing the shaft between the bearings. Bearing supports are to be of heavy-duty construction providing for self-centering fit with the casing for proper alignment. The bearing housing shall be of dust-proof design, incorporating lip-type grease seals in contact with the shaft to prevent the entrance of contaminants. Jacking bolts for external impeller adjustments are required (8” and 18” and larger do not use jacking bolts). Zerk-type grease fittings for bearing lubrication shall be supplied at the bearing housing. 2. The pump shaft shall be made from type 4140 alloy steel, of sufficient diameter to carry the maximum loads imposed and to prevent vibration and fatigue. The shaft shall be accurately machined along its entire length. Keyways shall be provided at both ends. 3. A renewable shaft sleeve, positive adhesive sealed to prevent leakage between the shaft and the sleeve, shall protect the shaft through the sealing box area. The shaft sleeve shall be stainless steel with Brinell hardness of 300-350. 4. Radial (inboard) bearings shall be grease-lubricated single-row deep-grooved ball type (double-row on 14” & 16”), (spherical roller on 18” thru 54”), self-aligning, designed to carry the hydraulic radial loads encountered in the service conditions. Thrust (outboard) bearings shall be angular contact, duplex mounted (tapered roller on 18” thru 54”), designed to carry the pump hydraulic axial and dead load thrust.
WRCRWA HORIZONTAL DRY PIT PUMP PLANT EXPANSION PROJECT 227500 - 3
5. Bearings shall be designed for an L10 life of 100,000 hours per AFBMA at best efficiency point. Grease relief ports with plugs shall be provided.
H. Base and Coupling
1. The combination pump and driver base shall be a heavy-duty fabricated steel open channel structural steel with large access openings to facilitate grouting. 2. An all-metal shaft guard completely enclosing the coupling shall be provided. 3. The coupling shall be a spacer type designed to permit the removal of the rotating assembly without disturbing the motor or the suction or discharge piping.
I. Fits and Hardware
1. The volute/casing, fronthead, backhead, and frame shall be manufactured with concentric shoulder fits to assure accurate alignment. All machined bolts, nuts, and capscrews shall be of the hex-head type and will not require the use of any special tools.
J. Vibration Limitations (Field)
1. The limits of vibration as set forth in the standards of the Hydraulic Institute shall govern.
K. Testing
1. A certified factory hydrostatic and performance test shall be performed on each pumping unit in accordance with Hydraulic Institute Standards, latest edition. Tests shall be sufficient to determine the curves of head, input horsepower, and efficiency relative to capacity from shutoff to 150% of design flow. A minimum of six points, including shutoff, shall be taken for each test. At least one point of the six shall be taken as near as possible to each specified condition. 2. Results of the performance tests shall be certified by a Registered Professional Engineer and submitted for approval before final shipment.
L. Pumps shall be manufactured by companies whose management system is registered to ISO- 9001:2000.
M. Pumps shall be supplied with a set of manufacturer recommended spare parts.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The pump manufacturer shall size and provide signed and stamped sizing calculations for the equipment anchorage. All calculations shall be in accordance with the latest edition of CBC and shall be signed and stamped by a registered professional engineer in the State of California.
WRCRWA HORIZONTAL DRY PIT PUMP PLANT EXPANSION PROJECT 227500 - 4
B. Install in strict accordance with the manufacturer’s instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations. Anchor bolts shall be set in accordance with the manufacturer’s recommendations.
C. Upon completion of the installation, the contractor shall submit a certificate from the manufacturer stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
END OF SECTION 227500
WRCRWA HORIZONTAL DRY PIT PUMP PLANT EXPANSION PROJECT 227500 - 5
SECTION 227535 - MULTI-STAGE CENTRIFUGAL PUMP SYSTEM
PART 1 - GENERAL
1.1 SUMMARY
A. Furnish and install a Non-Potable Water booster system capable of maintaining constant pressure. The system shall include vertical, non-self-priming, multistage, in-line, centrifugal pumps for installation in pipe systems and mounting on a foundation. The pumps shall be combined on a skid and consist of a pump and motor each. Electrical and controls will be provided by others.
B. Booster Pump System shall include:
1. Four (4) multi-stage pumps (3 duty, 1 standby). 2. Stainless steel suction and discharge manifolds 3. Suction and discharge isolation valves 4. Discharge check valves 5. Suction and discharge liquid filled pressure gauges with isolation valves 6. Individual pump service disconnect switches, pump fault lights, fault alarm (with silencer), and pump status (run/stop/fault) outputs to PLC shall be provided by the control and panel supplier.
1.2 CONDITIONS OF OPERATION
A. The operating point of each pump shall be variable flow capable of flow and head capacities as shown in the drawings.
1.3 WARRANTY
A. The warranty period shall be a non-prorated period of 24 months from date of installation, not to exceed 30 months from date of manufacture.
1.4 QUALITY ASSURANCE
A. The pump manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
1.5 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation.
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings for each type of pump, indicating dimensions, weights, materials, and methods of assembly of components.
WRCWRA MULTI-STAGE CENTRIFUGAL PUMP SYSTEM PLANT EXPANSION PROJECT 227535-1 C. Maintenance Data: Submit maintenance data and spare parts list for each type of pump. Include this data, product data, and shop drawings in the Operations and Maintenance manual; in accordance with requirements of Section 017823.
PART 2 - PRODUCTS
2.1 REQUIREMENTS
A. Pump to be vertical multistage, centrifugal with in-line design to enable the pump to be installed in a horizontal one-pipe system where the suction and discharge ports are in the same horizontal plane and have the same pipe dimensions. The design should allow for a more compact pump design and pipe work.
B. This application requires suction lift from an adjacent wet well. Pumps suction line shall incorporate a foot valve to keep suction line primed. In addition, check valves shall be installed on the suction side of each pump to help eliminate vacuum and maintain the pumps primed. Manufacturer shall design the pumps and pump skid to handle the suction conditions indicated in the design drawings.
C. Pump shall have a fixed numbers of stages. Pump should consist of two main components; motor and pump end.
D. The pump skid, including motors, pumps, suction lines, discharge lines, and valves will be installed outdoors and will be exposed directly to the elements. All components shall be rated for long-term outdoor installation.
E. Pump end to shall be stainless steel construction with all stainless steel stack components. Impeller stack to consist of an impeller chamber with an outer sleeve that secures to the pump head and base by means of stay-bolts. Pump skid base shall be epoxy coated cast iron.
F. Mechanical shaft seals to be maintenance-free cartridge type construction to allow service change out without removing the motor. Seal to be capable of handling various fluids and viscosity.
G. Pump motor shall be a high-temperature, heavy-duty premium efficiency NEMA C face TEFC and be capable of use with a variable speed drive. The motors shall be rated for an ambient temperature of at least 122 degrees F and comply with the requirements of Specification 220513, “Common Motor Requirements for Plumbing Equipment.”
H. Materials of construction:
1. Pump Head: Cast Iron A 48-30 B 2. Shaft: Stainless Steel ANSI 431 3. Impeller: Stainless Steel ANSI 304 4. Chamber: Stainless Steel ANSI 304 5. Outer Sleeve: Stainless Steel ANSI 304 6. O-Ring: EPDM or FKM 7. Base: Cast Iron, A 48-30 B WRCWRA MULTI-STAGE CENTRIFUGAL PUMP SYSTEM PLANT EXPANSION PROJECT 227535-2 8. Neck Ring: PTFE
2.2 ACCEPTABLE MANUFACTURERS
A. All products must fully comply with these specifications. Standard product must be modified, if required, for compliance.
1. Grundfos Pumps Corp. (Basis of Design) 2. Or Equal
2.3 QUALITY ASSURANCE
A. Pumps are to be engineered and manufactured under a written Quality Assurance program. The Quality Assurance program is to be in effect for at least five (5) years, to include a written record of periodic internal and external audits to confirm compliance with such program.
2.4 ELECTRICAL AND CONTROLS
A. Pumps are to be engineered and manufactured under a written Quality Assurance program. The Quality Assurance program is to be in effect for at least five (5) years, to include a written record of periodic internal and external audits to confirm compliance with such program.
PART 3 - INSTALLATION
3.1 Pumps shall be installed per manufacturer’s recommendations.
3.2 Contractor shall coordinate electrical and controls requirement with the pump skid manufacturer and the electrical/controls supplier to ensure a properly installed and operating pump system. The motor control (and VFD) portions of the pumps will be installed remotely from the pump skid and motors. Contractor is responsible to provide all wiring, conduit, controls, and other aspects to complete the installation of the pumps.
3.3 All exterior installed items, including pumps, motors, valves, piping, wiring, and other components shall be suitable for exposed, outdoor installation including high ambient operating temperatures for the pump motors and exposure to direct sunlight.
3.4 Pump shall be furnished with all typical spare parts (or spare parts kit) including a seal and gasket kit, and a stack kit. Pumps shall also be furnished with any specialty tools as typically supplied and recommended by the pump manufacturer. Submittals shall provide a detailed list of all included spare parts, including party numbers and quantities of each item.
3.5 Pump supplier shall provide startup and training services as outlined in Section 017900 – Demonstration and Training.
END OF SECTION 227535 WRCWRA MULTI-STAGE CENTRIFUGAL PUMP SYSTEM PLANT EXPANSION PROJECT 227535-3 SECTION 227540 – VERTICAL TURBINE CAN PUMPS
PART 1 - GENERAL
1.1 SUMMARY
A. This specification covers the furnishing of vertical turbine pumping units as required and to the expectation of the Engineer with regard to the manufacture of the equipment.
B. All equipment must be supplied by the same pump Manufacturer including bowls, impellers, column, shafting, heads, coupling, sleeves, seals, pump cans and motors. Well drillers, distributors, or other fabrication shops will not be allowed to furnish equipment built in their local fabrication shop. Equipment furnished under this section shall be fabricated and assembled in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by Engineer.
C. Except as modified or supplemented herein, all vertical turbine pumps shall conform to the applicable requirements of ANSI/AWWA E101 and the Hydraulic Institute Standards.
D. Supplier shall be certified to the ISO 9001 standard for design and manufacture of vertical turbine pumps.
1.2 CONDITIONS OF OPERATION
A. The operating point of each pump shall be variable flow capable of flow and head capacities as shown in pump schedule in the design drawings.
1.3 SUBMITTALS
A. Provide complete fabrication and assembly drawings together with detailed specifications and data covering materials, parts, devices and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. Information and submittals shall conform to the requirements of Section 013300 – Contractor Submittals. The data and specifications for each pumping unit shall not be limited to the following:
1. Name of manufacturer. 2. Type and model of pump including design rotative speed, number of stages, type of bowl bearings, type and line shaft bearings, shaft sizing. 3. Dimensions including size/length of pump column, size (OD) of pump bowls, location and size of discharge outlet connections, weight, and max overall dimensions. 4. Performance curves showing capacity versus head, NPSH required, efficiency, and bhp requirements plotted on scales with unit clearly indicated. 5. Also provide diagrams showing installation requirements including minimum clearances from nearby walls, adjacent pump units, required submerged depth for operation, distance of suction end from basin/can or floor bottom, additional adders for anti-vortexing, and all other pertinent information required to review the pump unit for performance and installation for each application. WRCWRA VERTICAL TURBINE CAN PUMPS PLANT EXPANSION PROJECT 227540-1 B. Provide operation and maintenance manuals and information in accordance with the requirements of Section 017823 – Operation and Maintenance Data.
1.4 WARRANTY
A. The warranty period shall be a non-prorated period of 12 months from date of installation, not to exceed 24 months pump OEM shipment.
1.5 WARRANTY
A. The pump manufacturer shall have at least five (5) similar installation in the US with an minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 PERFORMANCE
A. Pumping shall meet the requirements outlined in Division 26, including units utilizing a variable frequency drive (VFD).
B. Pump performance shall be stable and free from damaging cavitation, vibration, and noise within the design operating range.
C. Efficiency of any alternate pump proposed shall be within 5% of the design basis pump, as listed herein and in the pump schedule, for each application for all duty points in the operating range of the pump. The Minimum bowl efficiency at design flow and TDH shall be 82%.
D. For all pumps to be run utilizing a variable frequency drive, the pump curve shall be continuously rising and shall be free from dips & valleys from the design point to the shutoff head. The shutoff head shall be at least 115% of the head that occurs at the design point.
E. At any operating speed, the ratio of rotative speed to the critical speed of a unit or its components shall be less than 0.8 or more than 1.2.
2.2 MATERIALS OF CONSTRUCTION
A. The pump bowls shall be constructed Cast Iron ASTM A48 – enamel lined. Water passage on bowl sizes 4” through 19” shall be lined with porcelain enamel and larger sizes shall be fusion bonded epoxy lined type to reduce friction losses. The waterways and diffusion vanes shall be smooth and free from nodules, bumps and dips and shall be cast of high quality free of blow holes, sand holes and other detrimental defects. The bearings shall be bronze sleeve type.
The bowls shall be accurately machined and fitted with a suction bell with integral cast ribs supporting the suction bearing. The bearings shall be sleeve type of the material listed in the subsection “materials of construction” and are to be lubricated by the product being pumped.
WRCWRA VERTICAL TURBINE CAN PUMPS PLANT EXPANSION PROJECT 227540-2 The bearings are to be located above and below each impeller. The suction bearing shall be permanently packed with food grade grease, and shall have a length not less than 2 times the shaft diameter.
B. Impellers shall be of the enclosed type cast in one piece and shall be statically and dynamically balanced. Impeller shall consist of 836 Bronze (ASTM B584-90b Alloy 836).
C. The outer column pipe shall be flanged or as indicated in the design drawings, and constructed of ASTM A53 Gr. B steel pipe in interchangeable sections. The weight of the column pipe shall be sized no less than that stated in ASNI/AWWA specification E101, Section 5.1.
The column line shaft shall be turned and ground and manufactured of the material provided in the table provided below. They shall be furnished in interchangeable section not to exceed 10’ in length. The butting faces shall be machined square to the axis of the shaft with maximum permissible misalignment of the thread axis with the shaft axis 0.002” in 6”. The size of the shaft shall be no less than that determined by ANSI/AWWA-E101 specification Section 5.5 and shall be such that elongation due to hydraulic thrust will not exceed the axial clearance of the impellers in the pumps bowls. The line shaft bearings shall be sleeve type provided of the material listed in the above table. Line shaft bearing spacing shall be such that shaft first critical frequency shall be safely above or below the operating frequency.
D. The discharge head shall be fabricated of carbon steel materials using ASTM A181 flanges, ASTM A53 Grade B body pipe and ASTM A516 steel plate with the suction and discharge flanges inline with each other and located 180 degrees apart. Discharge head design shall be capable of containing maximum pressure developed by pump plus suction pressure. The suction flange shall be 150# ANSI raised face with bolt holes straddling suction centerline. The discharge flange shall be 150# ANSI raised face with bolt holes straddling the vertical centerline. A ¼” NPT pressure gauge connection shall be supplied on the top centerline of the suction and discharge outlets. A ¾” NPT barrel vent tap shall be located on the outer casing of the discharge head. The top of the discharge head shall be machined to accept a standard NEMA P base driver and have a diameter equal to the driver base diameter (BD). The base flange shall be machined, drilled & gasketed to provide a pressure containing seal to the top of the suction barrel. The head shaft shall be connected to the top line shaft beneath the motor to facilitate ease of assembly and maintenance.
All couplings and other moving or rotating parts shall be covered on all sides by an OSAH approved coupling guard. Each guard shall be designed for easy installation and removal. All necessary supports and accessories shall be provided for each guard.
A rigid Flanged Adjustable “Spacer” type Coupling (FASC) shall be provided to couple the motor shaft to the pump shaft. The spacer shall be of sufficient length to allow the mechanical seal to be removed without disturbing the motor. This coupling shall allow for the vertical adjustment of the shaft mounted impellers.
The discharge head shall be fitted with a mechanical seal. The seal shall be of the cartridge type, sleeve mounted, easily replaceable and have its face continuously flushed with the product being pumped. The seal shall be equivalent to the Chesterton 155 or John Crane 5611.
E. The bowl assembly OD, column ID & OD, discharge head ID & suction can ID shall be factory painted with a two part epoxy coating, such as Carboguard 891. The coating shall be applied in two coats of 4-6 mils DFT, with a final dry film thickness no less than 10-12 mils. Prior to WRCWRA VERTICAL TURBINE CAN PUMPS PLANT EXPANSION PROJECT 227540-3 coating, all surfaces are to receive a commercial blast meeting SSPC-SP10 and shall be primed.
F. Vertical turbine pumps shall be equipped with reverse rotation prevention devices and/or footer valves to prevent draining of the water column in the vertical pipe and pump when the pump is off-duty as required for the installation location(s). If these additions are not available, the pump manufacturer shall provide appropriate vacuum break/air release valves or devices for the pump on the discharge side of the pump before the discharge check valve to prevent damage or issues with pump operation during start up due to water draining from the pump column.
G. For barrel (can type) pumps, each pump barrel shall be of the ANSI/HI-9.8 length design and size recommended by the manufacturer and shall conform to Hydraulic Institute Standards. Barrel inlet nozzle and flange shall be located and sized properly per ANSI/HI9.8 standard. Pump barrel (can) must be designed in such a manner as to prevent submerged vortices from being developed. The barrel’s square top mounting plate shall be of sufficient thickness to drill and tap for ANSI rated flange bolting to match the base flange of the discharge head. The top mounting plate of the barrel shall be properly machined and be gasketed or “O” ringed for a zero leakage connection to the discharge head. The pressure rating of the barrel shall be capable of containing the maximum suction pressure. Each pump barrel shall be vented through the sub base to the air relief valve indicated. The pumping system shall be designed to be supported from the base of the can. The pump OEM shall provide the 3 future suction cans and covers as shown on the drawings.
The suction barrel shall be fitted with 2 vertical direction vanes to reduce hydraulic swirling. They should be welded to the inside of the barrel in line with the suction centerline and located 180 degrees apart.
H. Manufacturer shall review the installation location and conditions for each type of pump, and shall furnish any recommended accessories, such as anti-vortexing devices, to improve performance and minimize any issues with operating the pump.
I. The following table summarizes the materials of construction required for the pump.
Component Material Pump Bowls Cast Iron (ASTM A48 c130 - Enamel Lined) Impellers 836 Bronze – (ASTM B584-90b Alloy 836) Bowl Assembly Shaft 416 SS - (ASTM A582088a Type 416) Bowl Bearings Bronze - (ASTM B505-91 Alloy 932) Collets Steel - (ASTM A108-90a Gr 1215) Bowl Bolting 304 SS – (ASTM F593 Gr CW1) Bowl Wear Rings N/A Impeller Wear Rings N/A Strainer N/A Column Pipe Thickness Standard (Schedule 40) Column Bolting 304 SS – (ASTM F593 Gr CW1) Line Shaft 416 SS – (ASTM A582-88a)
WRCWRA VERTICAL TURBINE CAN PUMPS PLANT EXPANSION PROJECT 227540-4 Line Shaft Couplings 416 SS – (ASTM A582-88a) Line Shaft Bearings Styrene Butadiene Rubber (SBR) Bearing Retainers Ductile Iron – (ASTM A536-84 Gr 60-40-18) Discharge Head Fabricated Steel - (A516-Gr 70 plt, A105 flg, A53-Gr B pipe) Name Plate Stainless Steel Anchor Bolts Stainless Steel
2.3 ACCEPTABLE MANUFACTURERS
A. All products must fully comply with these specifications. Standard product must be modified, if required, for compliance.
1. Weir Floway, Inc. (Basis of Design) 2. Fairbanks Morse 3. Peerless Pump Company 4. Or Equal
PART 3 - EXECUTION
A. Pumps shall be installed per manufacturer’s recommendations including all auxiliary devices and accessories to minimize vibration, vortexing, cavitation, and otherwise facilitate and maximize the performance and reliable life of the pump unit.
B. Contractor shall coordinate electrical and controls requirement with the pump skid manufacturer to ensure a properly installed and operating pump system. The motor control (and VFD) portions of the pumps will be installed remotely from the pump skid and motors. Contractor is responsible to provide all wiring, conduit, controls, and other aspects to complete the installation of the pumps. All electrical components shall comply with the requirements outlined in Division 26 and Section 220513 – Common Motor Requirements for Plumbing Equipment.
C. All exterior installed items, including pumps, motors, valves, piping, wiring, and other components shall be suitable for exposed, outdoor installation including high ambient operating temperatures for the pump motors and exposure to direct sunlight.
D. Factory non-witnessed hydrostatic test of bowl, column, suction can and discharge head shall be performed per Hydraulic Institute standards. Each pumping unit consisting of the actual discharge head, column & bowl assembly to be supplied in the field shall be non-witness tested at the factory for capacity, power requirement, and efficiency at minimum head, rated head, shutoff head or point of discontinuity, and at as many other points as necessary for accurate performance curve plotting. Pump OEM can use a calibrated lab motor for these tests. All tests and test reports shall conform to the requirements and recommendations of the Hydraulic Institute Standards. If the pump fails to operate properly or fails to meet the specified conditions or requirements during shop testing, the pump manufacturer shall modify the pumping unit and perform additional tests. The pump manufacturer shall submit complete pump test reports, including test arrangement, instrumentation calibration data, test procedures, WRCWRA VERTICAL TURBINE CAN PUMPS PLANT EXPANSION PROJECT 227540-5 & test data in curve format. All test data shall be submitted to the engineer at least 5 days prior to shipment.
E. Pump shall be furnished with all typical spare parts (or spare parts kit) and any specialty tools as typically supplied and recommended by the pump manufacturer. Submittals shall provide a detailed list of all included spare parts, including party numbers and quantities of each item.
F. Pump supplier shall include services of a qualified representative to oversee the installation, startup, testing, and training of operator personnel. Refer to Section 017900 – Demonstration and Training for details on startup requirements. The representative shall be present when the equipment is placed in operation, and shall revisit the job site as often as necessary until all trouble is corrected and the equipment installation and operation are satisfactory in the opinion of ENGINEER.
G. The manufacturer’s representative shall furnish a written report certifying that the equipment has been properly installed and lubricated; is in accurate alignment; is free from any undue stress imposed by connecting piping or anchor bolts; and has been operated under full load conditions and that it operated satisfactorily.
H. All costs of these services shall be included in the contract price for the number of days and round trips to the site as required.
END OF SECTION 227540
WRCWRA VERTICAL TURBINE CAN PUMPS PLANT EXPANSION PROJECT 227540-6 SECTION 227545 – VERTICAL MIXED FLOW PUMPS
PART 1 - GENERAL
1.1 SUMMARY
A. This specification covers the furnishing of vertical mixed flow pump units as required and to the expectation of the Engineer with regard to the manufacture of the equipment.
B. All equipment must be supplied by the same pump manufacturer including bowls, impellers, column, shafting, heads, coupling, sleeves, seals, and motors. Well drillers, distributors, or other fabrication shops will not be allowed to furnish equipment built in their local fabrication shop. Equipment furnished under this section shall be fabricated and assembled in full conformity with drawings, specifications, engineering data, instructions, and recommendations of the equipment manufacturer, unless exceptions are noted by Engineer.
C. Except as modified or supplemented herein, all mixed flow pumps shall conform to the applicable requirements of ANSI/AWWA and the Hydraulic Institute Standards for mixed-flow type pumps.
1.2 CONDITIONS OF OPERATION
A. The operating point of each pump shall be variable flow capable of flow and head capacities as shown in pump schedule in the design drawings.
1.3 SUBMITTALS
A. Provide complete fabrication and assembly drawings together with detailed specifications and data covering materials, parts, devices and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. Information and submittals shall conform to the requirements of Section 013300 – Contractor Submittals. The data and specifications for each pumping unit shall not be limited to the following:
1. Name of manufacturer. 2. Type and model of pump including design rotative speed, number of stages, type and line shaft bearings, shaft sizing. 3. Dimensions including size/length of pump column including required ID and OD by the pump and pump can, location and size of discharge outlet connections, weight, and max overall dimensions. 4. Performance curves showing capacity versus head, NPSH required, efficiency, and bhp requirements plotted on scales with unit clearly indicated. Provide VFD curves for each type of unit where a variable flow is required. 5. Also provide diagrams showing installation requirements including minimum clearances from nearby walls, adjacent pump units, required submerged depth for operation, distance of suction end from basin or floor bottom, additional adders for anti-vortexing, and all other pertinent information required to review the pump unit for performance and installation for each application. WRCWRA VERTICAL MIXED FLOW PUMPS PLANT EXPANSION PROJECT 227545-1 B. Provide operation and maintenance manuals and information in accordance with the requirements of Section 017823 – Operation and Maintenance Data.
1.4 WARRANTY
A. The warranty period shall be a non-prorated period of 12 months from date of installation, not to exceed 18 months from date of shipment.
1.5 WARRANTY
A. The pump manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 PERFORMANCE
A. Pumping shall meet the requirements outlined in Division 26, including units utilizing a variable frequency drive (VFD).
B. Pump performance shall be stable and free from damaging cavitation, vibration, and noise within the design operating range.
C. Efficiency of any alternate pump proposed shall be no more than 5% less efficient than the pump listed in the pump schedule for each application for all duty points. All internal pump losses shall be computed and accounted for by the pump manufacturer to deliver the design pressure range indicated in the pump schedule.
2.2 MATERIALS OF CONSTRUCTION
A. The pump bowls shall be cast iron ASTM-A-48, class 30 iron, with a minimum tensile strength of 30,000 psi. The impeller/propeller shall be cast bronze and locked to the bowl shaft by a key and thrust collar. The bowl shaft shall be made from type 416 stainless steel PSQ, sleeve type bearings made from bronze, and split thrust collar and key made from stainless steel.
B. The suction bowl consists of flared inlet with straightening guide vanes to resist the formation of vortices and prevent pre-rotation of the water entering the impeller. The discharge bowl incorporates diffusion vanes that convert the velocity of the water leaving the impeller into pressure head. An inlet anti-vortex device will be provided as recommended by the manufacturer for each pump and application.
C. The size of the shaft shall be sufficient to safely transmit the required brake horsepower to the impeller to produce the specified performance. Bronze bushings shall be provided immediately above and below the impeller/propeller.
WRCWRA VERTICAL MIXED FLOW PUMPS PLANT EXPANSION PROJECT 227545-2 D. The discharge elbow and column shall be of fabricated mild steel with a minimum thickness of 0.25-inches.
E. The discharge head shall be fabricated of carbon steel materials using ASTM A181 flanges, ASTM A53 Grade B body pipe and ASTM A516 steel plate. All wetted pressure retaining parts shall be designed for a maximum working pressure equal to the pump shut off head. The discharge flange shall have a 150# ANSI raised face with bolt holes straddling the vertical centerline A ¼” NPT pressure gauge connection shall be supplied on the top centerline of the discharge outlet. The top of the discharge head shall be machined to accept a standard NEMA P base, driver and have a diameter equal to the driver base diameter (BD). The headshaft shall be coupled to the top lineshaft beneath the motor to facilitate ease of assembly and maintenance.
F. All couplings and other moving or rotating parts shall be covered on all sides by an OSAH approved coupling guard. Each guard shall be designed for easy installation and removal. Al necessary supports and accessories shall be provided for each guard.
G. A rigid Flanged Adjustable “Spacer” type Coupling (FASC) shall be provided to couple the motor shaft to the pump shaft. The spacer shall be of sufficient length to allow the mechanical seal to be removed without disturbing the motor. This coupling shall allow for the vertical adjustment of the shaft mounted impellers.
H. The pump shall be mounted and supported by a separate steel base plate (sole plate). The soleplate shall be drilled to match the base flange drilling of the discharge head. Abutting surfaces between the soleplate and the discharge head shall be machined to provide 100% surface contact with the discharge head base. The center opening diameter shall be of sufficient size to permit installation and removal of the complete pump assembly. The soleplate shall be permanently anchored, grouted and leveled within 0.003 inches per foot by the installing contractor.
I. The bowl assembly OD, column ID & OD, discharge head ID shall be factory painted with a two part epoxy coating, such as Carboguard 891. The coating shall be applied in two coats of 4- 6 mils DFT, with a final dry film thickness no less than 10-12 mils. Prior to coating, all surfaces are to receive a commercial blast meeting SSPC-SP10 and shall be primed.
J. Pumps shall be equipped with reverse rotation prevention devices and/or footer valves to prevent draining of the water column in the vertical pipe and pump when the pump is off-duty as required for the installation location(s). If these additions are not available, the contractor shall provide appropriate vacuum break/air release valves or devices for the pump on the discharge side of the pump before the discharge check valve to prevent damage or issues with pump operation during start up due to water draining from the pump column.
K. Manufacturer shall review the installation location and conditions for each type of pump, and shall furnish any recommended accessories, such as anti-vortex devices, to improve performance and minimize any issues with operating the pump.
2.3 ACCEPTABLE MANUFACTURERS
A. All products must fully comply with these specifications. Standard product must be modified, if required, for compliance. WRCWRA VERTICAL MIXED FLOW PUMPS PLANT EXPANSION PROJECT 227545-3 1. Cascade Pumps (Basis of Design) 2. Weir Floway, Inc. 3. Or Equal
PART 3 - EXECUTION
A. Pumps shall be installed per manufacturer’s recommendations including all auxiliary devices and accessories to minimize vibration, vortexing, cavitation, and otherwise facilitate and maximize the performance and reliable life of the pump unit.
B. Contractor shall coordinate electrical and controls requirement with the pump skid manufacturer to ensure a properly installed and operating pump system. The motor control (and VFD) portions of the pumps will be installed remotely from the pump skid and motors. Contractor is responsible to provide all wiring, conduit, controls, and other aspects to complete the installation of the pumps. All electrical components shall comply with the requirements outlined in Division 26 and Section 220513 – Common Motor Requirements for Plumbing Equipment.
C. All exterior installed items, including pumps, motors, valves, piping, wiring, and other components shall be suitable for exposed, outdoor installation including high ambient operating temperatures for the pump motors and exposure to direct sunlight.
D. Hydrostatic test of bowl, column, and discharge head shall be per Hydraulic Institute standards.
E. Pump shall be furnished with all typical spare parts (or spare parts kit) and any specialty tools as typically supplied and recommended by the pump manufacturer. Submittals shall provide a detailed list of all included spare parts, including party numbers and quantities of each item.
F. Pump supplier shall include services of a qualified representative to oversee the installation, startup, testing, and training of operator personnel. Refer to Section 017900 – Demonstration and Training for details on startup requirements.
END OF SECTION 227545
WRCWRA VERTICAL MIXED FLOW PUMPS PLANT EXPANSION PROJECT 227545-4 SECTION 227550 – SUBMERSIBLE WET WELL PUMPS
PART 1 - SYSTEM DESCRIPTION
1.1 SCOPE OF SUPPLY
A. The contractor shall supply pumps as indicated in the pump schedule.
1.2 CONDITIONS OF OPERATION
A. Each pump shall be capable of pumping at the hydraulic conditions shown in the pump schedule or on the drawings.
1.3 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation.
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings for each type of pump, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of pump. Include this data, product data, shop drawings in maintenance manual in accordance with requirements of Section 017823 – Operation and Maintenance Manuals.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. The following are acceptable:
1. KSB (Basis of Design) 2. Or Equal
B. All products, whether named as “acceptable”: or proposed as “equal” must fully comply with these specifications. Standard product must be modified, if required, for compliance. Manufacturer shall have installations of like or similar application with a minimum of 5 years’ service for this pump size.
2.2 MATERIALS – SUBMERSIBLE PUMPS
A. Pump case: Cast Iron, ASTM A48, Class 35
B. Motor Housing: Cast Iron, ASTM A48, Class 35
C. Impeller: Cast Iron, ASTM A48, Class 35
D. Intermediate Housing (Backplate): Cast Iron, ASTM A48, Class 35
E. Discharge Base Elbow: Cast Iron, ASTM A48, Class 35
WCRWRA SUBMERSIBLE WET WELL PUMPS PLANT EXPANSION PROJECT 227550-1
F. Pump/Motor Shaft:
1. With protective sleeve: Carbon Steel, ASTM A576,Gr.1045
2. Without sleeve: Stainless Steel, ASTM A276 A182 Type FXM-19
G. Shaft Sleeve: Stainless Steel, ASTM A276 A276 Type 420
H. Wear Ring, case: Cast Iron, ASTM A48, Minimum 200 Brinell
I. Wear Ring, Impeller: Stainless Steel, ASTM A276-400 Series, min. 300 Brinell
J. O-Rings: Nitrile Rubber (NBR)
K. Fasteners: Stainless Steel, ASTM A276 Type 316Ti.
L. Lower Seal Faces: Silicon Carbide/Silicon Carbide
M. Upper Seal Faces: Hard Metal stationary/Carbon rotating
N. Guide Cables (or pipes): Stainless Steel, ASTM A276 Type 316
O. Lifting Chain or cable: Stainless Steel, ASTM A276 Type 316
P. Oil-all uses (seal lubrication, motor cooling, etc.): Ecologically safe, paraffin base
Q. Power/Control Cable Jacket: Neoprene
2.3 POWER CABLE
A. Provide power/control cable with each pump. Cables shall be of sufficient length such that no additional cable, nor splicing of supplied cable shall be required to connect the pump to the power source, as shown on the Drawings.
B. Provide cable suitable for submersion in a screened, raw, municipal wastewater wet well sized in accordance with NEC requirements.
C. Provide one of the following cable entry sealing systems:
1. Provide cable terminal box on side of motor housing, with cable entry sealed to insure that no entry of moisture is possible into the high-voltage motor/terminal area even if the cable is damaged or severed below water level.
2. Provide a compressed grommet seal on the cable’s outer jacket only, with a sealed terminal board between the cable entry and motor housing as a secondary seal against leakage through a damaged cable jacket. Provide a moisture detector in the sealed junction chamber area to signal and shut down the pump motor before shorting and motor damage can occur.
2.4 TEMPERATURE PROTECTION
WCRWRA SUBMERSIBLE WET WELL PUMPS PLANT EXPANSION PROJECT 227550-2
A. Furnish temperature monitoring thermistors or bimetalles in motor windings for use in conjunction with and supplemental to external motor overload protection.
B. Arrange controls to shut down pump should any of the monitors detect high temperature and automatically reset once motor temperature returns to normal.
C. Set temperature monitors at levels recommended by pump manufacturer.
D. For motors rated 100 HP and larger, provide a temperature monitor for the lower bearing. Sensor to be a Resistance Type (RTD) temperature sensor with a linear relationship between temperature and resistance, with a supervision relay for each sensor to provide dry contact closures indicating “Status OK”, “Pre-Alarm: and “Alarm Shutdown” plus a 0-10 VDC analog signal follower for temperature indication.
2.5 SEAL LEAK DETECTION
A. Furnish a monitoring system to signal seal leakage.
B. Provide a sensor in the motor’s stator cavity which allows a control panel mounted relay to indicate leakage into the motor.
C. For motors rated 40 HP and larger, provide a stainless steel mechanical float in a separate leakage collection chamber to indicate seal leakage prior to its penetration of the lower bearing assembly.
2.6 MOTOR COOLING ACCESSORIES
A. If a cooling jacket is used on the motor, the pump manufacturer must provide flexible hose, valves, fittings, regulators and all other components needed to install a permanent flushing connection to an outside water supply.
PART 3 - FABRICATION
3.1 GENERAL
A. Provide pumps capable of handling raw, municipal sewage.
B. Design pumps to allow for removal and reinstallation without the need to enter the wet well and without removal of bolts, nuts or other fasteners.
C. Provide a pump which connects to a permanently mounted discharge connection by simple downward motion, without rotation, guided by at least two non-load-bearing guide cables or pipes. Final connection shall insure zero leakage between pump and discharge connection flange.
D. Provide a discharge connection/guide system so that no part of the pump bears directly on the floor of the wet well.
E. Provide Type 316 stainless steel chain of sufficient length to properly and safely lift pumps from the wet well.
WCRWRA SUBMERSIBLE WET WELL PUMPS PLANT EXPANSION PROJECT 227550-3
3.2 MAJOR COMPONENTS
A. Furnish major components (pump case, impeller, intermediate housing, motor housing) of cast material as specified in 2.2 with smooth surfaces devoid of blowholes and other irregularities.
B. All major castings shall be produced in the pump manufacturer’s own foundry under the manufacturer’s direct supervision.
C. Pump shall be coated with a two-component epoxy finish having a minimum 83% solids by volume. This coating shall be non-toxic and approve for both wastewater and water applications.
3.3 IMPELLER AND WEAR RINGS
A. Provide non-clog type impeller, capable of passing at minimum a 3” spherical solid.
B. Statically and dynamically balance the impeller.
C. Provide hard metal wear rings on case and impeller, of material and Brinell hardness specified, to insure maximum pump/impeller life and continuing high efficiencies.
D. Do not use soft metals (i.e. bronze, 304 or 316 stainless) or elastomers as wear ring material as these are incompatible with the grit contaminate expected in the pumpage.
3.4 SHAFT
A. Provide common pump/motor shaft of sufficient size to transmit full driver output with a maximum deflection of 0.002 inches measured at the lower mechanical seal. B. Provide one of the following shaft designs:
1. Machine the shaft of carbon steel (for maximum strength and motor efficiency) and isolate the shaft from the pumped media with a replaceable Type 420 stainless steel shaft sleeve under the lower mechanical seal.
2. Machine the entire shaft of A182 FXM-19 stainless steel.
D. Do not use carbon steel as shaft material without a stainless steel sleeve.
3.5 SHAFT SEAL
A. Provide two totally independent mechanical shaft seals, installed in tandem, each with its own independent spring system acting in a common direction.
B. Install the upper seal in an oil-filled chamber with drain and inspection plug (with positive anti-leak seal) for easy access from external to the pump.
C. Provide seals requiring neither routine maintenance nor adjustment, but capable of being easily inspected and replaced.
WCRWRA SUBMERSIBLE WET WELL PUMPS PLANT EXPANSION PROJECT 227550-4 D. Provide seals which are non-proprietary in design, with replacements available from a source other than the pump manufacturer.
E. Do not provide seals with the following characteristics: conventional double mechanical seals with single or multiple springs acting in opposed direction; cartridge-type mechanical seals; seals with face materials other than those specified; seals using the impeller hub as a mounting surface.
3.6 BEARINGS
A. Furnish upper and lower bearings, single row (preferred) or double row as needed to provide a B10 life of, at minimum, 40,000 hours at anticipated axial and radial loadings.
B. Provide either sealed/shielded (permanently lubricated) or open (regreaseable) bearings.
C. If open-type (non-shielded) bearings are used, provide re-lubrication ports with positive anti-leak plugs for periodic addition of lubrication from external to the pump.
3.7 MOTOR
A. Provide a motor which is squirrel cage, induction in design, housed in a completely watertight and air filled chamber, with a min 1.10 service factor.
B. Insulate the motor stator with, at minimum, Class F insulation rated for 311¡ F.
C. Provide motor cooling by one of the following methods:
1. Provide adequately rated motor with sufficient surface area for ambient only cooling (this is the preferred method).
2. Provide a submergence (cooling) jacket with passages either large enough to pass a 3 inch solid, or small enough to filter out all solids, while maintaining a minimum 2 ft./sec. Non-settling velocity at all pump operating speeds to prevent sedimentation of grease and grit. Jacket material shall be either cast iron or stainless steel.
3. Provide a submergence (cooling) jacket which does not comply with the solids handling or velocity requirements above with a permanent source and supply of external, clean cooling water (not sewage) and with all hose, fittings and accessories needed for supply and recycle of cooling water.
D. Provide motors which are capable of operating for extended periods in a dry mode without damage to motor or seals.
E. Provide motors which are designed, rated and warranted for continuous operation.
F. Do not provide motors which contain in excess of two (2) gallons of oil (combined total for cooling and seals), or which contain other than ecologically safe paraffin base oil.
WCRWRA SUBMERSIBLE WET WELL PUMPS PLANT EXPANSION PROJECT 227550-5 3.8 ACCESSORIES
A. Pumps shall be supplied with the following:
1. Cast iron, epoxy coated, flanged discharge elbows and stainless steel anchors; 2. Stainless steel guide rails as shown in the design drawings. 3. Stainless steel guide rail upper brackets. 4. Stainless steel lifting chain with sufficient length to reach crane system – refer to design drawings. 5. Stainless steel power cable hangers.
PART 4 - EXECUTION
4.1 INSTALLATION
A. Installation in strict accordance with the MANUFACTURER’S instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the MANUFACTURER’S recommendations. Anchor bolts shall be set in accordance with the MANUFACTURER’S recommendations.
B. Upon completion of the installation, the CONTRACTOR shall submit a certificate from the MANUFACTURER stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
4.2 EQUIPMENT TESTING
A. Tests shall be performed in accordance with the Test Code for Centrifugal Pumps per the Standards of the Hydraulic Institute. Tests shall be performed on the actual assembled pumps to be supplied – prototype model tests are not acceptable. Tests shall cover a range from shut-off to at minimum 20% beyond specified design capacity.
B. Conduct test per above specification on all supplied pumps, generating a curve showing actual flow, head, BHP and hydraulic efficiency.
C. Provide Foundry Composition Certificates (per ISO9001) for all major castings (pump case, impeller, motor housing) showing exact material composition and tests conducted to insure compliance with the material specifications.
4.3 VERIFICATION OF PERFORMANCE
A. Field test all pumps after installation to demonstrate satisfactory operation without excessive noise, vibration, cavitation or over-heating.
B. Any pump which fails to meet any of the specifications shall be modified, repaired or replaced. END OF SECTION 227550
WCRWRA SUBMERSIBLE WET WELL PUMPS PLANT EXPANSION PROJECT 227550-6 SECTION 227560 – CHEMICAL DOSING GEAR PUMPS
PART 1 - GENERAL
1.1 SUMMARY
A. This specification covers the furnishing of all chemical dosing gear-type pumps as indicated in the design drawings and the pump schedule. Chemical dosing pumps are supplied for multiple types of chemicals, and the individual performance and materials of construction for each specific chemical application are specified herein.
B. Manufacturer shall review each application, including flow range, required pressure range, and chemical to ensure the proper unit is supplied for each application. All equipment must be supplied by the same pump manufacturer.
1.2 CONDITIONS OF OPERATION
A. The operating point of each pump shall be variable flow capable of flow and head capacities as shown in pump schedule in the design drawings. Refer to each specific application and the details provided below regarding the various chemical and installation locations.
1.3 SUBMITTALS
A. Provide complete fabrication and assembly drawings together with detailed specifications and data covering materials, parts, devices and accessories forming a part of the equipment furnished, shall be submitted in accordance with the submittals section. Information and submittals shall conform to the requirements of Section 013300 – Contractor Submittals. The data and specifications for each pumping unit shall not be limited to the following:
1. Name of manufacturer. 2. Type and model of pump including design rotative speed, materials of construction, and performance curves. 3. Dimensions including overall size, dimensions to mechanical and electrical connection points, installation/mounting requirements and locations, and all other information required to analyze and install the pump. 4. Also provide diagrams showing installation requirements including minimum clearances from nearby walls, adjacent pump units, and all other pertinent information required to review the pump unit for performance and installation for each application.
B. Provide operation and maintenance manuals and information in accordance with the requirements of Section 017823 – Operation and Maintenance Data.
1.4 WARRANTY
A. The warranty period shall be a non-prorated period of 12 months from date of installation, not to exceed 24 months from date of manufacture.
WRCWRA CHEMICAL DOSING GEAR PUMPS PLANT EXPANSION PROJECT 227560-1
PART 2 - PRODUCTS
2.1 PERFORMANCE
A. Pumping shall meet the requirements outlined in Division 26, including units utilizing a variable frequency drive (VFD).
B. Pump performance shall be stable and free from damaging cavitation, vibration, and noise within the design operating range.
C. Pumps shall be self-priming, and provide a high range of turndown of at least 100:1 in terms of discharge flow capacity.
D. Pumps shall feature a magnetically coupled external gear and exceed 1% metering accuracy. Pumps shall be rated for a minimum 20,000 hours of operating life. Pump shall operate in a manner to avoid vapor lock, cavitation, while providing smooth flow delivery with minimal surging.
E. Efficiency of any alternate pump proposed shall be no more than 5% less efficient than the pump listed in the pump schedule for each application for all duty points. All internal pump losses shall be computed and accounted for by the pump manufacturer to deliver the design pressure range indicated in the pump schedule.
2.2 MATERIALS OF CONSTRUCTION
A. Pumps shall be external gear type pumps capable of delivering the fluid flow (displacement) at the pressure requirements indicated in the pump schedule.
B. Manufacturer shall review and confirm the suitability of the installation location and conditions for each type of pump, including chemical compatibility for each application. Any changes to the design materials or installation shall be presented to and approved by the Engineer.
C. Motor shall be heavy-duty rated, suitable for water treatment applications and shall comply with all requirements outlined in Division 26 and Section 220513 – Common Motor Requirements for Plumbing Equipment.
2.3 SODIUM HYPOCHLORITE SOLUTION PUMP REQUIREMENTS
A. The following conditions and design criteria are applicable for pumps transferring sodium hypochlorite (NaClO) solutions:
1. Chemical Solution: Sodium Hypochlorite (NaClO) 2. Solution Concentration: 12.5% NaClO by weight
B. Materials of construction for pumps servicing sodium hypochlorite are as follows:
1. Wetted Materials: Hastelloy C276 WRCWRA CHEMICAL DOSING GEAR PUMPS PLANT EXPANSION PROJECT 227560-2 2. Gear and Bearing Material: PEEK (Polyetheretherketone) 3. O-Ring: Viton
C. Provide a pump with sufficient torque and suitable outlet/inlet port sizes for the flow and pressure applications indicated in the design drawings.
2.4 SODIUM BISULFITE SOLUTION PUMP REQUIREMENTS
A. The following conditions and design criteria are applicable for pumps transferring sodium bisulfite solutions:
1. Chemical Solution: Sodium Bisulfite (NaHSO3) 2. Solution Concentration: 40% by weight
B. Materials of construction for pumps servicing sodium bisulfite are as follows:
1. Wetted Materials: 316 Stainless Steel 2. Gear and Bearing Material: PPS Polyphenylene Sulfide 3. O-Ring: Viton
C. Provide a pump with sufficient torque and suitable outlet/inlet port sizes for the flow and pressure applications indicated in the design drawings.
2.5 ACCEPTABLE MANUFACTURERS
A. All products must fully comply with these specifications. Standard product must be modified, if required, for compliance.
1. Tuthill W-Series (Basis of Design) 2. Or Equal
PART 3 - EXECUTION
A. Pumps shall be installed per manufacturer’s recommendations including all auxiliary devices and accessories to minimize vibration, vapor lock, cavitation, and otherwise facilitate and maximize the performance and reliable life of the pump unit.
B. Contractor shall coordinate electrical and controls requirement with the pump manufacturer to ensure a properly installed and operating pump system. Contractor is responsible to provide all wiring, conduit, controls, and other aspects to complete the installation of the pumps. All electrical components shall comply with the requirements outlined in Division 26 and Section 220513 – Common Motor Requirements for Plumbing Equipment.
C. All exterior installed items, including pumps, motors, valves, piping, wiring, and other components shall be suitable for exposed, outdoor installation including high ambient operating temperatures for the pump motors.
WRCWRA CHEMICAL DOSING GEAR PUMPS PLANT EXPANSION PROJECT 227560-3 D. Pump shall be furnished with all typical spare parts (or spare parts kit) and any specialty tools as typically supplied and recommended by the pump manufacturer. Submittals shall provide a detailed list of all included spare parts, including party numbers and quantities of each item.
E. Pump supplier shall include services of a qualified representative to oversee the installation, startup, testing, and training of operator personnel. Refer to Section 017900 – Demonstration and Training for details on startup requirements.
END OF SECTION 227560
WRCWRA CHEMICAL DOSING GEAR PUMPS PLANT EXPANSION PROJECT 227560-4 SECTION 227563 MOTOR DIAPHRAGM METERING PUMP
PART 1. GENERAL
1.1. SUMMARY
The work under this section includes the furnishing of all labor, materials, equipment, documentation, training and startup services for the manufacture and installation of skid mounted chemical metering systems suitable for application of all chemicals as listed in the Design Summary and as shown on the drawings and specified herein (the “Work”).
1.2. SUBMITTALS
Provide submittals in accordance with specification section 013300.
1.3. QUALITY ASSURANCE
A. The products of this section shall be provided by a single supplier; who shall demonstrate previous experience in the manufacture of skid-mounted chemical metering systems. This supplier shall be responsible for providing all equipment, accessories, spare parts, documentation and installation supervision required for a complete and operational chemical feed system.
B. Warranties
The system manufacturer shall provide a one (1) year parts and labor warranty for the metering pumps.
PART 2. PRODUCTS
2.1. ACCEPTABLE MANUFACTURERS
A. The manufacturer shall have a minimum of 5-year experience with a successful record of manufacturing and servicing of systems as specified herein.
B. Subject to compliance with requirements, provide pump(s) of the following:
1. Prominent (S2BAHM16050PVTS1702000) (Basis-of-Design) 2. Or equal
2.2. Chemical Metering Pumps
A. Motor Diaphragm Pumps
1. The chemical metering pump(s) shall be motor-driven, reciprocating, mechanically- actuated diaphragm type. The pump shall include motor, oil-lubricated gear reducer and cam-and-spring drive mounted in an aluminum housing, coated with a chemical resistant two-part epoxy finish. The pump shall be of a modular design to accommodate add-on pumps powered by a single electric motor.
WRCRWA MOTOR DIAPHRAGM METERING PUMP PLANT EXPANSION PROJECT 227563 - 1
2. The chemical metering pump manufacturer shall provide a two year warranty on the pump drive and one year warranty on the pump liquid end, including diaphragm and O-rings.
3. The pump shall be fully tested to meet rated flow and pressure by the manufacturer.
4. The power supply shall be 230 V, 60 Hz, 3 phase.
5. The liquid end shall be physically separated from the drive unit by back plate with weep hole creating an air gap. An elastomer shaft wiper seal shall prevent contamination of the solenoid if the primary diaphragm fails. The diaphragm shall be with PTFE-faced fluid contact surface.
6. For all pumps supplied without any analog or digital input or output capability, fixed speed, wash-down duty motors of the appropriate HP and voltage shall be provided. For all pumps supplied with any analog or digital input or output capability, inverter rated, wash-down duty motors of the appropriate HP and voltage shall be provided.
B. Chemical Feed Control Panel (CFCP)
1. For all mechanically and hydraulically actuated diaphragm pumps with automatic control indicated of the stroke rate or those desiring a separate controller, a chemical feed control panel shall be provided. Each separate chemical feed system shall be provided with its own operator control panel to be located as shown on the plans.
2. The CFCP shall allow the operator to manually adjust the speed of each chemical metering pump.
3. The Chemical Feed Pump Control Panel (CFCP) shall be provided as an integral part of a packaged chemical feed pump skid from Blue Planet Environmental Systems. The CFCP shall be UL Listed (UL 508) and UL/NEMA 4X rated and its enclosure shall be made of 316 Stainless Steel (316SS).
4. EACH PUMP LOCAL – The CFCP shall include the following local features for each pump; an AC Variable Frequency Drive (VFD) 60:1 @ 0.5% Open Loop, a “Hand-Off-Auto” Selector, a “Run” indicator, a manual “Speed” potentiometer, a digital “Speed” indicator, a “VFD fail” indicator, an Elapsed Time Meter (ETM), and a “High Temperature” Indicator. For all pumps with “automatic” indicated in the Stroke Length category of the Design Summary, a “Hand-Off-Auto” Selector, a manual “Stroke” potentiometer and a digital “Stroke” indicator shall be provided.
PART 3. EXECUTION
3.1. Installation
A. Install the chemical metering skids as indicated on the drawings and specified and in compliance with the manufacturer’s instructions.
3.2. Inspection and Testing
A. Upon completion of installation, a full operating test shall be performed in the presence of
WRCRWA MOTOR DIAPHRAGM METERING PUMP PLANT EXPANSION PROJECT 227563 - 2
the Engineer and a qualified manufacturer’s representative. The Contractor shall furnish all labor, materials and equipment required for such test and shall correct any deficiencies noted.
END OF SECTION 227563
WRCRWA MOTOR DIAPHRAGM METERING PUMP PLANT EXPANSION PROJECT 227563 - 3
SECTION 227565 - VARIABLE SPEED PERISTALTIC PUMP
PART 1 – GENERAL
1.1 DESCRIPTION
A. Pumps shall be positive displacement peristaltic type tubing pump with a brushless variable speed motor, non-spring loaded roller assembly located in the pumphead, integral tube failure detection system, tube life roller revolution counter with use alarm set-point and flexible tubing with attached connection fittings.
B. Pumps shall be dry self-priming, capable of being run dry without damaging effects to pump or tube, and shall have a maximum suction lift capability of up to 30' vertical water column.
C. Pump shall not require the use of check valves or diaphragms and shall not require dynamic seals in contact with the pumped fluid. Process fluid shall be contained within pump tubing and shall not directly contact any rotary or metallic components.
1.2 SUBMITTALS
A. Submit the following 1. Certified shop drawings. 2. Characteristic performance curve showing flow rate as a function of RPM and pressure. 3. Dimensional drawings. 4. Operating, maintenance, programming, and wiring instructions
1.3 WARRANTY
A. All components and operation of the pump shall be warranted by the manufacturer for at least period of five (5) years. Warranty shall include chemical damage to the pump head and roller assembly for a minimum of two (2) years.
1.4 DELIVERY, STORAGE, AND HANDLING
A. Shipping
1. Ship pump and drive assembled complete. Ship tubing separately for field installation and process line connection by contractor. 2. Pack all additional spare parts in containers bearing labels clearly designating contents and pieces of equipment for which intended. 3. Deliver spare parts at the same time as pertaining equipment. Deliver to Owner WRCRWA VARIABLE SPEED PERISTALTIC PUMP PLANT EXPANSION PROJECT 227565-1
after completion of work.
B. Receiving
1. Contractor to inspect and inventory items upon delivery to site. 2. Contractor to store and safeguard equipment, material, instructions, and spare parts in accordance with manufacturer's written instructions.
PART 2 – PUMP DESIGN
2.1 PERFORMANCE REQUIREMENTS
A. Pumps shall be capable of delivering the full flow range at the maximum discharge pressure listed in the pump schedule.
B. Required maximum discharge pressure is 125 psi with suction lift equivalent to 30 feet of water.
C. Pump shall be capable of running dry without damage and shall be capable of operating in both directions without output variation.
D. Accuracy shall be ±0.5 percent of full scale with precision (aka repeatability) also at ±0.5 percent.
E. Pump shall be designed and suitable for outdoor installation, in ambient air temperatures up to 115˚F and as low as 14˚F. Pumps will be installed on a stand beneath a stainless steel shade structure to protect the pump from direct sun exposure, especially during mid-day. Installer should take care to ensure that the control panel face does not face directly south.
2.2 PRODUCTS & ASSEMBLY
A. Pumphead
1. Shall be a single, unbroken track with a clear removable cover. 2. Tube failure detection system shall not be wholly located in the pumphead. The system shall not trigger with water contact. Float type switches shall not be used. 3. Squeeze rollers with encapsulated ball bearings directly coupled to a one piece thermoplastic rotor. Four polymeric rollers shall be provided; two squeeze rollers for tubing compression shall be located 180 degrees apart and two guide rollers that do not compress the tubing shall be located 180 degrees apart. The roller diameters and occlusion gap shall be factory set to provide the optimum tubing compression; field adjustment shall not be required. Spring loaded or hinged rollers shall not be used. 4. Rotor assembly shall be installed on a D-shaped, chrome plated motor shaft and removable without tools. 5. For tubing installation and removal, rotor assembly shall be rotated by the motor drive at 6 RPM maximum when the pumphead cover is removed. Hand cranking of the rotor assembly shall not be required. 6. Pump head and tubing compression surface shall be corrosion resistant Valox thermoplastic. WRCRWA VARIABLE SPEED PERISTALTIC PUMP PLANT EXPANSION PROJECT 227565-2
7. The pump head cover shall be clear, annealed acrylic thermoplastic with an integral ball bearing fitted to support the overhung load on the motor shaft. Cover shall include an imbedded magnetic safety interlock which will limit the motor rotation speed to 6 RPM when removed. 8. Cover shall be positively secured to the pump head using a minimum of four thumb screws. Tools shall not be required to remove the pump head cover.
9. Acceptable Manufacturers – Subject to the requirements of these specifications, acceptable suppliers include: a. Blue White Industries Flex-Pro M-series peristaltic pumps (design basis). b. or equal.
B. Pump Tube Assembly
1. To ensure pump performance and accuracy, only tubing provided by the manufacturer is acceptable. 2. Pump tube shall be assembled to connection fittings of PVDF material. 3. Connection fittings shall be permanently clamped to the tubing with stainless steel clamps. To prevent tubing misalignment and ensure accuracy, fittings shall insert into keyed slots located in the pump head and secured in place by the pump head cover. 4. Fittings shall accept 1/4” ID x 3/8” OD flexible tubing. 5. The following tube sizes shall be available:
WRCRWA VARIABLE SPEED PERISTALTIC PUMP PLANT EXPANSION PROJECT 227565-3
C. Drive System – Drive System shall be factory installed and totally enclosed in a NEMA 4X, (IP66) wash-down enclosure. Equipment shall be capable of operating on any input power form 110VAC 60 Hz single phase supply.
1. Motor shall be reversible, brushless DC gear motor rated for continuous duty and shall include overload protection. 2. Enclosure shall be cast aluminum with acidic liquid iron phosphate three-stage clean and coat pretreatment and exterior grade corrosion resistant polyester polyurethane powder coat. Closure shall be NEMA 4X rated. 3. Pump case shall be provided with 316 SS shelf leveling mounting brackets and hardware. 4. A wiring compartment shall be provided for connection of input/output signal wires and alarm output loads to un-pluggable type terminal block connectors. Terminal board shall be positively secured to the rear of the pump housing by two polymeric screws and fully enclosed by the wiring compartment cover. The terminal board shall not be disturbed by the removal of the wiring compartment cover. Ribbon cables shall not be used in the wiring compartment. Conduit hubs, liquid-tight connectors, connector through holes and tapped holes shall be sized in U.S. inches.
D. Control Circuitry – All control circuitry shall be integral to the pump.
1. All control circuitry shall be integral to the pump and capable of adjusting the pump motor speed from 0.01% to 100.00% in 0.01% increments less than 1% motor speed and in 0.1% increments greater than 1% motor speed (10,000:1 turndown ratio) 2. The pump output shall be capable of being manually controlled via front panel user touchpad controls. The pump motor speed shall be adjustable from 0.01% to 100.00% in 0.01% increments less than 1% motor speed and in 0.1% increments greater than 1% motor speed. 3. The pump output shall be capable of being remotely control via 4-20mA analog input. The input resolution shall be 0.01 of input value and capable of adjusting the pump motor speed from 0% to 100.0% motor speed in 0.1% increments. Four values shall be user configurable to define the low and high points on the output slope; a low input value, the required pump percentage of motor speed at the low input value, a high input value, the required pump percentage of motor speed at the high input value. 4. The pump output shall be capable of being remotely control via 0-10 VDC input. The input resolution shall be 0.01 of input value and capable of adjusting the pump motor speed from 0% to 100.0% motor speed in 0.1% increments. Four values shall be user configurable to define the low and high points on the output slope; a low input value, the required pump percentage of motor speed at the low input value, a high input value, the required pump percentage of motor speed at the high input value. 5. The pump output shall be capable of being remotely control via TTL/Cmos digital high speed pulse type input and an AC sine wave type pulse input in the range of 0 to 1000 Hz. The frequency resolution shall be 1 Hz and capable of adjusting the pump motor speed from 0% to 100.0% motor speed in 0.1% increments. Four values shall be user configurable to define the low and high points on the output slope; a low input value, the required pump percentage of motor speed at the low input value, a high input value, the required pump percentage of motor speed at the high input value. 6. The pump output shall be capable of being remotely control via pulse triggered batching. The pump shall accept a TTL/Cmos digital pulse type input and a contact closure type pulse input in the range of 1 to 9999 pulses per batch. The batch time shall be adjustable from 1 to 999999.9 seconds. The pump motor speed during the batch shall be adjustable from 0% to 100.0% motor speed in 0.1% increments.
WRCRWA VARIABLE SPEED PERISTALTIC PUMP PLANT EXPANSION PROJECT 227565-4
7. The pump shall include an internal cycle timer capable of automatically cycling the pump on and off. The pumping total cycle time shall be adjustable from 1 to 999999.9 seconds. The pumping on time during the cycle shall be adjustable from 1 to 999999.9 seconds. The pump motor speed during the cycle shall be adjustable from 0% to 100.0% motor speed in 0.1% increments. 8. The pump shall be capable of dispensing upon demand. The dispensing shall be manually triggered by pressing the front panel start button or by inputting a contact closure. The dispensing volume shall be adjustable from 1 to 999999.9 milliliters. The pump motor speed during the dispensing cycle shall be adjustable from 0% to 100.0% motor speed in 0.1% increments. 9. The pump shall be capable of automatically calculating the pump motor speed required to achieve a part per million dosing output that is proportional to a fixed system flow rate. The pump shall permit the user to input the dispensing chemical percentage concentration from 0% to 100.0% in 0.1% increments. The pump shall permit the user to input the dispensing chemical specific gravity from 0.1 to 9.9 in 0.1 increments. The pump shall permit the user to input the fixed system flow rate from 1.0 to 9999.9 liters per minute in 0.1 liters per minute increments. The pump shall permit the user to input the required dosing parts per million (PPM) from 0.1 to 100.0 in 0.1 increments. 10. The pump shall be capable of automatically calculating the pump motor speed required to achieve a part per million dosing output that is proportional to a variable system flow rate. The pump shall permit the user to input the dispensing chemical percentage concentration from 0% to 100.0% in 0.1% increments. The pump shall permit the user to input the dispensing chemical specific gravity from 0.1 to 9.9 in 0.1 increments. The pump shall permit the user to input a K-factor in pulses per liter from a sensor in the water system that outputs a high speed digital pulse from 0 to 1000 Hz that is proportional to the system water flow velocity. The pump shall permit the user to input the required dosing parts per million (PPM) from 0.1 to 100.0 in 0.1 increments. 11. Provide an 11-button front panel user touchpad control for stop/start, configuration menu access and navigation, operating mode selection, auto priming, display options selection, tube life data, and reverse direction. 12. Provide a multi-color VGA graphic LCD display for menu driven configuration settings, pump output value, service alerts, tube failure detection (TFD) system and flow verification system (FVS) alarms status, remote input signal values, tubing life timer value. Display color shall be green when indicating normal operation, blue when in stand- by, and red to indicate an alarm condition exists. 13. Provide for remote stop/start pump via 6-30 VDC powered loop or non-powered contact closure loop. 14. Provide a user selectable 4-20mA and 0-1000Hz output signal which are scalable and proportional to pump output volume. 15. Provide four contact closure alarm outputs. Three rated at 1A-115VAC, 0.8A-30VDC and one rated at 6A-250VAC, 5A-30VDC. Each alarm output shall be assignable to monitor any of the following pump functions: TFD system, FVS system, motor run/stop, motor failed to respond to commands, motor is running in reverse, general alarm (TFD, FVS, and/or motor over current), input signal failure, output signal failure, remote/local control status, revolution counter (tube life) set-point, or monitor which of the nine different pump operating modes is currently active. 16. Provide a four digit password protected configuration menu. 17. Provide a flow verification system with programmable alarm delay time from 1-255 seconds. FVS system shall monitor the FVS flow sensor while pump is running only. System shall not monitor pump while not running. 18. Provide a roller revolution counter display (tube life indicator) with user programmable alarm set-point value from 1 to 999,999,999 revolutions which can be assigned to any one
WRCRWA VARIABLE SPEED PERISTALTIC PUMP PLANT EXPANSION PROJECT 227565-5
of the 4 contact closure alarm outputs. 19. Provide a user programmable maximum RPM (revolutions per minute) set-point value. 20. Provide a user adjustable response delay time from 0 to 999.9 seconds for the remote start/stop input and the four contact closure alarm outputs to facilitate closed-loop applications. 21. Provide a power interruption pump restart option which is user programmable to either automatically restart or require a user re-start if AC mains power is interrupted.
PART 3 –EXECUTION
3.1 INSTALLATION
A. Contractor shall install items in accordance with manufacturer's printed instructions and as indicated and specified. Control panels for outdoor installations shall be provided with shade structures and installed to minimize exposure to sunlight.
B. Contractor to supply fittings for connection of pump to process.
3.2 SPARE PARTS
A. Contractor furnished package from the supplier shall include all recommended spare parts, including but not limited to:
1. Two (2) M3 tubes 2. Two (2) M3 roller assemblies
END OF SECTION 227565
WRCRWA VARIABLE SPEED PERISTALTIC PUMP PLANT EXPANSION PROJECT 227565-6
SECTION 227590 – SUBMERSIBLE DEWATERING PUMP
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall provide and install submersible dewatering pump (s) in structure sumps as indicated in the contract drawings.
1.2 SUBMITTALS
A. Shop Drawings: Submittals shall be made in accordance with Section 013300 – Contractor Submittals.
B. Spare Parts List: The Contractor shall obtain from the manufacturer and submit at the same time as Shop Drawings a list of provided spare parts for each piece of equipment. Contractor shall also furnish the name, address, and telephone number of the nearest distributor for each piece of equipment.
C. Operation and Maintenance Manual: Provide technical operation and maintenance manuals in accordance with Section 017823.
1.3 QUALITY ASSURANCE
A. Warranty: Each pump shall be supplied with manufacturer’s standard warranty of one (1) year from substantial completion.
PART 2 - PRODUCTS
2.1 GENERAL CONDITIONS
A. The pump manufacturer shall ensure that the pumps can operate in the following general conditions:
Operation Intermittent Drive Constant Speed Ambient Environment Outdoors Ambient Temperature 30 to 105 ¡F Fluid Service: Storm Water
2.2 PUMP PERFORMANCE REQUIREMENTS
A. Each pump shall satisfy the performance requirements as indicated in the design drawings. WRCRWA SUBMERSIBLE DEWATERING PUMP PLANT EXPANSION PROJECT 227590- 1
2.3 PUMP REQUIREMENTS
A. Discharge size = 2” NPT
B. Maximum solids 2”
C. Materials of construction:
1. Pump body and motor casing: AISI 304 SS 2. Impeller: AISI 304 SS 3. Motor shaft: AISI 304 SS 4. Suction strainer: AISI 304 SS 5. Elastomers: BUNA-N
2.4 PUMP MOTOR:
A. The pump motor shall have a class F insulation.
B. The motor shall be three-phase, 460 V.
C. Power cord supplied shall be a minimum 20 feet.
2.5 SPARE PARTS
A. The contractor shall supply manufacturer recommended spare parts.
2.6 ACCEPTABLE PUMP MANUFACTURERS
A. Goulds Pumps (Basis-of-Design)
B. Or equal
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install in strict accordance with the manufacturer’s instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations. Anchor bolts shall be set in accordance with the manufacturer’s recommendations.
B. Upon completion of the installation, the contractor shall submit a certificate from the manufacturer stating that the installation of the equipment is satisfactory, that the equipment is
WRCRWA SUBMERSIBLE DEWATERING PUMP PLANT EXPANSION PROJECT 227590- 2
ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
3.2 VERIFICATION OF PERFORMANCE
A. The Contractor shall field test all pumps after installation to demonstrate satisfactory operation without excessive noise, vibration, cavitation or over-heating. Any pump which fails to meet any of the contract specifications will be modified, repaired or replaced by the Contractor at no additional cost to the owner.
END OF SECTION 227590
WRCRWA SUBMERSIBLE DEWATERING PUMP PLANT EXPANSION PROJECT 227590- 3
SECTION 227600 – HORIZONTAL CENTRIFUGAL CHOPPER PUMPS
PART 1 - GENERAL
1.1 SUMMARY
A. The Vendor shall furnish centrifugal, dry well horizontal chopper pump(s) and all appurtenances as specified. The pump shall be specifically designed to pump waste solids at heavy consistencies. Materials shall be macerated and conditioned by the pump as an integral part of the pumping action. The pump must have demonstrated the ability to chop through and pump high concentrations of solids such as plastics, heavy rags, grease and hair balls, wood, paper products and stringy materials without plugging, both in tests and field applications.
1.2 QUALITY ASSURANCE AND PERFORMANCE AFFIDAVIT
A. The contractor shall submit manufacturer's standard warranty and a performance affidavit for equipment to be furnished in accordance with this section. The warranty for workmanship and materials shall be manufacturer's standard for 1 year from startup, not to exceed 18 months from factory shipment. In the performance affidavit, the manufacturer must certify to the Contractor and the Owner, that the Contract Documents have been examined, and that the equipment will meet in every way the performance requirements set forth in the Contract Documents for the application specified. Shop drawings will not be reviewed prior to the receipt by the Engineer of an acceptable performance affidavit. The performance affidavit must be signed by an officer of the company manufacturing the equipment, and witnessed by a notary public. The performance affidavit must include a statement that the equipment will not clog or bind on solids typically found in the application set forth.
1.3 QUALIFICATIONS
A. To assure unity of responsibility, the pumps and motors, shall be furnished and coordinated by the pump manufacturer. The Contractor shall assume full responsibility for the satisfactory operation of the entire pumping systems including pumps, motors, and controls as specified.
B. The equipment covered by these Specifications shall be standard units of proven ability as manufactured by competent organizations having long experience in the production of such equipment. The pumps shall be the standard cataloged product of the Manufacturer. The pumps furnished shall be designed, constructed and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed. Pumps shall be manufactured in accordance with the Hydraulic Institute Standards, except as otherwise specified herein.
C. All Equipment furnished under this Specification shall be new and unused and shall be the standard product of Manufacturers showing a successful record of manufacturing and servicing the equipment and systems specified herein for a minimum of five (5) years.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-1
D. The Manufacturer shall be fully responsible for the design, arrangement and operation of all connected rotating components of the assembled pumping unit to ensure that neither harmful nor damaging vibrations occur within the specified operating range. Design shall include fabricated steel base plate for mounting the units.
1.4 SUBMITTALS
A. Copies of all materials required to establish compliance with the specifications shall be submitted in accordance with the provisions of Section 013300. The submittal format shall be in the form of a booklet, suitably tabbed and divided to cover at least the areas noted below for each major equipment item. The submittal booklet shall include adequate detail and sufficient information for the Engineer to determine that all of the equipment proposed meets the detailed requirements of the Specifications. Incomplete or partial submittals will not be reviewed. Submittals shall include at least the following:
1. Certified shop and erection drawings showing all important details of construction, dimensions and anchor bolt locations. 2. Descriptive literature, bulletins and/or catalogs of the equipment. 3. Data on the characteristics and performance of each pump. Data shall include guaranteed performance curves, based on actual shop tests of similar units, which show that they meet the specified requirements for head, capacity and horsepower. Curves shall be submitted on 8 ½” by 11” sheets, at as large a scale as is practical. Catalog sheets showing a family of curves will not be acceptable. 4. A complete total bill of materials of all equipment (may be furnished with Operation and Maintenance manuals specified under paragraph 1.5). 5. A list of the Manufacturer’s recommended spare parts, in addition to those specified in paragraph 1.06 with the manufacturer’s current price for each item, shall be supplied. Include gaskets, packing, etc. on the list. List bearings by the bearings manufacturer’s numbers only. 6. Complete motor and control systems data.
B. Test Reports to be Submitted:
1. A schedule of the date of shop testing and delivery of the equipment to the job site. 2. Description of pump factory test procedures and equipment. 3. Copies of all tests results, as specified.
C. Complete operating and maintenance instructions shall be furnished for all equipment included under these specifications. The maintenance instructions shall include trouble shooting data and full preventative maintenance schedules and complete spare parts lists with ordering information.
D. Submit the Manufacturer’s Certificate of Installation, Testing and Instruction.
E. In the event that it is impossible to conform with certain details of the specifications due to different manufacturing techniques, describe completely all non-conforming aspects.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-2
1.5 OPERATING INSTRUCTIONS
A. Operating and maintenance manuals shall be furnished. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc., that are required to instruct operation and maintenance personnel unfamiliar with such equipment.
B. A trained instructor, with complete knowledge of proper operation and maintenance for all major components, shall be provided for two days to instruct representatives of the Owner and the Engineer on proper operation and maintenance. With the Owner’s permission, this work may be conducted in conjunction with the inspection of the installation and test run as provided under PART 3. If there are difficulties in operation of the equipment due to the Manufacturer’s design or fabrication, additional service shall be provided at no cost to the Owner.
1.6 TOOLS AND SPARE PARTS
A. One (1) set of all special tools required for normal operation and maintenance shall be provided. All such tools shall be furnished in a suitable steel tool chest complete with lock and duplicate keys.
B. The contractor shall supply manufacturer recommended spare parts, including the following:
1. Three (3) ¾” x 4” stainless steel bolts with nuts. 2. One (1) spare cutter bar. 3. One (1) spare impeller. 4. One (1) spare upper cutter. 5. One (1) spare cutter nut. 6. One (1) spare mechanical seal. 7. One (1) seal spanner wrench.
C. Spare Parts shall be properly bound and labeled for easy identification without opening the packaging and suitably protected for long term storage.
1.7 PRODUCT HANDLING
A. All parts shall be properly protected so that no damage deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation.
B. All equipment and parts must be properly protected against any damage during a prolonged period at the site.
C. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer.
D. Finished surfaces of all exposed pump openings shall be protected by wooden blanks, strongly built and securely bolted thereto.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-3
E. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.
F. After hydrostatic or other tests, all entrapped water shall be drained prior to shipment, and proper care shall be taken to protect parts from the entrance of water during shipment, storage and handling.
G. Each box or package shall be properly marked to show its net weight in addition to its contents.
1.8 WARRANTY
A. All equipment supplied under this section shall be warranted for a period of one (1) year from startup by the Contractor and the Manufacturer.
B. The equipment shall be warranted to be free from defects in workmanship, design and materials. If any part of the equipment should fail during the warranty period, it shall be replace in the machine(s) and the unit(s) restored to service at no expense to the Owner.
C. The Manufacturer’s warranty period shall run concurrently with the Contractor’s warranty period. No exception to this provision shall be allowed.
PART 2 - PRODUCTS
2.1 GENERAL
A. The equipment covered by these Specifications shall be standard units of proven ability as manufactured by reputable concerns having long experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed as shown on the Drawings.
B. All equipment shall be designed and built for 24-hour continuous service at any and all points within the specified range of operation, without overheating, without cavitation, and without excessive vibration or strain.
C. The pumping units required under this section shall be complete. All parts shall be so designed and proportioned as to have liberal strength, stability, and stiffness and to be especially adapted for the service to be performed. Ample room for inspection, repairs and adjustment shall be provided.
D. Stainless steel nameplates giving the name of the Manufacturer, the rated capacity, head, speed and all other pertinent data shall be attached to each pump, motor, and control panel.
E. All working parts of the pumps and motors, such as bearings, wearing rings, shaft, sleeves, etc., shall be standard dimensions built to limit gauges or formed to templates, such tat parts will be interchangeable between like units and such that the Owner may, at any time in the future, obtain replacement and repair parts for those furnished in the original machines.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-4
F. The nameplate ratings of the motors shall not be exceeded, nor shall the design service factor be reduced when the pump is operating at any point on its characteristic curve at maximum speed.
G. Mechanical equipment, including drives and electric motors shall be supplied and installed in accordance with applicable OSHA regulations. Stainless steel guards shall be installed on all rotation assemblies. The noise level of motors, unless otherwise noted, shall not exceed 85 dBA measured 3 meters from the unit under free field conditions while operating on utility power.
H. All lubrication fitting shall be brought to the outside of all equipment so that they are readily accessible from the outside without the necessity of removing covers, plates, housings, or guards.
2.2 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with these specifications, provide products by one of the following:
1. Vaughan, Inc. (Basis-of-Design) 2. Or equal.
B. It is the express intent of these specifications to accurately describe equipment that is a regular production item of the specified manufacturer, and that has a proven record of performance in identical (not just similar) applications in other treatment facilities. The chopper pump manufacturer shall have a minimum of twenty (20) years of documented experience in the design and production of chopper pumps of all types, and not less than five (5) years of experience in the production of the exact equipment as specified herein.
2.3 PUMPS
A. Design Criteria:
1. Use design criteria shown in the drawings (pump schedule):
B. Performance Requirements:
1. There shall be no significant change in vibration and noise level over the entire listed range of operating conditions of operating conditions of the pumping system. 2. Maximum motor speed shall not exceed 1800 rpm. 3. A motor sizing shall provide a minimum of 25% reserve hp as evidenced by specific requirements at maximum design condition on the certified performance curve. 4. Pumps shall not exceed 60Hz when operating at design conditions.
2.4 PUMP CONSTRUCTION
A. Casing and Back Pull-Out Adapter Plate: The pump casing shall be of semi-concentric design, with the first half of the circumference being cylindrical beginning after the pump outlet, and the remaining circumference spiraling outward to the 150 lb. flanged centerline discharge. Back pull-out adapter plate shall allow removal of pump components from above the casing, and allow external adjustment of impeller-to-cutter bar clearance. Casing and adapter plate
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-5
shall be ductile cast iron with all water passages to be smooth, and free of blowholes and imperfections for good flow characteristics.
B. Impeller: Shall be semi-open type with pump out vanes to reduce seal area pressure. Chopping/maceration of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter bar at the intake openings, with a set clearance between the impeller and cutter bar of .010" to .015". Impeller shall be cast steel heat treated to minimum Rockwell C 60 and dynamically balanced. The impeller shall be keyed to the shaft and shall have no axial adjustments or set screws required.
C. Cutter Bar Plate: Shall be recessed into the pump bowl and shall contain at least 2 shear bars extending diametrically across the intake opening to within 0.010-0.015” of the rotating cutter nut tooth, for the purpose of preventing intake opening blockage and wrapping of debris at the shaft area. Chopper pumps utilizing individually mounted shear bars shall not be acceptable. Cutter bar shall be T1 plate steel heat-treated to minimum Rockwell C 60.
D. Cutter Nut: The impeller shall be secured to the shaft using a special cutter nut, designed to cut stringy materials and prevent binding. The cutter nut shall be cast steel heat treated to minimum Rockwell C 60.
E. Upper Cutter: Shall be threaded into the back pull-out adapter plate above the impeller, designed to cut against the pump-out vanes and the impeller hub, reducing and removing stringy materials from the mechanical seal area. Upper cutter shall be cast steel heat treated to minimum Rockwell C 60.
F. Pump Shafting: The pump shaft and impeller shall be supported by ball bearings. Shafting shall be heat-treated steel, with a minimum diameter of 1.5 inches in order to minimize deflection during solids chopping.
G. Bearings: Shaft thrust in both directions shall be taken up by two back-to-back mounted single- row angular contact ball bearings. Two single-row radial bearings shall also be provided. Bearings shall be rated with a minimum B10 bearing life of 100,000 hours.
H. Bearing Housing: Shall be cast iron, and machined with piloted bearing fits for concentricity of all components. Bearing housing shall have oil bath lubrication using ISO Gr. 46 turbine oil and a side mounted site glass to provide a permanently lubricated assembly. Viton¨ double lip seals riding on stainless steel shaft sleeves are to provide sealing at each end of the bearing housing.
I. Seal: 1. Flushless Mechanical Seal system specifically designed to require no seal flush through the elimination of the stuffing box: The seal shall be cartridge-type with Viton O-rings and silicon carbide faces. The cartridge seal shall be pre-assembled and pre-tested so that no seal settings or adjustments are required. Any springs used to push the seal faces together must be shielded from the fluid to be pumped. The cartridge shall also include a 17-4PH, heat-treated seal sleeve and an ASTM A536 ductile iron seal gland. The mechanical seal faces shall be lubricated and cooled by a separate oil chamber.
J. Inlet Manifold: The pump assembly shall be mounted horizontally with a 150 lb. standard inlet flange, drain, cleanout and mounting feet.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-6
K. Shaft Coupling: Bearing housing and motor stool design is to provide accurate, self-aligning mounting for a C-flanged electric motor. Pump and motor coupling shall be T.B. Woods Sureflex elastomeric type.
L. Optional Belt Drive: Adjustable brackets shall be used to support an over-head mounted motor. Sheaves and belts shall be properly sized for horsepower ratings, and all guards are to be supplied with the belt drive system.
M. Stainless Steel Nameplates: Shall be attached to the pump and drive motor giving the manufacturer's model and serial number, rated capacity, head, speed and all pertinent data.
N. Spare Parts to be Furnished
1. One (1) set of mechanical seals and o-rings for each pump.
2.5 MOTORS
A. General:
1. The motors shall be suitable for wash down and extreme outdoor duty. 2. All motors shall be built in accordance with latest NEMA, IEEE, ANSI and AFBMA standards where applicable. 3. Motors shall conform to all requirements stipulated in the motor section of this specification. Motors shall be 460 V, 3-phase, TEFC with Class F insulation and have a 1.15 service factor. 4. The motors supplied shall be specifically designed for inverter duty to allow for the potential of future variable frequency drives. The motors shall be compatible with the pumps provided by the Manufacturer. 5. For pumps located with a Class 1 Division 1 environment, explosion-proof motors shall be provided.
2.6 PUMP DISCHARGE GAUGES
A. Pump Discharge Gauges: The Contractor shall furnish and install for each pump in tapped holes in the discharge piping to accommodate discharge gauges which shall be supplied by the Contractor as shown on the Drawings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Installation in strict accordance with the Manufacturer’s instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the Manufacturer’s recommendations. Anchor bolts shall be set in accordance with the Manufacturer’s recommendations.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-7
B. Upon completion of the installation, the Contractor shall submit a certificate from the Manufacturer stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
3.2 SHOP PAINTING
A. Before exposure to weather and prior to shop painting all surfaces shall be thoroughly cleaned, dry and free from all mill-scale, rust, grease, dirt and other foreign matter.
B. All exposed portions of the pumps and motors shall be coated with acrylic epoxy paint.
C. All nameplates shall be properly protected during painting.
3.3 FIELD PAINTING
A. Touch-up field painting shall be done by the contractor in accordance with the pump manufacturer’s recommendations.
B. All nameplates shall be properly protected during painting.
3.4 INSPECTION AND TESTING
A. General:
1. The Engineer shall have the right to inspect, test or witness tests of all materials or equipment to be furnished under these specifications, prior to their shipment from the point of the manufacture. 2. The Engineer shall be notified in writing prior to initial shipment, in ample time so that arrangements can be made for inspection by the Engineer. 3. Field tests shall not be conducted until such time that the entire installation is complete and ready for testing.
B. Factory Pump Tests:
1. Factory testing in accordance with the standards of the Hydraulic Institute shall be required for all pumps. 2. Certified pump performance curves shall be submitted, including head, capacity, and brake horsepower, for each pump supplied. 3. Prior to conducting a pump test, notification of such test and a list of test equipment and test procedures shall be forwarded to the Engineer at least ten working days before the schedule test date. All electronic transducers, meter, gauges, and other test instruments shall have been calibrated in accordance with the requirements of the Hydraulic Institute Standards. Copies of calibration data shall be provided. 4. All pumps shall be tested at full speed and complete staging through the specified range of flow, and head/capacity/efficiency curves plotted at maximum output speed. During each test, the pump shall be run at each head condition for sufficient time to accurately determine discharge, head, power input, and efficiency.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-8
5. If any pump tested fails to meet any specification requirement it will be modified until it meets all specification requirements. If any pump tested fails to meet the efficiency requirements at any of the listed flow or head conditions listed and all reasonable attempts to correct the inefficiency are unsuccessful, the pump(s) shall be replaced with units(s) which meet the specified requirements.
C. Field Inspection and Owner Instruction:
1. The Contractor shall furnish the services of the Manufacturer’s field service technician, who has complete knowledge of proper operation and maintenance of the equipment, for a period of not less than two (2) days to inspect the installed equipment, supervise the initial test run, and to provide instruction to the plant personnel. The first visit shall be checking and inspecting the equipment after it is installed. The second visit will be to operate and supervise the initial field test. 2. At least one (1) of the two (2) days shall be allocated solely to instruction of plant personnel in operation and maintenance of the equipment. The instruction period shall be scheduled at least 10 days in advance with the Owner and shall take place prior to start up and acceptance by Owner. The final copies of operation and maintenance manuals specified must be delivered to the Engineer prior to scheduling the instruction period with the Owner with the permission of the Engineer, these services may be combined with those specified by Paragraph 1.5.
D. Field Pump Tests:
1. In the presence of the Engineer such tests as necessary to indicate that the pumps and motors conform to the operating conditions specified shall be performed. A 30-day operating period of the pumps will be required before acceptance. If a pump performance does not meet the specified requirements, corrective measures shall be taken. All test procedures shall be in accordance with factory test procedures specified above and certified results of tests shall be submitted. Provide, calibrate and install all temporary gauges and meters, make necessary tapped holes in the pipes, and install all temporary piping and wiring required for the field acceptance tests. Written test procedures shall be submitted to the Engineer for approval 30 days prior to testing. 2. Noise and vibration tests shall be conducted in conformance with the Hydraulics Institute Test Codes and OSHA Standards of Occupational Noise Exposure. Maximum allowable noise level, corrected for background sound, shall not exceed 85 dBA when measured at a horizontal distance of 3 meters from the equipment being tested, at a height of 3 meters above floor level. The actual natural frequency of the installed pumping units will be verified using industry accepted procedures. 3. All pumps operating settings, alarms, controls, and shutdown devices shall be calibrated and tested ruing the field tests. 4. The Contractor shall furnish all power, water, facilities, labor, materials, supplies and test instruments required to conduct field test. 5. Deliver to the Engineer, upon completion of satisfactory testing of the equipment, reports as specified in Part 1.
E. Field Electric Control System Tests: 1. The electric control system shall be test operated for proper functioning prior to the pump mechanical test. The control system shall be checked out using simulated operating signals as per pump Manufacturer’s recommendations.
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-9
2. The Contractor shall check all drives for correct clearances, alignment and lubrication in accordance with Manufacturer’s instructions. The Contractor shall check direction of rotation of all motors and reverse connections if necessary.
F. Field Alarm System Testing:
1. Check each alarm and detection device for proper operation.
END OF SECTION 227600
WRCRWA HORIZONTAL CENTRIFUGAL CHOPPER PUMPS PLANT EXPANSION PROJECT 227600-10
SECTION 227650 – HORIZONTAL END SUCTION PUMPS
PART 1 - GENERAL
1.01 WORK INCLUDED
A. The Contractor shall provide horizontal ANSI end suction pumps, with horizontal electric motors and all appurtenant work, complete and operable, in accordance with the Contract Documents.
B. The Supplier shall examine the site conditions, intended application, and operation of the pump system and recommend the pump which will best satisfy the indicated requirements.
1.02 REFERENCE STANDARDS
A. Pumps shall be in accordance with ANSI/ASME B73.1 M – Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process.
1.03 SUBMITTALS
A. Shop Drawings: Submittals shall be made in accordance with Section 013300 – Contractor Submittals.
B. Spare Parts List: The Contractor shall obtain from the manufacturer and submit at the same time as Shop Drawings a list of provided spare parts for each piece of equipment. Contractor shall also furnish the name, address, and telephone number of the nearest distributor for each piece of equipment.
C. Operation and Maintenance Manual: Provide technical operation and maintenance manuals in accordance with Section 017823.
1.04 QUALITY ASSURANCE
A. Warranty: Each pump shall be supplied with manufacturer’s standard warranty of one (1) year from substantial completion.
PART 2 – PRODUCTS
2.01 GENERAL CONDITIONS
A. The pump manufacturer shall ensure that the pumps can operate in the following general conditions:
Location Flash Mix Pump Station Operation Intermittent Drive Single Ambient Environment Outdoor Temperature Ambient
WRCRWA HORIZONTAL END SUCTION PUMPS PLANT EXPANSION PROJECT 227650-1
B. The work of this section shall be suitable for long term operation under the following operating conditions:
Fluid Service Secondary Clarifier Effluent Fluid Temperature 50-70 OF Fluid Specific Gravity 1.0 Project Site Elevation 600 ft
2.02 PUMP PERFORMANCE REQUIREMENTS
Each pump shall satisfy the performance requirements as indicated in the design drawings.
2.03 PUMP REQUIREMENTS
A. Construction of horizontal end suction pumps shall conform to the following requirements:
No. Item Description 316 SS, self-venting top centerline discharge 1 Casing, Foot-Mounted with a fully continues gasket 2 Impeller 316 SS 3 Shaft 4140 Steel 4 Shaft Sleeve 316 SS 5 Seal Mechanical seal, flushing as required 6 Mounting Foot Mounted Steel-Double Row Ball 7 Bearings Min. life of two years 8 Lubrication Grease with inlet and drain fittings
B. Motor: The pump motor shall be of the horsepower shown in the design drawings. Pumps requiring a larger horsepower will not be accepted.
C. Drive: Direct drive with flexible coupling with TEFC, premium efficient, horizontal, electric motor suitable for 480 volt, 3 phase, 60 Hz power supply.
D. Noise: Each pump shall be capable of continuous operation without producing noise in excess of the Hydraulic Institute and OSHA guidelines.
2.04 PROTECTIVE COATING
A. Manufacturer to apply a 2-part epoxy finish, Tnemec series 1074 Endura-Shield II Top coat or equal. Epoxy coating will be continuous over the entire surface of the pumps.
2.05 SPARE PARTS
A. The following spare parts shall be furnished for each pump:
1. One set of mechanical seals 2. One set of all bearings 3. One shaft sleeve 4. Two sets of O-ring and Gasket kits. WRCRWA HORIZONTAL END SUCTION PUMPS PLANT EXPANSION PROJECT 227650-2
2.06 ACCEPTABLE PUMP MANUFACTURERS
A. Peerless Pump Company:
B. Or Equal
PART 3 – EXECUTION
3.01 VERIFICATION OF PERFORMANCE
A. The Contractor shall field test all pumps after installation to demonstrate satisfactory operation without excessive noise, vibration, cavitation or over-heating. Any pump which fails to meet any of the contract specifications will be modified, repaired or replaced by the Contractor at no additional cost to the owner.
END OF SECTION 227650
WRCRWA HORIZONTAL END SUCTION PUMPS PLANT EXPANSION PROJECT 227650-3
SECTION 227700 –HOT WATER RECIRCULATION PUMP
PART 1 - GENERAL
1.1 SUMMARY
A. Furnish and install as shown on the plans hot water centrifugal, in-line, single head pump(s).
1.2 CONDITIONS OF OPERATION
A. Each pump shall be capable of providing the hydraulic conditions shown in Pump Schedule.
1.3 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation.
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings for each type of pump, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of pump. Include this data, product data, shop drawings in maintenance manual; in accordance with requirements of Section 017823.
1.4 SUBMITTALS
A. Pump manufacturer shall have a minimum of five (5) installations in the US with a minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 REQUIREMENTS
A. Pump End: The pump end shall be of the in-line, multi-stage design with the motor mounted directly to the pump. The pump models shall be furnished as shown on the plans and installed in accordance with the recommendations of the manufacturer. The pump shall be capable of operating continuously at temperatures from 32¡ F to 284¡ F.
B. The pump suction/discharge chamber, pump head, motor stool and shaft coupling shall be constructed of cast iron. The impellers shall be constructed of stainless steel, laser welded through the front and back shrouds to the impeller vanes for increased efficiency. The shaft seal is a corrosion resistant maintenance free mechanical seal.
WRCRWA HOT WATER RECIRCULATION PUMP PLANT EXPANSION PROJECT 227700-1
C. The pumps shall be equipped with a cartridge seal, replaceable without disassembling the pump for all pump sizes. The seal shall be replaceable without removing the motor. Sleeve sealing shall be an O-ring design, allowing sleeve expansion and contraction without leaking.
D. Pumps shall be capable of local manual (hand) and system auto operation and shall be compatible with VFD operation. Refer to Electrical (Division 26) and Control (Division 40) for additional details regarding these requirements.
E. Motor: The motor shall be TEFC. The motor shall be a 3 phase AC motor operating at a nominal 1725 RPM with a minimum service factor of 1.15.
2.2 SPARE PARTS
A. Include all spare parts as recommended by manufacturer.
2.3 MANUFACTURERS:
A. Subject to compliance with the specifications given herein, the following manufacturers are acceptable:
1. Grundfos 3.0 LM 6/6.6 #48268045 (Basis-of-Design) 2. Or equal
2.4 VIBRATION LIMITATIONS
A. The limits of vibration as set forth in the standards of the Hydraulic Institute shall govern.
2.5 TESTING
A. The pumps shall be tested at the manufacturer’s plant before shipment in accordance with the Hydraulic Institute Standards. Certified copies of the test curves shall be submitted to the engineer.
2.6 QUALITY ASSURANCE
A. Pumps are to be engineered and manufactured under a written Quality Assurance program. The Quality Assurance program is to be in effect for at least five (5) years, to include a written record of periodic internal and external audits to confirm compliance with such program.
PART 3 - EXECUTION
3.1 INSTALLATION
WRCRWA HOT WATER RECIRCULATION PUMP PLANT EXPANSION PROJECT 227700-2
A. Install in strict accordance with the manufacturer’s instructions and recommendations in the locations shown on the Drawings. Installation shall include any alignment, anchoring or grouting required for proper installation. Additionally, installation shall include furnishing the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations. Anchor bolts shall be set in accordance with the manufacturer’s recommendations.
B. Upon completion of the installation, the contractor shall submit a certificate from the manufacturer stating that the installation of the equipment is satisfactory, that the equipment is ready for operation, and that the operating personnel have been suitably instructed in the operation, lubrication and are of each unit.
END OF SECTION 227700
WRCRWA HOT WATER RECIRCULATION PUMP PLANT EXPANSION PROJECT 227700-3
SECTION 227750 – CENTRIFUGAL HOT WATER BOOSTER PUMP
PART 1 - GENERAL
1.1 SUMMARY
A. Contractor shall provide vertical, non-self-priming, multi stage, in-line, centrifugal pumps and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 220513 “Common Motor Requirements for Equipment” apply to this section.
C. The Supplier shall examine the Site conditions, intended application, and operation of the pump system and recommend the pump which will best satisfy the indicated requirements.
D. A Non-Witness Factory Performance Test will be performed on each unit, the performance will include measuring flow and head at rated design condition, testing may be at a reduced speed measuring flow and head corresponding to the rated condition when adjusting for speed using the appropriate affinity laws. Use of a test diver is permitted for factory tests. Record measured Flow, Suction Pressure, Discharge Pressure and make observations on bearing temperatures and noise level. Factory Test will be signed by a licensed engineer employed by the pump manufacture. Any testing performed outside of the pump manufacture’s facility will not be considered or accepted.
E. Anchor Bolt Calculations will be submitted to engineer for approval prior to ordering of pumping equipment. Calculations to be done by a licensed design engineer in the State of California.
F. Provide startup and training services as outlined in Section 017900 “Demonstration and Training”.
1.2 CONDITIONS OF OPERATION
A. The operating point of each pump shall be variable flow capable of flow and head capacities as shown in the Drawings.
B. Service is for closed loop hot water circulation system. The pump shall be designed for continuous operation and pumping of hot water up to a temperature of 248˚F.
1.3 WARRANTY
A. The warranty period shall be a non-prorated period of 2 years from date of substantial completion, not to exceed 30 months from date of manufacture.
1.4 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation. WRCWRA CENTRIFUGAL HOT WATER BOOSTER PUMPS PLANT EXPANSION PROJECT 227750-1
B. Shop Drawings: Submit manufacturer's assembly-type (exploded view) shop drawings for each type of pump, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of pump. Include this data, product data, and shop drawings in the Operations and Maintenance manual; in accordance with requirements of Section 017823. “Operation and Maintenance Data”.
1.5 QUALITY ASSURANCE
A. Pump manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 GENERAL REQUIREMENTS
A. Pump shall meet full performance range indicated in the pump schedule in the Contract Drawings including minimum flows, maximum flows, at the design pressure(s) indicated. Efficiencies shall be no less than 5% of the efficiency of the pump indicated in the pump schedule for all design points. For alternate pump suppliers, provide pump performance information to Engineer for approval prior to submitting bids. Contractor responsible for providing pump with satisfactory materials of construction and performance if pump other than that indicated in the schedule is to be provided
B. Pump motor shall be heavy-duty premium efficiency NEMA C face TEFC and be capable of use with a variable speed drive. The motors shall comply with the requirements of Specification 220513, “Common Motor Requirements for Plumbing Equipment.”
C. Service is for closed loop hot water circulation system. The pump shall be designed for continuous operation and pumping of hot water up to a temperature of 248˚F.
D. Materials of construction:
1. Pump Housing: Cast iron EN-JS 1050 DIN W.-Nr. 80-55-06 ASTM. 2. Pump Head/Base: Cast iron 3. Impeller: Stainless steel ANSI 304 4. Mounting: On a foundation 5. Motor: TEFC, 3-phase AC motor operating at a nominal 3450 RPM with a minimum service factor of 1.15.
2.2 ACCEPTABLE MANUFACTURERS
A. All products must fully comply with these specifications. Standard product must be modified, if required, for compliance.
1. Grundfos Pump Corporation CR 64-1-1 Product # 96418857 (Basis of Design) 2. Or equal WRCWRA CENTRIFUGAL HOT WATER BOOSTER PUMPS PLANT EXPANSION PROJECT 227750-2
2.3 SPARE PARTS
A. Include all spare parts as recommended by manufacturer.
2.4 ELECTRICAL AND CONTROLS
A. Pumps shall be capable of local manual (hand) and system auto operation and shall be compatible with VFD operation. Refer to Electrical (Division 26) and Control (Division 40) for additional details regarding these requirements.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Contractor shall install pump equipment as recommended by the pump manufacturer.
B. Contractor shall provide startup and training services from a certified representative of the pump manufacturer. Contractor shall coordinate pump operation requirements with electrical system and associated equipment utilizing the booster pumps.
C. The inspection, startup, and field adjustment services required for all of the end-suction pumps listed shall be furnished in at least 1 separate trip to the project site.
D. Tests for acceptable vibration will be made at no additional cost to the owner in field on each pump system. . All field tests will be running tests with the pump pumping product for which it is intended and each pump system will be tested separately with no other pumps running. All tests will be done in the presence of the design engineer or owner representative. Amplitude as used in this specification will mean peak to peal displacement, the requirement for testing for acceptable vibration will be the measurement of this peak to peak displacement at 5 separate points on the motor and five separate points on the discharge head. The vibration tests will be performed by using a vibxpert manufactured by pruftechnik or equal.
END OF SECTION 227750
WRCWRA CENTRIFUGAL HOT WATER BOOSTER PUMPS PLANT EXPANSION PROJECT 227750-3
SECTION 229000 – SINGLE STAGE AIR COMPRESSOR
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: 1. Single stage stationary air compressor
1.2 ACTION SUBMITTALS
A. Product Data: Submit manufacturer’s technical product data and installation instructions for compressor units in accordance with Section 013300.
1.3 DELIVERY STORAGE AND HANDLING
A. Deliver product only after proper facilities are available.
B. Deliver and store packaged products in original containers with seals unbroken and labels intact until time of use.
1.4 WARRANTY
A. Provide manufacturer’s standard warranty.
PART 2 - PRODUCTS
A. Acceptable Manufacturers
1. Ingersoll Rand, 2. Or equal.
B. Furnish and install one (1) single stage stationary air compressor with a 60 gallon integral tank mounted. The tank shall be sized to provide a minimum of 10 cfm at 90 psig and shall be rated for continuous operation. The tank shall include the following features: 1. A manual thermal overload protection of the motor. 2. Belt guard shields flywheel and motor sheave 3. Easy to change filter 4. Weather resistant powder coat finish 5. Automatic stop and start through pressure switch 6. 230-volt, single phase, 60 Hz.
WRCRWA SINGLE STAGE AIR COMPRESSOR PLANT EXPANSION PROJECT 229000 - 1
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: All equipment shall be installed in accordance with manufacturer’s written instructions.
B. Upon completion of the installation, each piece of equipment and each system shall be tested for satisfactory operation without leakage, excessive noise, vibration, overheating, etc. all equipment must be adjusted and checked for misalignment, clearance, supports, and adherence to safety standards.
END OF SECTION 229000
WRCRWA SINGLE STAGE AIR COMPRESSOR PLANT EXPANSION PROJECT 229000 - 2
SECTION 230000 – GENERAL HEATING, VENTILATION, AND AIR CONDITIONING
PART 1 - GENERAL
1.1 SUMMARY
A. Drawings and general provisions of Contract, including General and Special Conditions and Division-1 Specification sections, apply to work of this section.
B. Refer to other Division 23-sections for ductwork and ductwork accessories required in conjunction with work of this section.
1.2 DESCRIPTION OF WORK:
A. The following HVAC equipment will be provided and installed by the Contractor per this section and as shown in the drawings.
1. Provide wall mounted air conditioner(s) as noted in drawings. 2. Provide exhaust fans as noted in drawings. 3. Provide fixed louvers as noted in drawings. 4. Provide gravity and actuated dampers as noted in drawings. 5. Provide all other HVAC equipment as shown in the drawings.
1.3 QUALITY ASSURANCE
A. Manufacturer’s Qualifications: Firms regularly engaged in manufacture of HVAC equipment of the types materials, and sizes required, whose products have been in satisfactory use in similar services.
B. Installer’s Qualifications: A firm with at least 3 years of successful installation experience on projects with HVAC equipment work similar to that required for this project.
C. Codes and Standards:
1. Refrigeration systems shall be constructed in accordance with ASHRAE Standard ASHRAE 15 “Safety Code for Mechanical Refrigeration”. 2. Refrigeration systems shall meet or exceed the minimum COP/Efficiency levels as prescribed in ASHRAE 90A “Energy Conservation in New Building Design”. 3. Refrigeration units shall be listed by UL and have UL label affixed.
1.4 SUBMITTALS:
A. All submittals shall be made to the Engineer in accordance with Section 013300,Contractor Submittals.
WRCRWA GENERAL HVAC PLANT EXPANSION PROJECT 230000-1 B. Product Data: Submit manufacturer’s technical product data, including rated capacities of selected model, clearly indicated weights, dimensions, required clearances, and methods of assembly of components, furnished specialties and accessories; and installation and start-up instructions.
C. Wiring Diagrams: Submit ladder-type wiring diagrams for power and control wiring required for final installation equipment and control. Clearly differentiate between portions of wiring that are factory-installed and portions to be field-installed.
D. Shop Drawings: Submit manufacturer’s assembly-type shop drawing for each type of HVAC equipment, indicating materials and methods of assembly of components.
E. Maintenance Data: Submit maintenance data, including cleaning instructions for finishes and spare parts lists. Include this data, product data, and shop drawings in maintenance manuals; in accordance with requirements of Division 017823.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Handle HVAC equipment and components carefully to prevent damage, breaking, denting, and scoring. Do not install damaged packaged equipment or components; replace with new.
B. Store packaged HVAC equipment and components in clean dry place off the ground. Protect from weather, dirt, fumes, water construction debris, and physical damage.
C. Comply with Manufacturer’s rigging and installation instructions for unloading packaged HVAC equipment and moving them to final location for installation.
PART 2 - PRODUCTS
2.1 HVAC SCHEDULE:
A. All HVAC equipment is located in the HVAC SCHEDULE in the drawings. The schedule contains the location, service, capacity/size, and models. Where no model is indicated, the Contractor shall appropriately size the equipment and submit it to the Engineer for approval.
PART 3 - EXECUTION
3.1 INSTALLATION:
A. General: Install HVAC equipment in accordance with manufacturer’s installation instructions. Install units plumb and level, unless otherwise recommended by manufacturer, firmly anchored in locations indicated, and maintain manufacturer’s recommended clearances.
WRCRWA GENERAL HVAC PLANT EXPANSION PROJECT 230000-2 3.2 START-UP:
A. Provide the services of a factory-authorized service representative to start-up air conditioning equipment in accordance with manufacturer’s written start-up instructions. Test controls and demonstrate compliance with requirements. Replace damaged or malfunctioning controls and equipment.
3.3 OPERATING AND MAINTENANCE TRAINING:
A. Provide services of manufacturer’s service representative to instruct Owner’s personnel in operation and maintenance of HVAC equipment. Training shall include start-up and shutdown, servicing and preventative maintenance schedule and procedures, and troubleshooting procedures plus procedures for obtaining repair parts and technical assistance.
END OF SECTION 230000
WRCRWA GENERAL HVAC PLANT EXPANSION PROJECT 230000-3 SECTION 230513 - COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes general requirements for single-phase and polyphase, general-purpose, horizontal, small and medium, squirrel-cage induction motors for use on ac power systems up to 600 V and installed at equipment manufacturer's factory or shipped separately by equipment manufacturer for field installation.
1.2 COORDINATION
A. Coordinate features of motors, installed units, and accessory devices to be compatible with the following:
1. Motor controllers. 2. Torque, speed, and horsepower requirements of the load. 3. Ratings and characteristics of supply circuit and required control sequence. 4. Ambient and environmental conditions of installation location.
PART 2 - PRODUCTS
2.1 GENERAL MOTOR REQUIREMENTS
A. Comply with NEMA MG 1 unless otherwise indicated.
2.2 MOTOR CHARACTERISTICS
A. Duty: Continuous duty at ambient temperature of 40 deg C and at altitude of 600 feet above sea level.
B. Capacity and Torque Characteristics: Sufficient to start, accelerate, and operate connected loads at designated speeds, at installed altitude and environment, with indicated operating sequence, and without exceeding nameplate ratings or considering service factor.
2.3 POLYPHASE MOTORS
A. Description: NEMA MG 1, Design B, medium induction motor.
B. Efficiency: Energy efficient, as defined in NEMA MG 1.
C. Service Factor: 1.15.
WRCRWA COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT PLANT EXPANSION PROJECT 230513 - 1 D. Multispeed Motors: Variable torque.
1. For motors with 2:1 speed ratio, consequent pole, single winding. 2. For motors with other than 2:1 speed ratio, separate winding for each speed.
E. Rotor: Random-wound, squirrel cage.
F. Bearings: Regreasable, shielded, antifriction ball bearings suitable for radial and thrust loading.
G. Temperature Rise: Match insulation rating.
H. Insulation: Class F.
I. Code Letter Designation:
1. Motors 15 HP and Larger: NEMA starting Code F or Code G. 2. Motors Smaller than 15 HP: Manufacturer's standard starting characteristic.
J. Enclosure Material: Cast iron for motor frame sizes 324T and larger; rolled steel for motor frame sizes smaller than 324T.
2.4 POLYPHASE MOTORS WITH ADDITIONAL REQUIREMENTS
A. Motors Used with Reduced-Voltage and Multispeed Controllers: Match wiring connection requirements for controller with required motor leads. Provide terminals in motor terminal box, suited to control method.
B. Motors Used with Variable Frequency Controllers: Ratings, characteristics, and features coordinated with and approved by controller manufacturer.
1. Windings: Copper magnet wire with moisture-resistant insulation varnish, designed and tested to resist transient spikes, high frequencies, and short time rise pulses produced by pulse-width modulated inverters. 2. Energy- and Premium-Efficient Motors: Class B temperature rise; Class F insulation. 3. Inverter-Duty Motors: Class F temperature rise; Class H insulation. 4. Thermal Protection: Comply with NEMA MG 1 requirements for thermally protected motors.
2.5 SINGLE-PHASE MOTORS
A. Motors larger than 1/20 hp shall be one of the following, to suit starting torque and requirements of specific motor application:
1. Permanent-split capacitor. 2. Split phase. 3. Capacitor start, inductor run. 4. Capacitor start, capacitor run.
B. Multispeed Motors: Variable-torque, permanent-split-capacitor type.
WRCRWA COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT PLANT EXPANSION PROJECT 230513 - 2 C. Bearings: Pre-lubricated, antifriction ball bearings or sleeve bearings suitable for radial and thrust loading.
D. Motors 1/20 HP and Smaller: Shaded-pole type.
E. Thermal Protection: Internal protection to automatically open power supply circuit to motor when winding temperature exceeds a safe value calibrated to temperature rating of motor insulation. Thermal-protection device shall automatically reset when motor temperature returns to normal range.
PART 3 - EXECUTION (Not Applicable)
END OF SECTION 230513
WRCRWA COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT PLANT EXPANSION PROJECT 230513 - 3 SECTION 233100 - FIBERGLASS REINFORCED DUCT
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall furnish and install fiberglass reinforced plastic (FRP) duct and all appurtenances, complete and in place, all in accordance with the requirements of the Drawings.
B. Section Includes:
1. FRP Piping
1.2 RELATED SPECIFICATIONS
A. Section 220529 – Hangers and Supports for Piping and Equipment
B. Section 013300 – Contractor Submittals
1.3 REFERENCED SPECIFICATIONS, CODES, AND STANDARDS
A. Codes: All codes, as referenced herein, are specified in Section entitled “Reference Standards.”
B. Commercial Standards
1. ASTM D 3567 Practice for Determining Dimensions of “Fiberglass” (Glass- Fiber Reinforced-Thermosetting-Resin) Pipe and Fittings.
2. ASTM C 582 Standard Specification for Contact - Molded Reinforced Thermosetting Plastic (RTP) Laminates for Corrosion - Resistant Equipment.
3. AWWA M-45 American Water Works Manual of Water Supply Practices "Fiberglass Pipe Design"
4. ASTM D 3982 “Standard Specification for Contact Molded “Fiberglass” Duct and Hoods” or NBS PS 15-69 “Custom Contact-Molded Reinforced Polyester Chemical-Resistant Process Equipment”
5. ASTM D 2992 “Standard Practice for Obtaining Hydrostatic Design Basis for Fiberglass Pipe and Fittings”
6. ASTM D 2310 “Standard Classification for Machine-Made “Fiberglass” Pipe
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-1
1.4 SUBMITTALS
A. Shop Drawings
1. The Contractor shall submit Shop Drawings of duct and fittings in accordance with the requirements in the Sections titled “Piping, General” and “Submittals”. 2. Fabrication drawings shall have details on Laminate Sequence used.
B. Additional Submittal Information: The following items shall be submitted:
1. A letter from the resin supplier stating that the material used for this project complies with the specification and meet all corrosion requirements. 2. Design calculations performed by the manufacturer and stamped by a Professional Engineer for record purposes. 3. Duct manufacturer shall submit certified test results in accordance with ASTM 2992. Engineer will confirm that supplier has completed ASTM 2992 testing. 4. Samples shall be representative of the ductwork (construction method and material used) to be supplied on this project
PART 2 - PRODUCTS
2.1 GENERAL
A. Manufacturer: Provide FRP duct as manufactured by one of the following without exception.
1. Belco Manufacturing Company, Inc. 2. Ershigs, Inc. 3. NOV Fiber Glass Systems 4. Smith Fibercast, a Varco Company 5. Or equal.
B. Service conditions:
1. All equipment shall be designed for a minimum working pressure of 12" WC Positive and 12 " WC Negative pressure. Buried duct shall be designed per AWWA M-45 Standards and be rated for H-20 Loading. The minimum wall thickness for all FRP duct shall conform to the following:
a. Wall thickness for internal positive pressure should be determined by ASTM 2310 using duct manufacturers Certified ASTM 2992 HDB test results. A full copy of the HDB testing should be submitted with the wall thickness calculations.
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-2
b.
Duct Inside Minimum Wall Diameter (inches) Thickness (inches)
3 - 16 0.1875 18 - 24 0.220 30 - 36 0.250
2. The fiberglass reinforced plastic (FRP) ductwork shall be designed and fabricated for odor control service to carry warm, moisture-laden air with hydrogen sulfide, mercaptans and other organic and inorganic compounds typically associated with wastewater treatment. 3. Resin:
a. Resin shall be premium corrosion resistant and fire retardant brominated vinyl ester. Resin shall not contain pigments, dyes, colorants or fillers. Product should have a class 1 flame spread rating (25 or less). b. Thixotropic agents may be added to control resin viscosity per resin manufacturer's recommendation. c. Acceptable resins shall be:
1) AOC Vipel K022 2) Ashland Chemical Hetron FR992 3) Interplastics CoRezyn 8442. 4) Or approved equal.
4. Reinforcement:
a. Surfacing veil shall be C glass veil with a silane finish and a styrene soluble binder. b. Chopped strand mat shall be Type E glass minimum 1-1/2 ounces per square foot with silane finish and styrene soluble binder. c. Continuous roving for chopper gun spray up shall be Type E glass. d. Woven roving shall be Type E glass minimum 24 ounces per square yard with a five by four weave. e. Continuous roving for filament winding shall be Type E glass with a silane finish.
C. Construction:
1. All FRP ductwork shall be of filament wound construction for sizes >10" diameter and hand lay-up or filament wound construction for 10" and smaller. Cast pipe with no reinforced internal corrosion barrier or press molded fittings will not be accepted. 2. Maximum allowable deflection for any size ductwork shall be ½ inch between supports and for any size of duct under worse case operating conditions. 3. FRP ductwork shall be designed using a safety factor of 10 to 1 for pressure and 5 to 1 for vacuum without exception. 4. Out-of-roundness of duct shall be limited to 1% of the diameter.
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-3
5. Length of all flanged duct sections shall not vary more than ± 1/2 inch at 70 F. 6. All un-flanged duct shall be square on the ends in relation to the center axis within 7. ± 1/8 inch up to and including 24-inch diameter and within ± 3/16 inch for all diameters greater than 24-inch. 8. Laminates:
a. All ductwork shall have a resin-rich inner surface, an interior corrosion barrier, an interior structural layer and an exterior corrosion layer and UV resistant coating. b. Inner surface: Nominal 10 mils thick composed of a single ply of the C glass surfacing veil embedded in a resin-rich surface. Resin content shall be 90%. c. Interior layer: Nominal 90 mils thick composed of at least two layers of chopped strand mat or equivalent chopped strand. Resin content shall be 75%. d. Structural layer: Type E glass to meet minimum wall thickness as specified. The total wall thickness includes the inner surface.
1) Contact molded structural layer shall include alternate layers of chopped strand mat and woven roving. 2) Filament wound structural layer shall be preceded by a layer of chopped strand mat or spray chop. The structural layer shall consist of a minimum of two complete cross hatched layers of continuous filaments applied in a helix angle of 55 to 65 degrees for above-ground ductwork and 75 deg. for any buried ductwork.
e. Exterior corrosion layer: Single A or C Veil shall be applied to all duct exterior f. Exterior UV resistant coating: Factory applied paraffinated gel coat with UV inhibitors.
9. Fittings:
a. All fittings shall be hand lay-up construction fabricated from the same resin and have the same strength as hand lay-up FRP ductwork. b. The internal diameter of all fittings shall be equal to the adjacent duct. c. The tolerance on angles of all fittings shall be ±1 degree up to and including 24 inch diameter and ± 1/2 degree for 30 inch diameter and above.
10. Elbows:
a. The centerline radius of all elbows shall be 1-1/2 times the diameter. b. Elbows 24-inch diameter and smaller shall be smooth radius. Elbows 30- inch and larger shall be mitered. Provide a minimum of two mitered joints (3-piece) for all elbows above 45 Deg.
11. Flanges:
a. Provide flanged connections to flexible connectors, expansion joints, vessels, demisters, fans, silencers and other locations as shown on the drawings. b. Flanges shall be hand lay-up construction. Dimensions shall be in accordance with ASTM D 3982, Table 1, and the Duct Dimension Schedule. c. Flanges shall be drilled in accordance with ASTM D 3982, Table 1. Backs of flange face shall be flat so that washer seats fully on bolt face and flange backing.
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-4
d. Flange tolerances shall be in ASTM D 3982, Section 8, Tolerances. e. Gaskets shall be EPDM, full face and minimum 1/8 inch thickness. f. All bolts, nuts and washers shall be Type 316 stainless steel.
12. Joints:
a. Provide all butt and strap joints in accordance with ASTM D 3982, Table 2, and manufacturer’s drawings. b. Field weld kits shall be supplied by the duct manufacturer. All necessary fiberglass and reinforcing material shall be supplied pre-cut and individually packaged for each joint. Bulk Glass rolls will not be acceptable. c. All resin, catalyst and putty shall be supplied in quantities to complete all field joints plus 20% extra for waste.
13. Flexible Connectors: a. Furnish flexible connectors at each inlet and outlet of fan and in the duct runs where required for expansion, contraction and movement. Flexible connections shall be integral flange molded arch type units constructed of EPDM rubber 1/4-in thick, reinforced with a strong synthetic asbestos-free fabric suitable for corrosive service. The flexible connections shall be designed to minimize the transition of vibration from the fans to the ductwork at the suction and discharge connections. Expansion or contraction flexible connections shall be designed to allow 1-in movement. Working length or “live” length shall be as designed by the manufacturer to allow up to 1-in of movement. Ends shall be flanged, with flanges matching duct connection flanges. Corners on rectangular expansion joints shall be molded and free of patches or splices. The flexible connections shall be suitable for outdoor service and temperature ranges from minus 10 up to 125 degrees F, and pressure to 5 psig. Specially fabricated split type 316 stainless steel retaining back-up bars shall be supplied to prevent damage to the EPDM rubber flanges when type 316 stainless steel bolts are tightened. b. Where the construction of the flexible connections or vibration isolator results in a cross sectional area of the connection which is less than 90 percent of the adjacent ductwork, the size of the connection shall be increased to provide a cross sectional area equal to or greater than 90 percent of the adjacent duct. c. Provide flexible duct connections at both the intake and discharge connections for all fans except as noted below. 1) Wall and roof fans that have integral motor/fan wheel isolation d. Ductwork spacing and alignment for flexible connections shall be aligned to the tolerances of the flexible connection manufacturer, or plus/minus 1/4-in whichever is less. Bolts shall be torque to the manufacture’s recommendations. Do not over tighten. e. Where flexible connections are used as expansion joints, the manufacturer’s compression recommendations must be followed. When the temperature at installation differs from the temperature in the compression recommendation, a correction shall be made. f. Manufacturer: 1. Holz Rubber Company 2. Mercer Rubber Company 3. Proco Products, Incorporated 4. Or equal
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-5
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: All FRP pipes shall be installed in a neat and workmanlike manner, properly aligned, and cut from measurements taken at the site to avoid interferences with structural members, architectural features, openings and equipment. Exposed pipes shall afford maximum headroom and access to equipment, and where necessary, all piping shall be installed with sufficient slopes for venting or drainage of liquids and condensate to low points. All installations shall be acceptable to the Engineer. Contractor shall obtain training by the pipe manufacturer’s field representative in the correct installation and support of all FRP piping.
B. Supports and Anchors: All ducting shall be firmly supported with fabricated or commercial hangers or supports in accordance with the requirements in Section 220529, “Hangers and Supports for Piping and Equipment”. Where necessary to avoid stress on equipment or structural members, the pipes shall be anchored or harnessed. Expansion joints and guides shall compensate for duct expansion due to temperature differences.
3.2 PIPE PREPARATIONS
A. Prior to installation, each duct length and all fittings shall be carefully inspected, flushed clean of any debris or dust, and straightened, if not true. All duct and fittings shall be equally cleaned before assembly.
3.3 PIPE JOINTS
A. Butt and Wrap Joints: Prior to joining, ends shall be ground smooth. All dust and debris must be fully removed. Ends shall be resin-coated to prevent corrosion, in pipe 24" Diameter and above an interior corrosion wrap is required. The joint should be of equal strength as the pipe. A butt and wrap sequence and thickness chart should be shown on the fabrication drawings. The laminate sequence for each size duct should be supported by a separate section in the design calculations.
B. Supports and Anchors: All piping shall be firmly supported with fabricated or commercial hangers or supports in accordance with the requirements in the Section titled “Pipe Supports”. Where necessary to avoid stress on equipment or structural members, the pipes shall be anchored or harnessed. Expansion joints and guides shall compensate for pipe expansion due to temperature differences.
3.4 INSPECTION AND FIELD TESTING
A. Inspection: All finished installations shall be carefully inspected for proper joints and sufficient supports, anchoring, interference, and damage to pipe, fittings, and coating. Damage shall be repaired to the satisfaction of the Engineer.
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-6
B. Field Testing: Prior to enclosure or buying, all piping systems shall be pressure tested at 1-1/2 times the maximum working pressure. The Contractor shall furnish all test equipment, labor, materials and devices at no extra cost to the Owner.
1. Leakage may be determined by loss of pressure, soap solution, chemical indicator, or other positive and accurate method. All fixtures, devices, or other accessories which are to be connected to the lines and which would be damaged if subjected to the test pressure shall be disconnected and ends of the branch lines plugged or capped as required during the testing procedures. 2. Leaks shall be repaired to the satisfaction of the Engineer and the system shall be re- tested until no leaks are found.
END OF SECTION 233100
WRCRWA FIBERGLASS REINFORCED DUCT PLANT EXPANSION PROJECT 233100-7
SECTION 233113 - METAL DUCTS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Rectangular ducts and fittings. 2. Round ducts and fittings. 3. Sheet metal materials. 4. Sealants and gaskets. 5. Hangers and supports. 6. Seismic-restraint devices.
B. Related Sections:
1. Section 233313 "Ductwork Accessories" for dampers.
1.2 PERFORMANCE REQUIREMENTS
A. Delegated Duct Design: Duct construction, including sheet metal thicknesses, seam and joint construction, reinforcements, and hangers and supports, shall comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" and performance requirements and design criteria indicated in "Duct Schedule" Article.
B. Airstream Surfaces: Surfaces in contact with the airstream shall comply with requirements in ASHRAE 62.1.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Shop Drawings:
1. Fabrication, assembly, and installation, including plans, elevations, sections, components, and attachments to other work. 2. Factory- and shop-fabricated ducts and fittings. 3. Duct layout indicating sizes, configuration, and static-pressure classes. 4. Elevation of top of ducts. 5. Dimensions of main duct runs from building grid lines. 6. Fittings. 7. Reinforcement and spacing. 8. Seam and joint construction. 9. Penetrations through fire-rated and other partitions. 10. Equipment installation based on equipment being used on Project.
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 1 11. Locations for duct accessories, including dampers, turning vanes, and access doors and panels. 12. Hangers and supports, including methods for duct and building attachment and vibration isolation.
C. Delegated-Design Submittal:
1. Sheet metal thicknesses. 2. Joint and seam construction and sealing. 3. Reinforcement details and spacing. 4. Materials, fabrication, assembly, and spacing of hangers and supports. 5. Design Calculations: Calculations (in accordance with all applicable codes), including analysis data signed and sealed by the qualified professional engineer responsible for their preparation for selecting hangers and supports.
1.4 INFORMATIONAL SUBMITTALS
A. Coordination Drawings: Plans, drawn to scale, on which the following items are shown and coordinated with each other, using input from installers of the items involved:
1. Duct installation in congested spaces, indicating coordination with general construction, building components, and other building services. Indicate proposed changes to duct layout. 2. Suspended ceiling components. 3. Structural members to which duct will be attached. 4. Size and location of initial access modules for acoustical tile. 5. Penetrations of smoke barriers and fire-rated construction. 6. Items penetrating finished ceiling including the following:
a. Lighting fixtures. b. Air outlets and inlets. c. Speakers. d. Sprinklers. e. Access panels. f. Perimeter moldings.
B. Welding certificates.
1.5 QUALITY ASSURANCE
A. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel," for hangers and supports. AWS D1.2/D1.2M, "Structural Welding Code - Aluminum," for aluminum supports. AWS D9.1M/D9.1, "Sheet Metal Welding Code," for duct joint and seam welding.
B. Welding Qualifications: Qualify procedures and personnel according to the following:
1. AWS D1.1/D1.1M, "Structural Welding Code - Steel," for hangers and supports. 2. AWS D1.2/D1.2M, "Structural Welding Code - Aluminum," for aluminum supports.
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 2 3. AWS D9.1M/D9.1, "Sheet Metal Welding Code," for duct joint and seam welding.
C. ASHRAE Compliance: Applicable requirements in ASHRAE 62.1, Section 5 - "Systems and Equipment" and Section 7 - "Construction and System Start-up."
D. ASHRAE/IESNA Compliance: Applicable requirements in ASHRAE/IESNA 90.1, Section 6.4.4 - "HVAC System Construction and Insulation."
PART 2 - PRODUCTS
2.1 RECTANGULAR DUCTS AND FITTINGS
A. General Fabrication Requirements: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" based on indicated static-pressure class unless otherwise indicated.
B. Transverse Joints: Select joint types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 2-1, "Rectangular Duct/Transverse Joints," for static-pressure class, applicable sealing requirements, materials involved, duct- support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible."
C. Longitudinal Seams: Select seam types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 2-2, "Rectangular Duct/Longitudinal Seams," for static-pressure class, applicable sealing requirements, materials involved, duct- support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible."
D. Elbows, Transitions, Offsets, Branch Connections, and Other Duct Construction: Select types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Chapter 4, "Fittings and Other Construction," for static-pressure class, applicable sealing requirements, materials involved, duct-support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible."
2.2 ROUND DUCTS AND FITTINGS
A. General Fabrication Requirements: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Chapter 3, "Round, Oval, and Flexible Duct," based on indicated static-pressure class unless otherwise indicated.
B. Transverse Joints: Select joint types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 3-1, "Round Duct Transverse Joints," for static-pressure class, applicable sealing requirements, materials involved, duct-support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible."
C. Longitudinal Seams: Select seam types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 3-2, "Round Duct Longitudinal Seams,"
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 3 for static-pressure class, applicable sealing requirements, materials involved, duct-support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible."
D. Tees and Laterals: Select types and fabricate according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Figure 3-5, "90 Degree Tees and Laterals," and Figure 3-6, "Conical Tees," for static-pressure class, applicable sealing requirements, materials involved, duct-support intervals, and other provisions in SMACNA's "HVAC Duct Construction Standards - Metal and Flexible."
2.3 SHEET METAL MATERIALS
A. General Material Requirements: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" for acceptable materials, material thicknesses, and duct construction methods unless otherwise indicated. Sheet metal materials shall be free of pitting, seam marks, roller marks, stains, discolorations, and other imperfections.
B. Galvanized Sheet Steel: Comply with ASTM A 653/A 653M.
1. Galvanized Coating Designation: G60. 2. Finishes for Surfaces Exposed to View: Mill phosphatized.
C. Carbon-Steel Sheets: Comply with ASTM A 1008/A 1008M, with oiled, matte finish for exposed ducts.
D. Stainless-Steel Sheets: Comply with ASTM A 480/A 480M, Type 304 or 316, as indicated in the "Duct Schedule" Article; cold rolled, annealed, sheet. Exposed surface finish shall be No. 2B, No. 2D, No. 3, or No. 4 as indicated in the "Duct Schedule" Article.
E. Aluminum Sheets: Comply with ASTM B 209 Alloy 3003, H14 temper; with mill finish for concealed ducts, and standard, one-side bright finish for duct surfaces exposed to view.
F. Reinforcement Shapes and Plates: ASTM A 36/A 36M, steel plates, shapes, and bars; black and galvanized.
1. Where black- and galvanized-steel shapes and plates are used to reinforce aluminum ducts, isolate the different metals with butyl rubber, neoprene, or EPDM gasket materials.
G. Tie Rods: Galvanized steel, 1/4-inch minimum diameter for lengths 36 inches or less; 3/8-inch minimum diameter for lengths longer than 36 inches.
2.4 SEALANT AND GASKETS
A. General Sealant and Gasket Requirements: Surface-burning characteristics for sealants and gaskets shall be a maximum flame-spread index of 25 and a maximum smoke-developed index of 50 when tested according to UL 723; certified by an NRTL.
B. Two-Part Tape Sealing System:
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 4 1. Tape: Woven cotton fiber impregnated with mineral gypsum and modified acrylic/silicone activator to react exothermically with tape to form hard, durable, airtight seal. 2. Tape Width: As required. 3. Sealant: Modified styrene acrylic. 4. Water resistant. 5. Mold and mildew resistant. 6. Maximum Static-Pressure Class: 10-inch wg, positive and negative. 7. Service: Indoor and outdoor. 8. Service Temperature: Minus 40 to plus 200 deg F. 9. Substrate: Compatible with galvanized sheet steel (both PVC coated and bare), stainless steel, or aluminum.
C. Water-Based Joint and Seam Sealant:
1. Application Method: Brush on. 2. Solids Content: Minimum 65 percent. 3. Shore A Hardness: Minimum 20. 4. Water resistant. 5. Mold and mildew resistant. 6. Maximum Static-Pressure Class: 10-inch wg, positive and negative. 7. Service: Indoor or outdoor. 8. Substrate: Compatible with galvanized sheet steel (both PVC coated and bare), stainless steel, or aluminum sheets.
D. Flanged Joint Sealant: Comply with ASTM C 920.
1. General: Single-component, acid-curing, silicone, elastomeric. 2. Type: S. 3. Grade: NS. 4. Class: 25. 5. Use: O.
E. Flange Gaskets: Butyl rubber, neoprene, or EPDM polymer with polyisobutylene plasticizer.
F. Round Duct Joint O-Ring Seals:
1. Seal shall provide maximum leakage class of 3 cfm/100 sq. ft. at 1-inch wg and shall be rated for10-inch wg static-pressure class, positive or negative. 2. EPDM O-ring to seal in concave bead in coupling or fitting spigot. 3. Double-lipped, EPDM O-ring seal, mechanically fastened to factory-fabricated couplings and fitting spigots.
2.5 HANGERS AND SUPPORTS
A. Hanger Rods for Noncorrosive Environments: Cadmium-plated steel rods and nuts.
B. Strap and Rod Sizes: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Table 5-1, "Rectangular Duct Hangers Minimum Size," and Table 5-2, "Minimum Hanger Sizes for Round Duct."
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 5 C. Steel Cable End Connections: Cadmium-plated steel assemblies with brackets, swivel, and bolts designed for duct hanger service; with an automatic-locking and clamping device.
D. Duct Attachments: Sheet metal screws, blind rivets, or self-tapping metal screws; compatible with duct materials.
E. Trapeze and Riser Supports:
1. Supports for Galvanized-Steel Ducts: Galvanized-steel shapes and plates. 2. Supports for Stainless-Steel Ducts: Stainless-steel shapes and plates. 3. Supports for Aluminum Ducts: Aluminum or galvanized steel coated with zinc chromate.
2.6 SEISMIC-RESTRAINT DEVICES
A. General Requirements for Restraint Components: Rated strengths, features, and applications shall be as defined in reports by an agency acceptable to authorities having jurisdiction.
1. Structural Safety Factor: Allowable strength in tension, shear, and pullout force of components shall be at least four times the maximum seismic forces to which they will be subjected.
B. Channel Support System: Shop- or field-fabricated support assembly made of slotted steel channels rated in tension, compression, and torsion forces and with accessories for attachment to braced component at one end and to building structure at the other end. Include matching components and corrosion-resistant coating.
C. Restraint Cables: ASTM A 603, galvanized-steel cables with end connections made of cadmium-plated steel assemblies with brackets, swivel, and bolts designed for restraining cable service; and with an automatic-locking and clamping device or double-cable clips.
D. Hanger Rod Stiffener: Steel tube or steel slotted-support-system sleeve with internally bolted connections or reinforcing steel angle clamped to hanger rod.
E. Mechanical Anchor Bolts: Drilled-in and stud-wedge or female-wedge type. Select anchor bolts with strength required for anchor and as tested according to ASTM E 488.
PART 3 - EXECUTION
3.1 DUCT INSTALLATION
A. Drawing plans, schematics, and diagrams indicate general location and arrangement of duct system. Indicated duct locations, configurations, and arrangements were used to size ducts and calculate friction loss for air-handling equipment sizing and for other design considerations. Install duct systems as indicated unless deviations to layout are approved on Shop Drawings and Coordination Drawings.
B. Install ducts according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" unless otherwise indicated.
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 6 C. Install round ducts in maximum practical lengths.
D. Install ducts with fewest possible joints.
E. Install factory- or shop-fabricated fittings for changes in direction, size, and shape and for branch connections.
F. Unless otherwise indicated, install ducts vertically and horizontally, and parallel and perpendicular to building lines.
G. Install ducts close to walls, overhead construction, columns, and other structural and permanent enclosure elements of building.
H. Install ducts with a clearance of 1 inch, plus allowance for insulation thickness.
I. Route ducts to avoid passing through transformer vaults and electrical equipment rooms and enclosures.
J. Where ducts pass through non-fire-rated interior partitions and exterior walls and are exposed to view, cover the opening between the partition and duct or duct insulation with sheet metal flanges of same metal thickness as the duct. Overlap openings on four sides by at least 1-1/2 inches.
K. Protect duct interiors from moisture, construction debris and dust, and other foreign materials.
3.2 INSTALLATION OF EXPOSED DUCTWORK
A. Protect ducts exposed in finished spaces from being dented, scratched, or damaged.
B. Trim duct sealants flush with metal. Create a smooth and uniform exposed bead. Do not use two-part tape sealing system.
C. Grind welds to provide smooth surface free of burrs, sharp edges, and weld splatter. When welding stainless steel with a No. 3 or 4 finish, grind the welds flush, polish the exposed welds, and treat the welds to remove discoloration caused by welding.
D. Maintain consistency, symmetry, and uniformity in the arrangement and fabrication of fittings, hangers and supports, duct accessories, and air outlets.
E. Repair or replace damaged sections and finished work that does not comply with these requirements.
3.3 DUCT SEALING
A. Seal ducts to the following seal classes according to SMACNA's "HVAC Duct Construction Standards - Metal and Flexible":
1. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible." 2. Outdoor, Supply-Air Ducts: Seal Class A. 3. Outdoor, Exhaust Ducts: Seal Class C.
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 7 4. Outdoor, Return-Air Ducts: Seal Class C. 5. Unconditioned Space, Supply-Air Ducts in Pressure Classes 2-Inch wg and Lower: Seal Class B. 6. Unconditioned Space, Supply-Air Ducts in Pressure Classes Higher Than 2-Inch wg: Seal Class A. 7. Unconditioned Space, Exhaust Ducts: Seal Class C. 8. Unconditioned Space, Return-Air Ducts: Seal Class B. 9. Conditioned Space, Supply-Air Ducts in Pressure Classes 2-Inch wg and Lower: Seal Class C. 10. Conditioned Space, Supply-Air Ducts in Pressure Classes Higher Than 2-Inch wg: Seal Class B. 11. Conditioned Space, Exhaust Ducts: Seal Class B. 12. Conditioned Space, Return-Air Ducts: Seal Class C.
3.4 HANGER AND SUPPORT INSTALLATION
A. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Chapter 5, "Hangers and Supports."
B. Building Attachments: Concrete inserts, powder-actuated fasteners, or structural-steel fasteners appropriate for construction materials to which hangers are being attached.
1. Where practical, install concrete inserts before placing concrete. 2. Install powder-actuated concrete fasteners after concrete is placed and completely cured. 3. Use powder-actuated concrete fasteners for standard-weight aggregate concretes or for slabs more than 4 inches thick. 4. Do not use powder-actuated concrete fasteners for lightweight-aggregate concretes or for slabs less than 4 inches thick. 5. Do not use powder-actuated concrete fasteners for seismic restraints.
C. Hanger Spacing: Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible," Table 5-1, "Rectangular Duct Hangers Minimum Size," and Table 5-2, "Minimum Hanger Sizes for Round Duct," for maximum hanger spacing; install hangers and supports within 24 inches of each elbow and within 48 inches of each branch intersection.
D. Hangers Exposed to View: Threaded rod and angle or channel supports.
E. Support vertical ducts with steel angles or channel secured to the sides of the duct with welds, bolts, sheet metal screws, or blind rivets; support at each floor and at a maximum intervals of 16 feet.
F. Install upper attachments to structures. Select and size upper attachments with pull-out, tension, and shear capacities appropriate for supported loads and building materials where used.
3.5 SEISMIC-RESTRAINT-DEVICE INSTALLATION
A. Install ducts with hangers and braces designed to support the duct and to restrain against seismic forces required by applicable building codes. Comply with SMACNA's "Seismic Restraint Manual: Guidelines for Mechanical Systems."
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 8 1. Space lateral supports a maximum of 40 feet o.c., and longitudinal supports a maximum of 80 feet o.c. 2. Brace a change of direction longer than 12 feet.
B. Select seismic-restraint devices with capacities adequate to carry present and future static and seismic loads.
C. Install cables so they do not bend across edges of adjacent equipment or building structure.
D. Install cable restraints on ducts that are suspended with vibration isolators.
E. Install seismic-restraint devices using methods approved by an agency acceptable to authorities having jurisdiction.
F. Attachment to Structure: If specific attachment is not indicated, anchor bracing and restraints to structure, to flanges of beams, to upper truss chords of bar joists, or to concrete members.
G. Drilling for and Setting Anchors:
1. Identify position of reinforcing steel and other embedded items prior to drilling holes for anchors. Do not damage existing reinforcement or embedded items during drilling. Notify the Architect if reinforcing steel or other embedded items are encountered during drilling. Locate and avoid prestressed tendons, electrical and telecommunications conduit, and gas lines. 2. Do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength. 3. Wedge Anchors: Protect threads from damage during anchor installation. Heavy-duty sleeve anchors shall be installed with sleeve fully engaged in the structural element to which anchor is to be fastened. 4. Set anchors to manufacturer's recommended torque, using a torque wrench. 5. Install zinc-coated steel anchors for interior applications and stainless-steel anchors for applications exposed to weather.
3.6 CONNECTIONS
A. Comply with SMACNA's "HVAC Duct Construction Standards - Metal and Flexible" for branch, outlet and inlet, and terminal unit connections.
END OF SECTION 233113
WRCRWA METAL DUCTS PLANT EXPANSION PROJECT 233113 - 9 SECTION 233313 – DUCTWORK ACCESSORIES
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes dampers for the following systems:
1. Wall dampers for ventilation. 2. FRP Expansion joints. 3. Inline flow control FRP dampers.
1.2 QUALITY ASSURANCE
A. Manufacturer's Qualifications
1. Firms regularly engaged in manufacture of ductwork accessories, of types and sizes required, whose products have been in satisfactory use in similar service for not less than 3 years.
1.3 SUBMITTALS
A. Submit manufacturer's technical product data for each type of ductwork accessory, including dimensions, capacities, and materials of construction; and installation instructions.
B. Submit manufacturer's assembly-type shop drawings for each type of ductwork accessory showing interfacing requirements with ductwork, method of fastening or support, and methods of assembly of components.
C. Submit manufacturer's maintenance data including parts lists for each type of duct accessory. Include this data, product data, and shop drawings in maintenance manual; in accordance with requirements of Division 1.
1.4 ADDITIONAL SUBMITTAL INFORMATION
A. The Contractor shall submit a copy of this specification with check-marks by each line to show full compliance or a note with attached supporting information noting any deviation for Engineer review.
B. A letter from the resin supplier stating that the material used for this project complies with the specification and meet all corrosion requirements.
C. Design calculations performed by the manufacturer and stamped by a Professional Engineer for record purposes.
D. Duct manufacturer shall submit certified test results in accordance with ASTM 2992. Engineer will confirm that supplier has completed ASTM 2992 testing.
WRCRWA DUCTWORK ACCESSORIES PLANT EXPANSION PROJECT 233313-1 E. Samples shall be representative of the ductwork (construction method and material used) to be supplied on this project
1.5 REFERENCES
A. Codes and Standards
1. SMACNA Compliance: Comply with applicable portions of SMACNA "HVAC Duct Construction Standards, Metal and Flexible". 2. Industry Standards: Comply with ASHRAE recommendations pertaining to construction of ductwork accessories, except as otherwise indicated. 3. UL Compliance: Construct, test, and label fire dampers in accordance with UL Standard 555 "Fire Dampers and Ceiling Dampers". 4. NFPA Compliance: Comply with applicable provisions of NFPA 90A "Air Conditioning and Ventilating Systems", pertaining to installation of ductwork accessories. 5. ASTM D 3567: Practice for Determining Dimensions of Fiberglass Pipe and Fittings. 6. ASTM C 582: Standard Specification for Contact – Molded Reinforced Thermosetting Plastic (RTP) Laminates for Corrosion – Resistant Equipment 7. AWWA M-45: American Water Works Manual of Water Supply Practices “Fiberglass Pipe Design.” 8. ASTM D 3982: Standard Specification for Contact Molded “Fiberglass” Duct and Hoods or NBS PS 15-69 “Custom Contact-Molded Reinforced Polyester Chemical-Resistant Process Equipment.” 9. ASTM D 2992: “Standard Practice for Obtaining Hydrostatic Design Basis for Fiberglass Pipe and Fittings.” 10. ASTM D 2310: “Standard Classification for Machine-Made Fiberglass Pipe.”
1.6 DELIVERY, STORAGE AND HANDLING
A. Protection
1. Protect shop-fabricated and factory-fabricated accessories and purchased products from damage during shipping, storage and handling. Prevent end damage and prevent dirt and moisture from entering ducts and fittings.
B. Storage
1. Where possible, store accessories inside and protect from weather. Where necessary to store outside, store above grade and enclosed with waterproof wrapping.
PART 2 - PRODUCTS
2.1 WALL VENTILATION DAMPERS
A. Ductwork shall be reinforced and the damper properly supported without strain.
B. Protect all dampers mounted in a duct system which requires special treatment such as acid resistant coating as specified for that system.
WRCRWA DUCTWORK ACCESSORIES PLANT EXPANSION PROJECT 233313-2 C. Provide damper operators with diaphragms or motors of proper size, so that the motors will operate against the static pressure of the systems. Provide each damper motor with a bracket for attaching to ductwork, building structure or equivalent. Damper motors in plenums shall be mounted on damper frames. Do not install motors in ducts.
D. Control dampers shall be low leakage type with spring loaded side seals, inflatable butyl or neoprene fabric edge seals, bronze or teflon bearings, 6063-T5 extruded aluminum blades and frame. Bird screen included. Parallel action. Air leakage not to exceed 3 CFM per square foot at 4" upstream static pressure. Acceptable manufacturers:
1. American Warming and Ventilating 2. Honeywell. 3. Or equal
2.2 FRP EXPANSION JOINTS
A. Provide expansion joints where shown on the Drawings.
B. Expansion joints shall be manufactured by Proco Products Company, or equal.
C. Expansion joints shall be flanged where connecting ductwork to equipment or where indicated in the drawings; otherwise, slip-type will be acceptable.
2.3 FRP INLINE DAMPERS
A. Furnish and install at locations shown on plans, round FRP single-blade butterfly-style fiberglass dampers, with flanged ends. Contractor to provide connecting bolts, nuts and washers. Damper frame shall be of one piece construction with a resin rich interior corrosion barrier minimum of 100 mils. A structural lay-up shall consist of alternate layers of chopped strand mat and woven roving to conform to ASME/ANSI RTP-1 and PS15-69. The glass to resin ratio shall be a minimum of 35% glass to 65% resin. Wall thickness, flange thickness, drilling pattern and width shall conform to PS15-69. Exterior surface of the damper shall contain UV inhibitors and a gel-coat, color to match duct system. Pressure drop across the damper shall not exceed 0.20” w.c. at a free area velocity of 1,000 ft/min, tested according to AMCA 500D-98.
B. The damper blade shall be constructed of the same material as the damper frame and shall have a resin rich surfacing veil on both sides. Blade stiffeners shall be FRP or FRP encapsulated as required for stiffness.
C. All dampers 24” or larger shall be provided with gear operators with an epoxy coating. Dampers smaller than 24” shall be supplied with hand quadrant actuators fabricated of Type 316 stainless steel with a 5-stage locking quadrant indicator. All balancing dampers shall have a fully adjustable slot with an extra hole drilled in the handle for Contractor to “drill and pin-in place” once system is balanced so the handle cannot vibrate loose.
D. The axle shall be pultruded fiberglass as required to meet corrosion resistance requirements. Leakage shall not exceed 3 cfm per sq. ft. at 12” w.c., and 5.25 cfm per sq. ft. at 30” w.c. when tested according to AMCA 500D-98. Damper shall be provided with stainless steel hand locking quadrant, or gear operators, as required.
WRCRWA DUCTWORK ACCESSORIES PLANT EXPANSION PROJECT 233313-3 E. Fabrication:
1. Frame and blade: premium vinyl ester. Blade shall fully encapsulate shaft. Blades that bolt to a single side of the shaft will NOT be accepted. 2. Shaft: Type 316 stainless steel for all dampers. 3. Bearings and bushings: Teflon. 4. Pins and all hardware: Type 316 stainless steel. 5. Shaft seals: EPDM. 6. Provide all round isolation dampers with a blade stop consisting of FRP angles with full circumference EPDM seals. 7. All dampers shall have flanged ends. Contractor to provide connecting bolts, nuts and washers.
F. All FRP fabrication shall meet or exceed quality requirements of PS15-69 and ASME/ANSI RTP-1.
G. Where dampers are electrically actuated, motors shall meet the requirements of Section 260000 of the Specifications.
H. The damper shall be warranted for eighteen (18) months from the date of shipment to be free from defects in manufacturing, materials, or workmanship.
I. Acceptable Manufacturers:
1. Belco Manufacturing Company, Inc. 2. Swartwout, Division of Phillips Industries, 3. Ershigs, Inc. 4. Or equal.
PART 3 - EXECUTION
3.1 INSPECTION
A. Examine areas and conditions under which ductwork accessories will be installed. Do not proceed with work until unsatisfactory conditions have been corrected in manner acceptable to Installer.
3.2 INSTALLATION OF DUCTWORK ACCESSORIES
A. Install ductwork accessories in accordance with manufacturer's installation instructions, with applicable portions of details of construction as shown in SMACNA standards, and in accordance with recognized industry practices to ensure that products serve intended function.
3.3 FIELD QUALITY CONTROL
A. Operate installed ductwork accessories to demonstrate compliance with requirements. Test for air leakage while system is operating. Repair or replace faulty accessories, as required to obtain proper operation and leak-proof performance.
WRCRWA DUCTWORK ACCESSORIES PLANT EXPANSION PROJECT 233313-4 3.4 ADJUSTING AND CLEANING
A. Adjusting
Adjust ductwork accessories for proper settings.
1. Cleaning: Clean factory-finished surfaces. Repair any marred or scratched surfaces with manufacturer's touch-up paint.
END OF SECTION 233313
WRCRWA DUCTWORK ACCESSORIES PLANT EXPANSION PROJECT 233313-5 SECTION 233400 - EXHAUST AND VENT FANS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of Contract, including General and Special Conditions and Division-1 Specification sections, apply to work of this section.
1.2 DESCRIPTION OF WORK
A. Extent of power and gravity ventilator work required by this section is indicated on drawings and schedules, and by requirements of this section.
B. Providing and Installation of fans as noted in the HVAC schedule.
1.3 SUBMITTALS
A. Refer to Division-1 section 013300 “Contractor Submittals” for contractor submittal requirements.
PART 2 - PRODUCTS
2.1 WALL MOUNTED EXHAUST FANS
A. GENERAL:
Provide exhaust fan of type, size and capacity as scheduled and as specified herein.
B. TYPE:
Wall mounted, U.L. listed, direct driven aluminum propeller exhaust fan with integral housing, shutter and inlet guard. Wall panels shall have continuously welded corners. Fan shall be enclosed in minimum 18 gauge galvanized steel wall housing with factory installed shutter and inlet guard. Provide with an automatic damper (spring close).
All ungalvanized steel fan components shall be painted to exceed 1,000 hour salt spray under ASTM B117 test method. Propeller shall be balanced in accordance with AMCA Standard 204-96, Balance Quality and Vibration Levels for Fans. Motor shall be 115/1/60, open drip proof type.
C. MANUFACTURERS:
1. Dayton 2. Loren Cook 3. ACME 4. Or equal
WRCRWA EXHAUST AND VENT FANS PLANT EXPANSION PROJECT 233400-1 2.2 IN-LINE EXPLOSION PROOF FANS
A. DESIGN 1. Plastic radial fan shall be used for ventilation of aggressive mediums. The housing shall be rotatable in 45¡ steps allowing for up to eight (8) positions of discharge in counter clockwise direction (CCW). The shaft exit shall be sealed against the housing with a V-ring seated on the impeller hub. The pressure of the sealing lip decreases with increasing speed.
B. MATERIALS OF CONSTRUCTION
1. Housing: The housing shall be produced following a rotational casting procedure and made of gray polypropylene (PP). The construction shall allow for the removal of the motor, impeller and the console without disconnecting the housing from the duct system. 2. Impellers: The impellers shall be high efficiency backward curved radial design, made of polypropylene and shall be balanced. The inlet side of the hub shall be covered with a steel plate. 3. Motors: Single and three phase motors are to be used as specified. Single phase motors shall be dual voltage (115/230V) unless otherwise specified. Three phase motors shall be dual voltage (230/460V) unless otherwise specified. Single phase motors and three phase motors shall be totally enclosed fan cooled with thermal overload protection and shall be explosion proof. 4. Consoles: The consoles shall be made of stainless steel providing support of the motor and housing and make up the backplate of the housing. The motor supporting plate shall be attached to the console. 5. Anti-vibration dampers: The system shall be supplied with the manufacturer’s standard set of anti-vibration dampeners.
PART 3 - EXECUTION
3.1 INSPECTION
A. GENERAL:
Examine areas and conditions under which exhaust and vent fans are to be installed.
3.2 INSTALLATION OF FANS
A. GENERAL:
Except as otherwise indicated or specified, install fans in accordance with manufacturer's installation instructions and recognized industry practices to insure that products serve the intended function.
B. Coordinate work with work of roofing, walls and ceilings, as necessary for proper interfacing.
C. CONTROL DAMPERS:
Install control dampers and mount damper motors.
WRCRWA EXHAUST AND VENT FANS PLANT EXPANSION PROJECT 233400-2
3.3 ADJUSTING AND CLEANING:
A. CLEANING:
Clean factory-finished surfaces.
B. Adjust and tighten belts and sheaves.
C. Check and adjust clearances between fan and fan housing.
D. Provide lubrication.
END OF SECTION 233400
WRCRWA EXHAUST AND VENT FANS PLANT EXPANSION PROJECT 233400-3 SECTION 233713 - DIFFUSERS, REGISTERS, AND GRILLES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: 1. Rectangular and square ceiling diffusers. 2. Fixed face registers. 3. Fixed face grilles.
B. Related Sections:
1. Section 233116 "Ductwork Accessories" for fire and smoke dampers and volume-control dampers not integral to diffusers, registers, and grilles.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated, include the following:
1. Data Sheet: Indicate materials of construction, finish, and mounting details; and performance data including throw and drop, static-pressure drop, and noise ratings. 2. Diffuser, Register, and Grille Schedule: Indicate drawing designation, room location, quantity, model number, size, and accessories furnished.
B. Samples: For each exposed product and for each color and texture specified.
PART 2 - PRODUCTS
2.1 CEILING DIFFUSERS
A. Rectangular and Square Ceiling Diffusers:
1. Devices shall be specifically designed for variable-air-volume flows. 2. Material: Steel. 3. Finish: Baked enamel, white. 4. Face Size: As indicated on drawings. 5. Face Style: Three cone. 6. Mounting: Surface. 7. Pattern: Fixed. 8. Dampers: Radial opposed blade. 9. Accessories:
a. Equalizing grid. b. Plaster ring.
WRCRWA DIFFUSERS, REGISTERS, AND GRILLES PLANT EXPANSION PROJECT 233713 - 1 c. Safety chain. d. Wire guard. e. Sectorizing baffles. f. Operating rod extension.
2.2 REGISTERS AND GRILLES
A. Fixed Face Register:
1. Material: Steel. 2. Finish: Baked enamel, white. 3. Face Arrangement: 1/2-by-1/2-by-1/2-inch grid core. 4. Core Construction: Integral. 5. Frame: 1-1/4 inches wide. 6. Mounting Frame: Filter. 7. Mounting: Countersunk screw. 8. Damper Type: Adjustable opposed blade. 9. Accessory: Filter.
B. Fixed Face Grille:
1. Material: Steel. 2. Finish: Baked enamel, white. 3. Face Arrangement: 1/2-by-1/2-by-1/2-inch grid core. 4. Core Construction: Integral. 5. Frame: 1-1/4 inches wide. 6. Mounting Frame: Filter. 7. Mounting: Countersunk screw. 8. Accessory: Filter.
2.3 SOURCE QUALITY CONTROL
A. Verification of Performance: Rate diffusers, registers, and grilles according to ASHRAE 70, "Method of Testing for Rating the Performance of Air Outlets and Inlets."
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install diffusers, registers, and grilles level and plumb.
B. Ceiling-Mounted Outlets and Inlets: Drawings indicate general arrangement of ducts, fittings, and accessories. Air outlet and inlet locations have been indicated to achieve design requirements for air volume, noise criteria, airflow pattern, throw, and pressure drop. Make final locations where indicated, as much as practical. For units installed in lay-in ceiling panels, locate units in the center of panel. Where architectural features or other items conflict with installation, notify Architect for a determination of final location.
WRCRWA DIFFUSERS, REGISTERS, AND GRILLES PLANT EXPANSION PROJECT 233713 - 2 C. Install diffusers, registers, and grilles with airtight connections to ducts and to allow service and maintenance of dampers, air extractors, and fire dampers.
3.2 ADJUSTING
A. After installation, adjust diffusers, registers, and grilles to air patterns indicated, or as directed, before starting air balancing.
END OF SECTION 233713
WRCRWA DIFFUSERS, REGISTERS, AND GRILLES PLANT EXPANSION PROJECT 233713 - 3 SECTION 234000 – FIBERGLASS REINFORCED PLASTIC FANS
PART 1 - GENERAL
1.1 The fan shall be size as noted in the equipment schedule, single-width, single-inlet as designed and manufactured by The New York Blower Company Model 241 (Basis of Design), or equal. The fan shall be constructed such that all surfaces in contact with the corrosive gas stream are to be made of solid, corrosion- resistant FRP. All nuts, bolts and fasteners in contact with the gas stream shall be type 316 SST and encapsulated in FRP. Fans shall be AMCA Arrangement 1, 8, 9, 9F, or 10. AMCA Arrangement 4, which places the motor shaft in the corrosive gas stream, is unacceptable.
1.2 SUBMITTALS
A. Submittals shall include:
a. Detail description of materials of construction.
b. Equipment cut sheets with dimensional drawings.
c. Wiring diagrams.
d. Operational curves confirming that the performance requirements are met.
1.3 REFERENCES
A. American National Standards Institute (ANSI) B16.9 factory made wrought steel butt welded fittings.
B. American Society for Testing and Materials (ASTM) :
1. A 240 – Standard Specification for Heat-Resisting Chromium and Chromium –Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels.
PART 2 - PERFORMANCE
2.1 Fan ratings shall be based on tests made in accordance with AMCA Standard 210 and licensed to bear the AMCA Certified Ratings Seal for Air Performance. Fans not licensed to bear the AMCA Seal for performance shall be tested, at supplier’s expense, in an accredited AMCA laboratory. Fans shall have a sharply rising pressure characteristic extending throughout the operating range to assure quiet and stable operation. Fan brake horsepower shall be equal to or less than 7.5 BHP at 4 inches static pressure and 6,000 CFM at 0.0638 lbs/cuft density
2.2 Fan manufacturers shall provide sound power level ratings for fans tested and rated in accordance with AMCA Standards 300 and 301. Tests shall be performed in an accredited AMCA lab-oratory. Sound power ratings shall be in decibels (reference 10-12 watts) in eight octave bands. Sound power
WRCRWA FRP FANS PLANT EXPANSION PROJECT 234000-1 levels will be corrected for installation by the specifying engineer. dBA levels only are not acceptable.
2.3 Bearings are to be grease lubricated, precision anti-friction ball or spherical roller, self-aligning, pillow block design. Bearings shall be designed for a minimum L-10 life of 30,000 hours (150,000 hours L-50 life) when rated at the fan’s maximum cataloged operating speed. Fan bearings shall be accessible for inspection and maintenance. Bearings enclosed within the fan housing where they can be exposed to the corrosive gas stream are not acceptable.
2.4 All steel fan surfaces are to be thoroughly cleaned prior to painting using a combination of washing and hand/power tool cleaning per SSPC-SP1, SSPC-SP2 and SSPC-SP3 standards. After cleaning, surfaces of bolted metal components shall be coated and allowed to dry prior to final assembly. After assembly, all fan exterior surfaces are to receive one coat of epoxy enamel finish to a thickness of 2-3 mils d.f.t. All fasteners external to the gas stream shall be plated for extra corrosion protection.
PART 3 - PRODUCTS
3.1 CONSTRUCTION
A. Fan shall be constructed in accordance with ASTM D-4167 standard specification for fiber- reinforced plastic fans and blowers to ensure structural integrity. All parts exposed to the gas stream shall be constructed of, or encapsulated in, an FRP laminate capable of resisting continuous airstream temperatures of 250¡F. All resins shall be clear to allow detection of subsurface imperfections. Use of pigments, gel coats, inhibitors and additives which may disguise flaws in the laminate are prohibited. Other minimum construction requirements shall consist of the following:
1. Housing - Fan housing shall be constructed of a fire-retardant polyester resin with an ASTM E84 Class I rating. Housing laminate construction shall conform to ASTM Standard C-582.
B. Airstream surfaces shall be smooth to minimize resistance and prevent build-up of airborne contaminants. Fan shall be furnished with flanged outlet.
C. Shaft hole openings shall be fitted with a Teflon¨ closure having a maximum clearance of 1/32” to minimize leakage. Inlet assembly shall be bolted to permit wheel removal.
D. Wheel - Wheel shall be of backwardly-inclined, non-overloading design for increased efficiency. Wheel shall be fabricated of a fire-retardant vinyl ester resin with an ASTM E84 Class I rating. Wheel hub shall be permanently bonded to the shaft and completely encapsulated in FRP to insure corrosion-resistant integrity. Steel wheels coated with FRP, or wheels with taper-lock hubs, are not acceptable.
E. Shaft - Shaft shall be ASTM A-108 steel, grade 1040/1045 with an FRP sleeve fixed securely and bonded to the wheel backplate. The sleeve shall extend out through the housing shaft hole for corrosion protection. The shaft first critical speed shall be at least 125% of the fan’s maximum operating speed. Shaft shall be countersunk for tachometer readings
WRCRWA FRP FANS PLANT EXPANSION PROJECT 234000-2 PART 4 - EXECUTION
4.1 BALANCE AND RUN TEST
A. The wheel and shaft shall be dynamically balanced as an assembly, and the fan will be balanced in accordance with the limits set forth in AMCA 204, Section 6, Table 6-3 for Industrial Process and Power Generation Equipment level BV-3 (0.15 in/sec. filter-in at both bearings in the horizontal and vertical planes).
4.2 WARRANTY
A. Fan manufacturer shall warrant that all fan components shall be free from defects in materials and workmanship for a period of one (1) year after shipment from its plant.
4.3 ACCESSORIES
A. Accessories shall be provided as called for in the plans and specifications. Required accessories include: 1. Cleanout Door 2. Inspection Port 3. Unitary Base, Spring 4. Flanged Inlet 5. Inlet Box 6. Isolation Rails, Spring 7. Flange Drilling 8. Threaded Drain w/PVC Plug 9. V-Belt Drive, Adjustable 10. Shaft Seal (Viton) 11. Parallel Blade Outlet Damper 12. Positive Screw Adjustment 13. Graphite Impregnation 14. Surface Veil 15. All-Vinyl Ester Airstream 16. Heavy Duty Slide Rails 17. Narrow Width Construction 18. Safety Equipment: Belt Guard, Shaft Guard, Coupling Guard 19. Weather Cover
END OF SECTION 234000
WRCRWA FRP FANS PLANT EXPANSION PROJECT 234000-3 SECTION 236200 - PACKAGED COMPRESSOR AND CONDENSER UNITS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes packaged, air-cooled, refrigerant compressor and condenser units suitable for rooftop or wall mounted installation.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Shop Drawings: For compressor and condenser units. Include plans, elevations, sections, details, and attachments to other work.
1. Wiring Diagrams: For power, signal, and control wiring.
1.3 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
B. Fabricate and label refrigeration system according to ASHRAE 15, "Safety Standard for Refrigeration Systems."
C. ASHRAE/IESNA 90.1 Compliance: Applicable requirements in ASHRAE/IESNA 90.1, Section 6, "Heating, Ventilating, and Air-Conditioning."
1.4 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of compressor and condenser units that fail in materials or workmanship within specified warranty period.
1. Failures include, but are not limited to, the following:
a. Compressor failure. b. Condenser coil leak.
2. Warranty Period: Ten years from date of Substantial Completion.
WRCRWA PACKAGED CONDENSER UNITS PLANT EXPANSION PROJECT 236200 - 1 PART 2 - PRODUCTS
2.1 COMPRESSOR AND CONDENSER UNITS, AIR COOLED, 3 TO 10 TONS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Bard Manufacturing Company, Inc. 2. Or Equal.
B. Description: Factory assembled and tested; consisting of compressor, condenser coil, fan, motors, refrigerant reservoir, and operating controls. All units shall be factory assembled, piped, internally wired and fully charged with R-410a. Units shall be UL listed and carry a UL label. All units shall be factory run tested to check cooling operation, fan and blower rotation and control sequence. Cooling performance shall be rated in accordance with AHRI standards.
C. Compressor: Scroll, hermetically sealed, high efficiency.
1. Motor: Single speed, and includes thermal- and current-sensitive overload devices, start capacitor, relay, and contactor.
D. Refrigerant: R-410A. Unit shall have refrigerant control.
E. Evaporator Coil: Internally enhanced 3/8” OD seamless copper tubing mechanically bonded to aluminum fins, factory pressure and leak tested at 250 to 300 psig. All units shall have TXV to control refrigerant flow.
F. Condenser Coil: Condenser coil shall be continuously wrapped, corrosion resistant all aluminum with minimum brazed joints. The coil is seamless aluminum tubing glued to continuous aluminum fin. Coils are lab tested to withstand 2,000.0 pounds of pressure per square inch. The outdoor coil provides low airflow resistance and efficient heat transfer. The coil shall be protected on all four sides by louvered panels.
G. Indoor Air Fan: Direct-drive, aluminum propeller fan; with permanently lubricated, totally enclosed fan motor with thermal-overload protection and ball bearings. Isolated motor/blower assembly from unit with rubber mounts.
H. Outdoor Fan: Direct-drive, aluminum propeller fan. Permanently lubricated weather proof motor with built-in thermal overload protection.
I. System Controls: To include condenser fan, evaporator fan and compressor contacts.
J. Accessories:
1. Full modulating economizer: This accessory shall be field installed and be composed of following items: 0-100% fresh air damper, damper drive motor, and fixed dry bulb enthalpy control. Solids state enthalpy or differential enthalpy control is an option. Economizer operations shall be controlled by the pre-set position of the enthalpy control. A barometric relief damper shall be standard with the downflow economizer and provide
WRCRWA PACKAGED CONDENSER UNITS PLANT EXPANSION PROJECT 236200 - 2 a pressure operated damper that shall be gravity closing and prohibit entrance of outside air on equipment off cycle.
2. Start Kit: Extra compressor starting capacity for single phase equipment.
3. Programmable Electronic Thermostat: Programmable electronic thermostat shall provide heating setback and cooling setup with 7-day, programming.
K. Unit Casing: Galvanized steel finished with baked enamel; with removable panels for access to controls, weep holes for water drainage, and mounting holes in base. Mount service valves, fittings, and gage ports on exterior of casing. Corrosion resistant exterior screws shall be used.
2.2 SOURCE QUALITY CONTROL
A. Energy Efficiency: Equal to or greater than prescribed by ASHRAE/IESNA 90.1, "Energy Efficient Design of New Buildings except Low-Rise Residential Buildings," Section 6, "Heating, Ventilating, and Air-Conditioning."
B. Testing Requirements: Factory test sound-power-level ratings according to ARI 270 or ARI 370.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install units level and plumb, firmly anchored in locations indicated.
B. Install roof-mounting units using roof curb and coordinate with other disciplines.
C. Maintain manufacturer's recommended clearances for service and maintenance.
D. Loose Components: Install electrical components, devices, and accessories that are not factory mounted.
3.2 CONNECTIONS
A. Where installing piping adjacent to equipment, allow space for service and maintenance of equipment.
B. Connect refrigerant piping to air-cooled compressor and condenser units; maintain required access to unit. Install furnished field-mounted accessories.
3.3 FIELD QUALITY CONTROL
A. Perform tests and inspections.
B. Tests and Inspections:
WRCRWA PACKAGED CONDENSER UNITS PLANT EXPANSION PROJECT 236200 - 3 1. Perform each visual and mechanical inspection and electrical test. Certify compliance with test parameters. 2. Leak Test: After installation, charge system with refrigerant and oil and test for leaks. Repair leaks, replace lost refrigerant and oil, and retest until no leaks exist. 3. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor operation and unit operation, product capability, and compliance with requirements. 4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. 5. Verify proper airflow over coils.
C. Verify that vibration isolation and flexible connections properly dampen vibration transmission to structure.
END OF SECTION 236200
WRCRWA PACKAGED CONDENSER UNITS PLANT EXPANSION PROJECT 236200 - 4 SECTION 238316 – RADIANT HEATING HYDRONIC PIPING
PART 1 - GENERAL
1.1 SUMMARY
A. Hydronic radiant heating systems using PEX tubing in slab applications, and as distribution piping.
B. The work described in this section includes, but is not limited to, the following:
1. Complete hydronic radiant heating system including tubing, manifolds, fittings, tubing, installation systems, fasteners and controls. 2. Coordination with the selection and installation of circulation pumps and distribution piping. 3. Coordination with system controls and automation. 4. System commissioning and startup service.
C. Related Sections
1. The following sections, though not exhaustive, may have an impact on installation of the hydronic radiant heating system:
a. 033000 Cast in Place Concrete b. 220719 Piping Insulation
1.2 REFERENCES
A. Abbreviations and Acronyms
1. PEX – Crosslinked polyethylene 2. EVOH – Ethyl Vinyl Alcohol (oxygen barrier compound) 3. SDR 9 - Standard Dimension Ratio 9 The SDR is the ratio of pipe diameter to wall thickness. SDR 9 – Outside diameter of pipe is 9x the wall thickness of pipe
B. Reference Standards
1. ASTM – American Society for Testing and Materials
a. ASTM F876 Standard Specification for Crosslinked Polyethylene (PEX) Tubing b. ASTM F877 Standard Specification for Crosslinked Polyethylene (PEX) Hotand Cold-Water Distribution Systems c. ASTM F1960 Standard Specification for Cold Expansion Fittings with PEX reinforcing Rings for Use with Cross-linked Polyethylene (PEX) Tubing
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 1
d. ASTM 1807-11ae1 Standard Specification for Metal Insert Fittings Utilizing a Copper Crimp Ring for SDR9 Cross-linked Polyethylene (PEX) Tubing and SDR9 Polyethylene of Raised Temperature (PE-RT) Tubing
2. ASTM F2098-08 Standard Specification for Stainless Steel Clamps for Securing SDR9 Cross-linked Polyethylene (PEX) Tubing to Metal Insert and Plastic Insert Fittings 3. DIN – German Institute for Standardization a. DIN 4726 Warm water surface heating systems and radiator connecting systems - Plastics piping systems and multilayer piping systems (used to evaluate oxygen diffusion performance) 4. PPI – Plastic Pipe Institute a. PPI TR-3 Policies and Procedures for Developing Hydrostatic Design (SDB) and Minimum Required Strength (MRS) Ratings for Thermoplastic Piping Materials or Pipe b. PPI TR-4 Recommended Hydrostatic Strengths and Design Stresses for Thermoplastic Piping and Fitting Compounds
1.3 SUBMITTALS
A. General
1. Submit listed submittals in accordance with Conditions of the Contract and Division 1 Submittal Procedures Section
B. Product Data
1. Submit manufacturer’s product submittal forms, brochures, technical data sheets, catalog pages and installation manuals for each product listed in this section. 2. Submit data in sufficient detail to indicate compliance with the contract documents.
C. Shop Drawings
1. Submit manufacturer's detailed drawings showing layouts, fixing details and piping details of all areas where hydronic radiant systems are indicated along with product and performance data for each component. 2. Submit drawings showing details of manifolds, including all connections and valves. If manifolds are to be installed on a wall, then the details should include all fixture details. If the manifolds are to be installed in wall cavities, then provide all fixture and access details. 3. Specify piping materials and temperature/pressure ratings. 4. Provide drawings showing the location of all expansion and penetration sleeves, showing coordination with concrete slab expansion joints. Provide confirmation of concrete slab expansion requirements and the use of any concrete additives. 5. Provide drawings showing piping manifold locations and installation details. 6. Provide control sequences and requirements for control hardware devices. Indicate compliance and coordination with requirements of other specification sections. 7. Provide piping sample with certification of properties.
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 2
8. Submit manufacturer's report detailing that the hydronic radiant system has been installed in accordance with this specification and the manufacturer's specified instructions. 9. Submit report indicating that installation was performed according to the manufacturer's instructions. Include pressure testing documentation as required in related specification sections. 10. Submit start-up report demonstrating that system meets required capacity, is fully functional and commissioned to the satisfaction of system manufacturer.
D. Certificates
1. Submit contractor(s) certification statement(s) that the hydronic radiant system has been installed in accordance with this specification.
E. Closeout
1. Maintenance Contracts
a. Submit maintenance contract for system or any part in the system, as required.
2. Operation and Maintenance Data
a. Provide operational and maintenance data; b. Final as-built tubing layout drawing.
3. Warranty Documentation
a. Submit final executed warranty document for system
1.4 QUALITY ASSURANCE
A. Qualifications
1. Manufacturer
a. Manufacturer shall have a minimum of ten years experience in similar systems. b. Manufacturer shall provide products of consistent quality in appearance and physical properties.
2. Installers
a. Installers shall have demonstrated experience on projects of similar size and complexity with documentation proving successful completion of system installation and/or training hosted/approved by the system manufacturer.
1.5 DELIVERY, STORAGE AND HANDLING
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 3
A. General
1. Comply with Section 016100, Product Requirements
B. Ordering
1. Comply with manufacturer’s ordering instructions and lead-time requirements to avoid construction delays.
C. Delivery
1. Deliver materials in original, unopened, undamaged containers or packaging with manufacturer identification labels intact.
D. Storage
1. Store materials in dry, enclosed, well-ventilated area protected from exposure to harmful environmental conditions. 2. PEX tubing and manifold openings shall be covered or capped to prevent contaminants from entering. 3. Do not expose PEX tubing to direct sunlight for more than 30 days. If construction delays are encountered, cover the tubing to prevent exposure to direct sunlight.
E. Handling
1. PEX tubing shall be kept away from sharp objects and not be handled in a way as to cause damage and/or puncture. 2. Protect materials from damage by other trades.
1.6 WARRANTY
A. Manufacturer’s Warranty
1. Provide manufacturer’s standard warranty document.
a. PEX tubing shall be under warranty for a period of thirty (30) years, non-prorated, against failure due to defect in material or workmanship beginning with successful pressurized water tests immediately following system installation. b. Manifolds and fittings shall be under warranty for a period of five (5) years, non- prorated, against failure due to defect in material or workmanship beginning with successful pressurized water tests immediately following system installation. c. Warranty Period for Radiant Rollout Mat (RROM) twenty five (25) years, non- prorated warranty against failure due to defect in material or workmanship, beginning with date of installation for tubing. Ten (10) year, non-prorated warranty against failure due to defect in material or workmanship, beginning with date of installation for in-slab engineered polymer fittings.
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 4
d. Electrical and control parts shall be under warranty for a period of two (2) years, non- prorated, against failure due to defect in material or workmanship beginning with successful pressurized water tests immediately following system installation.
2. Manufacturer’s warranty is in addition to, and not a limitation of, other rights the Owner may have under contract documents.
PART 2 - PRODUCTS
2.1 MANUFACTURER
A. Subject to compliance with requirements, provide products by one of the following:
1. Uponor, USA (Basis-of-Design) 2. Roth Industries 3. Mr.PEX Systems, Inc. 4. Or Equal.
B. All components shall be supplied by one manufacturer.
2.2 MATERIALS
A. Tubing
1. All tubing shall be Engel Method Crosslinked polyethylene (PEX-a). 2. Tubing shall conform to ASTM F876, ASTM F877 and tested for compliance by independent third party agency. 3. Pipe shall be rated for continuous operation of 100 psi gauge pressure at 180⁰F temperature (690 kPa at 82⁰C) and 80 psi gauge pressure at 200⁰F (550 kPa at 93⁰C). 4. The minimum bend radius for cold bending of the tubing shall be no less than six (6) times the outside diameter. Bends with a smaller radius shall require the use of manufacturer supplied metal bend supports. 5. supply long sweep elbows for PEX tubing protection, see drawings for details.
B. Manifolds
1. Stainless Steel Manifolds
a. For system compatibility, use 1 ½ -inch valved stainless steel manifolds offered by the PEX tubing manufacturer. b. Install valved - manifolds primarily for wall-hung or boxed applications. c. Use manifolds with an isolation valve or a combination isolation and balancing valve on each outlet. d. Use manifolds that support - ¾ inch PEX tubing.
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 5
e. Ensure manifold end cap offers tapping for 1/8 inch FNPT and ½ inch FNPT for vent and drain. f. Install supply-and-return piping to the manifold in a reverse-return configuration to ensure self-balancing. g. If the supply-and-return piping is in direct return configuration, install and balance flow setters on the return leg of each manifold to the mains. h. Install a pressure gauge on both supply and return line to ensure operational pressure of each line.
C. Fittings
1. ASTM F1960 cold-expansion fitting manufactured from the following material types: a. UNS No.C69300 Lead-free (LF) Brass b. 20 % glass-filled polysulfone as specified in ASTM D6394 c. Unreinforced polysulfone as specified in ASTM D6394 d. Blend of polyphenylsulfone (55 -80 %) and reinforced polysulfone as specified in ASTM D6394 e. Reinforcing cold-expansion rings shall be manufactured from the same source as PEX-a piping manufacturer and marked “F1960”.
D. Manifold Cabinets
1. Manifold cabinets, if required, shall be constructed of 304 stainless steel. 2. Cabinets may be surface mount on wall or floor or recessed mount. 3. Cabinets shall have knockouts on each side and open at bottom or top for tubing. 4. Cabinets shall be lockable.
E. Preassembled Radiant Heating Rollout Mats (RROM)
1. Manufacturer: Uponor or Equal 2. Mat Construction a. RROM shall be constructed with 5/8” hePEX tubing with loops at 6” on center spacing. b. RROM shall be constructed in nominal widths of 5 feet, with maximum lengths of 225 feet. RROM shall be custom designed based on the floor plant to ensure that mat pressure drops at the required flow rates will not exceed the scheduled maximums. c. RROM shall be constructed with acetyl polymer support strips at every seven feet. Tubing shall be secured to the support strips using 6 inch plastic zip ties. d. Header assembly: In-slab reverse return header assembly shall be constructed of 4/4 inch hePEX with Engineered Polymer ASTM F1960 cold expansion fittings.
3 Radiant Rollout Mats shall be pressure tested prior to shipping and shall be delivered to the job site less than 20 psi of pressure. RROM shall be tagged and permanently labeled according to the shop drawings.
H. Accessories
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 6
1. Use accessories with the installation of the hydronic radiant heating system as recommended by or available from the manufacturer.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verification of Conditions
1. Verify that site conditions are acceptable for installation of the hydronic radiant heating system.
a. Verify that work from other trades will not interfere with installation. b. All installation areas shall be cleaned and free from all construction debris.
2. Do not proceed with installation of the hydronic radiant heating system until unacceptable conditions are corrected.
3.2 INSTALLATION
A. General 1. Install system according to design parameters and final shop drawings. All installation notes shown on the drawings shall be followed. 2. Determine manifold locations before installing tubing. 3. Mount manifolds in previously prepared locations and/or in previously installed cabinets. Manifold should be installed as level and plumb. 4. At connections and fittings, use a plastic tubing cutter to ensure square and clean cuts. 5. Tubing shall be dispensed using a suitable uncoiling device. Remove twists prior to securing tubing. Fasten tubing at no more than 3 feet intervals, being careful not to twist the tubing. In thin concrete or gypsum slabs, secure tubing every 2 feet. Use only fasteners supplied or approved by the PEX tubing manufacturer. 6. At time of installation of each loop of tubing, connect the tubing to the correct manifold outlet and record zone area serviced and tubing length for balancing. If manifold is not installed, cap the tubing ends and label the tubing’s loop number along with S for supply and R for return and loop length. 7. Manufacturer of finished flooring shall be consulted to confirm maximum surface temperature, maximum increase of temperature rate during start up period, cure rates and any additional information important to maintaining flooring warranty. 8. If the radiant heating system substrate material (thermal mass) requires curing and/or has other limitations which can be influenced by the radiant heating system while in operation, then the radiant heating system shall not be put into operation until such time that the substrate material has fully cured or set according to the material requirements of the substrate manufacturer.
B. Slab-on-Grade
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 7
1. Fasten the tubing to the flat mesh or reinforcing bar in accordance with the PEX tubing manufacturer’s installation recommendations. 2. Use closer tubing on-center distances along exterior walls. Increase tubing on-center distances as the installation moves away from the exterior wall(s).
a. Use 6 inches (152mm) on center for exterior section of the design. b. Do not exceed 9 inches (229mm) on center for interior sections of the design. c. Do not install tubing within 6 inches (152mm) of any wall. d. Refer to the submitted radiant floor design layout for actual on-center information.
3. If the design requires under-slab insulation, the structural engineer determines the vertical compressive strength of the high-density extruded board insulation. The radiant floor design determines the required insulation resistance value (R-value). 4. When using high-density board insulation, staple the tubing to the insulation board with Foam Staples. 5. Use edge insulation when the heated system directly contacts an exterior wall or beam. 6. Install tubing at a consistent depth below the surface elevation as determined by the project engineer. Ensure sufficient clearance to avoid control joint cuts. 7. In areas where tubing must cross metal expansion joints in the concrete, ensure the tubing passes below the joints. Depending on the manufacturer's and structural engineer's recommendation, fibrous expansion joints may tolerate penetration. 8. For tubing that exits the slab in a 90-degree bend, use metal or PVC bend supports.
3.3 FIELD QUALITY CONTROL
A. Air Leak Testing
1. Completed system shall be leak tested by applying air pressure to a minimum of 60 psig. (do not exceed 150psig) 2. Use liquid leak detector or soap solution to check for leakage at manifold connections.
B. System Filling and Purging
1. System shall be filled with required fluid, as determined by design, and purged of air.
C. Liquid Leak Testing
1. Perform a preliminary leak test by pressurizing the system to the greater of 1.5 times the maximum operating pressure or 100psig for 30 minutes.
a. As tubing expands, restore pressure, first at 10 minutes into the test and again at 20 minutes. b. At the end of the 30-minute preliminary test, pressure shall not fall by more them 8 psig from the maximum, and there shall be no leakage.
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 8
2. After successfully performing the preliminary leak test, perform the main leak test immediately.
a. The test pressure shall be restored and continued as the main test for 2 hours. b. The system pressure shall not fall more than 3 psig after 2 hours. c. No leakage shall be detected.
3. Test pressure shall be maintained and monitored during installation of thermal mass (slab).
a. If a leak is detected during installation of thermal mass, leak shall be found immediately and the area cleared for repair using manufacturer’s approved repair coupling and heat shrink material. b. Retest before covering repair.
4. If liquid leak test is performed with water, precautions must be taken to prevent freezing until project is complete. 5. If liquid leak test is performed with water and operating fluid is a glycol and water solution, system must be purged with air before filling with solution.
D. Complete and furnish leak test reports to owner or general contractor, as required.
3.4 SYSTEM ADJUSTING
A. Loop Flow Balancing
1. Equalize the flow in each loop of a manifold. Perform this function for each individual manifold.
B. Manifold Flow Adjusting
1. Adjust flow to each individual manifold with the use of a flow control or circuit setter device. Flows determined by design requirements.
C. Floor Surface Temperatures
1. Once system is operating at full temperature, verify floor surface temperatures are within design and flooring manufacturer limits.
3.5 CLEANING
A. Remove temporary coverings and protection of adjacent work areas.
B. Repair or replace damaged installed products.
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C. Clean installed products in accordance with manufacturer’s instructions prior to owner’s acceptance.
D. Remove construction debris from project site and legally dispose of debris.
3.6 DEMONSTRATION
A. Demonstrate operation of system to Owner or Owner’s personnel.
B. Instruct Owner or Owner’s personnel in type, concentration and maintenance of the water and glycol solution, if present.
C. Provide Owner or Owner’s personnel with manufacturer’s installation, operation and maintenance instructions for installed components within the system.
3.7 PROTECTION
A. Protect installed work from damage by subsequent construction activity on the site.
B. Provide Owner with photos and drawings of completed work.
END OF SECTION 238316
WRCRWA RADIANT HEATING HYDRONIC PIPING PLANT EXPANSION PROJECT 238316 - 10
SECTION 239000 - FIXED LOUVERS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes fixed, extruded-aluminum and formed-metal louvers.
B. Related Requirements:
1. Section 081113 "Hollow Metal Doors and Frames" for louvers in hollow-metal doors.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product.
1. For louvers specified to bear AMCA seal, include printed catalog pages showing specified models with appropriate AMCA Certified Ratings Seals.
B. Shop Drawings: For louvers and accessories. Include plans, elevations, sections, details, and attachments to other work. Show frame profiles and blade profiles, angles, and spacing.
C. Samples: For each type of metal finish required.
D. Delegated-Design Submittal: For louvers indicated to comply with structural performance requirements, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.
1.3 INFORMATIONAL SUBMITTALS
A. Product Test Reports: Based on tests performed according to AMCA 500-L.
B. Windborne-debris-impact-resistance test reports.
PART 2 - PRODUCTS
2.1 PERFORMANCE REQUIREMENTS
A. Windborne-Debris-Impact Resistance: Louvers located within 30 feet of grade shall pass basic- protection, large-missile testing requirements in ASTM E 1996 when tested according to ASTM E 1886. Test specimens shall be no smaller in width and length than louvers indicated for use on Project.
WRCRWA FIXED LOUVERS PLANT EXPANSION PROJECT 239000 - 1 B. Louver Performance Ratings: Provide louvers complying with requirements specified, as demonstrated by testing manufacturer's stock units identical to those provided, except for length and width according to AMCA 500-L.
2.2 FIXED, EXTRUDED-ALUMINUM LOUVERS
A. Horizontal, Drainable-Blade Louver:
1. Basis-of-Design Product: Subject to compliance with requirements, provide product indicated on Drawings or comparable product by one of the following:
a. Dayton b. American Warming and Ventilating; a Mestek company. c. Louvers & Dampers; a division of Mestek, Inc. d. Ruskin Company; Tomkins PLC. e. Krueger, Division of Air System Components f. Or Equal.
2. Louver Depth: 6 inches. 3. Frame and Blade Nominal Thickness: Not less than 0.080 inch. 4. Mullion Type: Exposed. 5. Louver Performance Ratings:
a. Point of Beginning Water Penetration: Not less than 900 fpm.
6. AMCA Seal: Mark units with AMCA Certified Ratings Seal.
2.3 LOUVER SCREENS
A. General: Provide screen at louvers indicated.
1. Screen Location for Fixed Louvers: Interior face. 2. Screening Type: Bird screening.
B. Louver Screen Frames: Same type and form of metal as indicated for louver to which screens are attached.
C. Louver Screening for Aluminum Louvers:
1. Bird Screening: Stainless steel, 1/2-inch- square mesh, 0.047-inch wire.
2.4 MATERIALS
A. Aluminum Extrusions: ASTM B 221, Alloy 6063-T5, T-52, or T6.
B. Aluminum Sheet: ASTM B 209, Alloy 3003 or 5005 with temper as required for forming, or as otherwise recommended by metal producer for required finish.
C. Galvanized-Steel Sheet: ASTM A 653/A 653M, G60 zinc coating, mill phosphatized.
WRCRWA FIXED LOUVERS PLANT EXPANSION PROJECT 239000 - 2 D. Fasteners: Use types and sizes to suit unit installation conditions.
1. Use Phillips flat-head screws for exposed fasteners unless otherwise indicated. 2. For fastening aluminum, use aluminum or 300 series stainless-steel fasteners. 3. For fastening galvanized steel, use hot-dip-galvanized steel or 300 series stainless-steel fasteners. 4. For color-finished louvers, use fasteners with heads that match color of louvers.
E. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.
F. Color: Selected by Owner.
2.5 FABRICATION
A. Fabricate frames, including integral sills, to fit in openings of sizes indicated, with allowances made for fabrication and installation tolerances, adjoining material tolerances, and perimeter sealant joints.
B. Join frame members to each other and to fixed louver blades with fillet welds , threaded fasteners, or both, as standard with louver manufacturer unless otherwise indicated or size of louver assembly makes bolted connections between frame members necessary.
2.6 GALVANIZED-STEEL SHEET FINISHES
A. Finish louvers after assembly.
B. Surface Preparation: Clean surfaces with nonpetroleum solvent so surfaces are free of oil and other contaminants. After cleaning, apply a conversion coating compatible with the organic coating to be applied over it. Clean welds, mechanical connections, and abraded areas and repair according to ASTM A 780.
C. Baked-Enamel or Powder-Coat Finish: Immediately after cleaning and pretreating, apply manufacturer's standard two-coat, baked-on finish consisting of prime coat and thermosetting topcoat, with a minimum dry film thickness of 2 mils.
1. Color and Gloss: As indicated by manufacturer's designations.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Locate and place louvers level, plumb, and at indicated alignment with adjacent work.
B. Use concealed anchorages where possible. Provide brass or lead washers fitted to screws where required to protect metal surfaces and to make a weathertight connection.
C. Provide perimeter reveals and openings of uniform width for sealants and joint fillers, as indicated.
WRCRWA FIXED LOUVERS PLANT EXPANSION PROJECT 239000 - 3 D. Protect unpainted galvanized and nonferrous-metal surfaces that are in contact with concrete, masonry, or dissimilar metals from corrosion and galvanic action by applying a heavy coating of bituminous paint or by separating surfaces with waterproof gaskets or nonmetallic flashing.
3.2 ADJUSTING
A. Restore louvers damaged during installation and construction so no evidence remains of corrective work. If results of restoration are unsuccessful, as determined by Architect, remove damaged units and replace with new units.
END OF SECTION 239000
WRCRWA FIXED LOUVERS PLANT EXPANSION PROJECT 239000 - 4
SECTION 260000 – GENERAL ELECTRICAL REQUIREMENTS
PART 1 - GENERAL
1.1 SUMMARY
A. It is the intent of this part of the Contract Documents to cover the work and materials necessary for erecting a complete electrical system, tested and ready for continuous use. The system shall be constructed in accordance with the Contract Documents, and Federal, State, and Local codes and regulations.
1.2 RELATED SECTIONS
A. The Contractor shall coordinate the work with other trades, and furnish and install the equipment in accordance with the manufacturers’ requirements.
B. The Related Work can be found in other Divisions of these specifications, such as, but not limited to:
Division 0 Bidding Requirements, Contract Forms, and Conditions of the Contract Division 1 General Requirements Division 2 Sitework Division 3 Concrete Division 9 Finishes Division 14 Conveyance Equipment Division 15 Owner Furnished and Owner Selected Equipment Division 22 Plumbing Division 23 Heating Ventilating and Air Conditioning Division 40 Process Integration
1.3 GENERAL PROVISIONS
A. Minimum sizes of equipment, and electrical devices, are indicated but it is not intended to show every offset and fitting, nor every structural or mechanical difficulty that will be encountered during the installation of the work.
B. Work indicated on the Plans is approximately to scale, but actual dimensions and detailed Plans should be followed as closely as field conditions permit. Field verification of scale dimensions on Plans is governed by field conditions. Installation of systems and equip- ment is subject to clarification as indicated in reviewed shop drawings and field coordina- tion.
C. Discrepancies indicated on different Plans, between Plans and actual field conditions, or between Plans and Contract Documents shall be promptly brought to the attention of the Engineer for clarification, prior to purchasing and installing equipment.
D. The alignment of equipment and conduit shall be adjusted to accommodate architectural changes, or to avoid work of other trades, without extra expense to the Owner.
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-1
E. The Contractor shall furnish and install the parts and pieces necessary to the installation of equipment, in accordance with the best practice of the trade, and in conformance with the requirements of these Contract Documents.
F. Items not specifically mentioned in these Contract Documents, or noted on the Plans, or indicated on reviewed shop drawings, but which are obviously necessary to make a com- plete working installation, shall be deemed to be included herein.
G. The Contractor shall lay-out and install electrical work prior to placing floors and walls. Furnish and install sleeves and openings through floors and walls, required for installa- tion of conduits. Sleeves shall be rigidly supported and suitably packed, or sealed, to pre- vent ingress of wet concrete. Spacers shall be installed in order to prevent conduit movement. Dimensions indicated for electrical equipment and their installation are re- strictive dimensions.
H. The Contractor shall furnish and install inserts and hangers required to support conduits and other electrical equipment. If the inserts, hangers, sleeves, or other mounting hard- ware are improperly placed, or installed, the Contractor shall do necessary work, at their own expense, to rectify the errors.
I. Electrical equipment shall be capable of operating successfully at full-rated load, without failure, at an ambient air temperature of 40 degrees C, and specifically rated for the alti- tude indicated on the Plans. Electrical equipment not rated for operation at that tempera- ture shall be provided with air conditioning to meet the manufacturers’ operating temper- ature.
J. If any contradictions, contrasts, nonhomogeneity, or inconsistency appears, the most strict criteria noted and the collective requirements in any and all of the project docu- ments shall apply.
K. The Contractor shall perform necessary saw cutting, core drilling, excavating, removal, shoring, backfilling, and other work required for the proper installation of conduits, whether inside, or outside of the buildings and structures. The Contractor shall repair and patch where demolition has taken place in a manner to match existing original structure.
1.4 REGULATIONS, CODES, AND STANDARDS
A. Electrical work, including connection to electrical equipment integral with mechanical equipment, shall be performed in accordance with the latest published regulations, codes, and standards, of the following:
1. National Electrical Code (NEC) 2. State and local codes 3. Institute of Electrical and Electronic Engineers (IEEE) 4. American National Standards Institute (ANSI) 5. American Society for Testing and Materials (ASTM) 6. Insulated Cable Engineers Association (ICEA) 7. National Electrical Manufacturers Association (NEMA) Standards 8. Federal Occupational Safety and Health Act (OSHA) 9. National Fire Protection Association (NFPA)
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-2
B. When applicable, the material used in the performance of the electrical work shall be listed by the Underwriters' Laboratories, Inc. (UL) for the class of service for which they are intended.
1.5 SUBMITTALS
A. It is the obligation of the Contractor to organize their work, so that a complete electrical, instrumentation, and control system for the facility will be provided, and will be support- ed by accurate shop and record drawings, and O&M manuals.
B. The Contractor shall submit detailed shop drawings and data prepared and organized by the suppliers. The quantity of submittal sets required shall be as specified in the Contract Documents.
C. The submittals shall be neatly grouped and organized by specification section number, and sub-section. Related information shall be highlighted, and the specific product shall be marked. All submittals shall be complete, and presented in one package. Incomplete submittals will be returned without review. If a portion of the project requires a fast track schedule, that portion only may be submitted earlier under a separate cover letter. The following shall be submitted to the Engineer and returned, reviewed to the Contractor be- fore fabrication is started.
1. A complete list of the equipment and materials, including the manufacturer's name, product specification, descriptive data, technical literature, performance charts, cata- log cuts, installation instructions, and spare part recommendations for each different item of the equipment specified. The above shall clearly show all the specified re- quirements as described in the Specifications including but not limited to specific U.L. and NEMA rating, technical capabilities, test result verifications, Seismic Zone rating, and acceptance letters.
2. Drawings containing complete wiring and schematic diagrams, control diagrams, and any other details required to demonstrate that the system has been coordinated and will operate as intended. Drawings shall also show proposed layout, anchoring, sup- port, and appurtenances of equipment, and equipment relationship to other parts of the work including clearances for maintenance and operations.
3. Any exceptions to these specifications, with the reasons for requesting such excep- tions, with calculations and drawings for redesign of related components, including detail drawings showing internal and assembly details, with installation instructions. Proposed layout showing any modifications or exceptions to related work made nec- essary by this work, with calculations and drawings showing such modifications or exceptions.
4. Prior to project acceptance, The Contractor shall submit “Record Drawings” of the electrical, control, and instrumentation, along with step-by-step procedure manuals for the installation, operation start-up, and maintenance of the equipment. Each set shall include installation, operating, troubleshooting, and maintenance and overhaul instructions in complete detail. It shall also include possible breakdowns and repairs, and troubleshooting guides, as well as simplified wiring and control diagrams of the system installed. This shall provide the Owner with comprehensive information on
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-3
all systems and components to enable operation, service, maintenance and repair. Exploded or other detailed views of all equipment, devices, assemblies, and accesso- ry components shall be included, together with complete parts lists and ordering in- structions.
5. Record Drawings: a. The Contractor shall maintain a marked up set of Contract Document Plans showing actual installed circuit numbers, conduit sizes, cable tray routing, number of conductors, conductor sizes (larger than #12 AWG), and all other deviations from the design Plans. b. Underground conduit and concealed items shall be dimensioned on the Plans from permanent, visible, building features. c. The Contractor shall provide actual motor size, starter size, and overload heater size, along with all other protective equipment for all 480 V and motor circuits as part of the one-line record drawings. d. The Contractor shall revise all conductor identification and panel schedules to indicate as-built conditions.
PART 2 - PRODUCTS
2.1 GENERAL MATERIALS AND METHODS
A. Materials, equipment, and parts comprising any unit, or part thereof, specified or indicat- ed on the Plans, shall be new and unused, of current manufacture, and of highest grade consistent with the state of the art. Damaged or dirty materials, equipment, and parts, are not considered to be new and unused, and will not be accepted.
B. Field verification of scale dimensions on Plans is directed, since actual locations, distanc- es, and levels will be governed by actual field conditions. The Contractor shall also re- view architectural, structural, yard, mechanical, and other Plans, and the accepted electri- cal and mechanical shop drawings, and shall adjust their work to conform to the condi- tions indicated therein.
C. The fabricator of major components, such as distribution panelboards, switchgear, and motor control centers, shall also be the manufacturer of the major devices therein. Where possible, the major components shall be manufactured and supplied by the same fabrica- tor.
D. Refer to various Division sections for individual equipment manufacturers. Indicated manufacturers are subject to strict compliance with the specifications and complete pro- ject documents. The reference to a particular manufacturer does not relieve the Contrac- tor from conforming to the specified requirements.
2.2 NAMEPLATES
A. Where indicated elsewhere in these specifications, or on the Plans, the Contractor shall furnish and install nameplates, which shall be white laminate with black letters. The nameplates shall be fastened to the various devices with round head stainless steel screws. Each disconnecting means for service, feeder, branch, or equipment conductors shall have nameplates indicating its purpose.
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-4
2.3 EQUIPMENT ASSEMBLIES
A. Equipment assemblies, such as Service Entrance Sections, Switchgear, Switchboards, Control and Distribution Panels, and other custom fabricated electrical enclosures shall bear a UL label as a complete assembly. The UL label on the individual components making up the assembly will not be considered sufficient to meet the present requirement. Whenever a generic UL label does not apply for the assembly, a serialized UL label shall be affixed to the assembly, and the serial number shall be submitted with the assembly record shop drawings.
B. Custom fabricated electrical control panels, and enclosures shall bear a serialized UL la- bel affixed by a local inspector, and the serial number shall be submitted with the assem- bly record shop drawings.
2.4 SEISMIC RESTRAINT
A. The construction area is classified by the International Building Code (IBC) as Seismic Class D. The Code requires that not only the structures, but also major electrical compo- nents be designed and installed in a manner which will preclude damage during a seismic event. All electrical equipment shall be securely anchored and seismic braced in accord- ance with regulations contained in the most recent adopted edition of the IBC, and the Sheet Metal and Air Conditioning Contractor’s National Association (SMACNA) "Guidelines for Seismic Restraints of Electrical Systems".
B. Units mounted and secured directly to structure shall be provided with connectors of suf- ficient strength to meet the restraining criteria.
C. All electrical equipment which is securely anchored (hard mounted) to the building or structure shall have supports designed to withstand lateral and vertical "G" loadings equal to or greater than IBC requirements and SMACNA guidelines.
D. Shop drawings are required for all equipment anchors, supports and seismic restraints. Submittals shall include weights, dimensions, load/deflection data, center of gravity, standard connections, manufacturer's recommendations, and behavior problems (vibra- tion, thermal, expansion, etc.) associated with equipment.
PART 3 - EXECUTION
3.1 UTILITY SERVICE AND EQUIPMENT
A. The Contractor shall be responsible for contacting and coordinating the electrical utility work with the electrical utility company. The Contractor shall be responsible for furnish- ing and installing equipment and material required to bring electrical power service to the service location in conformance with the electrical utility requirements. The Contractor may have to provide the following for the electrical utility company's primary (from utili- ty power line to the utility transformer) and secondary (from utility transformer to the service) electrical lines in accordance with the electrical utility company’s specifications and requirements:
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-5
1. Conduits and cables (verify quantity and sizes) 2. Trenching, backfill, and compacting (verify trench size(s), backfill material, and compaction percentage requirements) 2. Concrete pad(s) (for pad mounted transformer(s)) 3. Cable protection along the vertical drop at the utility company’s pole (if pole mount- ed transformer(s)) 4. Other items required by the power utility company’s specifications 5. The Contractor shall also submit copies of service entrance shop drawings to the utility, per utility submittal requirements, prior to submittal to the Engineer. The Contractor shall obtain written approval from the power utility company that the ser- vice entrance equipment is acceptable prior to release the order to the supplier for fabrication. A copy of the approval letter from the utility shall be transmitted to the Engineer along with the submittal.
3.2 INSTALLATION OF ELECTRICAL EQUIPMENT
A. Coordinate the installation of electrical equipment with other trades.
1. Arrange for the building in of equipment during structure construction. 2. Where equipment cannot be built-in during construction, arrange for sleeves, box- outs, and other openings, as required to allow installation of equipment after structure construction is complete.
B. Verify that equipment will fit support layouts indicated.
C. Equipment Dimensions and Clearances:
1. Do not use equipment that exceeds the indicated dimensions except as approved in writing by the Engineer. 2. Do not use equipment or arrangements of equipment that reduce required clearances or exceed the space allocation.
D. Install equipment in accordance with the manufacturer's instructions.
E. Equipment Access:
1. Install equipment so it is readily accessible for operation and maintenance. 2. Equipment shall not be blocked or concealed. 3. Do not install electrical equipment such that it interferes with normal maintenance requirements of other equipment.
F. Equipment shall be installed plumb, square and true with the building construction, and shall be securely fastened.
G. Outdoor wall-mounted equipment, and indoor equipment mounted on earth, or water bearing walls, shall be provided with corrosion-resistant spacers to maintain ¼-inch sepa- ration between the equipment and the wall.
H. Screen or seal all openings into outdoor equipment to prevent the entrance of rodents and insects.
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-6
I. Equipment fabricated from aluminum shall not be imbedded in earth or concrete.
J. Provide all necessary anchoring devices and supports.
1. Use supports as detailed on the Plans and as specified. 2. Supports and anchoring devices shall be rated and sized based on dimensions and weights verified from approved equipment submittals. 3. Hardware shall be stainless steel. 4. Do not cut, or weld to, building structural members. 5. Do not mount safety switches and external equipment to other equipment enclosures, unless enclosure mounting surface is properly braced to accept mounting of external equipment.
K. Contractor shall verify exact rough-in location and dimensions for connection to electri- cal items furnished by others.
1. Shop drawings shall be obtained from those furnishing the equipment. 2. Proceeding without proper information may require the Contractor to remove and re- place work that does not meet the conditions imposed by the equipment supplied. 3. Provide sleeves wherever openings are required through new concrete or masonry members. Place sleeves accurately and coordinate locations with the Engineer. 4. Should any cutting and patching be required on account of failure of the Contractor to coordinate penetrations, such cutting and patching shall be done at the expense of the Contractor. a. The Contractor shall not endanger the stability of any structural member by cutting, digging, chasing, or drilling and shall not, at any time, cut or alter the work without the Engineer's written consent. 1) Provide additional reinforcing if required. 2) Cutting shall be done neatly using proper tools and methods. b. Subsequent patching to restore walls, ceilings, or floors to their original con- dition shall be done by the Contractor.
L. Provide concrete foundations or pads required for electrical equipment as indicated or specified.
1. Floor-mounted equipment shall be mounted on a 3-inch concrete housekeeping pad unless otherwise noted on the drawings. Pad shall be poured on top of the finished floor or slab. Contractor shall verify the distance to all equipment from the finished floor meets the current NEC requirements. All modifications shall be made to the electrical equipment as required. 2. All conduits penetrating concrete floors shall have a 3-inch concrete housekeeping pad unless otherwise noted on the drawings. Conduits should be grouped as allowed to limit the number of housekeeping pads required.
3.3 TEMPORARY POWER
A. The Contractor shall furnish, install, and maintain, temporary power and lighting systems needed for construction. This temporary system shall include weatherproof panel(s) for the Contractor’s main breakers and distribution system. Ground fault interrupting equipment shall be installed. Connections shall be watertight, with wiring done with
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-7
Type SO portable cable. After construction is completed, the Contractor shall remove temporary power equipment and devices.
3.4 CUTTING AND REPAIRING
A. Where it becomes necessary to cut into existing work for the purpose of making electrical installations, core drills shall be used for making circular holes. Other demolition meth- ods for cutting or removing shall be reviewed by the Engineer prior to starting the work.
B. The Contractor shall repair damage caused by construction, or demolition work, and re- store damaged areas to original condition.
3.5 CORROSION PROTECTION
A. Wherever dissimilar metals, except conduit and conduit fittings, come in contact, the Contractor shall isolate these metals, as required, with neoprene washers, 9 mil polyeth- ylene tape, or gaskets. Where fastening conduit, electro plated, or equivalent fasteners and stainless steel bolts shall be used.
B. Factory finishes damaged during shipping, or construction, shall be restored to original new condition. Rust shall be removed, and bare metal surfaces shall be primed and painted to match the original surrounding finish.
C. Electrical panels, switchgear, motor control centers, and other electrical equipment, shall be shipped in sealed dust and moisture proof plastic sheet enclosures, and the seal main- tained until units are installed. Said units shall be new and free of any dirt, dust, water, grease, rust, damaged parts or components. Relays, starters, circuit breakers, switches, contacts, insulators, mechanisms, and buses shall be free of dust, dirt, oil, moisture, metal shavings, and other debris before testing and energizing.
D. Equipment shall be protected at all times with plastic sheet covers until the area is free of dirt, dust, paint spray, water, heat, and other trades. Heat shall be provided to eliminate condensation. All repairs due to storage will be the responsibility of the contractor.
3.6 COORDINATION OF THE ELECTRICAL SYSTEM
A. The Contractor shall verify actual equipment, and motor full-load, and locked-rotor cur- rent ratings. The necessary minimum equipment, wire, and conduit sizes are indicated on the Plans. If the Contractor furnishes equipment of different ratings, the Contractor shall coordinate the actual current rating of equipment furnished with the branch circuit con- ductor size, the overcurrent protection, the controller size, the motor starter, and the branch circuit overcurrent protection. The branch circuit conductors shall have a current carrying capacity of not less than 125 percent of the actual full-load current rating. The size of the branch circuit conductors shall be such that the voltage drop from the overcur- rent protection devices, up to the equipment, shall not exceed 2 percent, when the equip- ment is running at full-load and rated voltage.
3.7 TESTING
A. The electrical work shall be free from improper grounds, and from short circuits. The correctness of the wiring shall be verified first by visual comparison of the conductor
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-8
connections with connection diagrams. Next, individual circuit continuity checks shall be made by using electrical circuit testers. Last, the correctness of the wiring shall be verified by the actual electrical operation of the electrical and mechanical devices. Any deviation from the wiring indicated on the Plans, or accepted Drawings, shall be correct- ed and indicated on the record drawings.
B. Each conductor shall be identified as required by the Contract Documents. This identifi- cation shall be indicated on the record drawings to enable rapid and accurate circuit trac- ing by maintenance personnel.
3.8 ONE-LINE DIAGRAMS
A. One-line diagrams, as indicated on the Drawings, show circuit voltages, circuit protection rating, and other pertinent data. Where conflicts exist on the Drawings, the one-line diagrams shall take precedence. Grounding conductors are not necessarily indicated. See grounding requirements specified elsewhere herein.
END OF SECTION 260000
WRCRWA GENERAL ELECTRICAL REQUIREMENTS PLANT EXPANSION PROJECT 260000-9
SECTION 260513 – MEDIUM VOLTAGE CABLE
PART 1 - GENERAL
1.1 SUMMARY
A. This Specification covers the minimum requirements for the design, materials, fabrication, inspection, testing and supply of 15KV medium voltage cables and cable terminations. The medium voltage cables shall meet the requirements as specified herein.
1.2 REFERENCES
A. The cable shall be manufactured and tested in complete and strict accordance with Association of Edison Illuminating Companies (AEIC)
1. CS6-82 and applicable sections of ICEA CS6 2. CS8-00, Specification for Extruded Dielectric Shielded Power Cables rated 5 through 46KV
B. American National Standards Institute/Institute of Electrical and Electronics Engineers (ANSI/IEEE)
1. C2, National Electrical Safety Code 2. 386, Standard for Separable Insulated Connector Systems for Power Distribution Systems Above 600V
C. American National Standards Institute/National Fire Protection Association (ANSI/NFPA)
1. 70, National Electrical Code
D. American Society of Testing and Materials (ASTM)
1. B3, Standard Specification for Soft or Annealed Copper Wire 2. B8, Standard Specification for Concentric Lay Stranded Copper Conductors, Hard, Medium Hard, or Soft
E. Institute of Electrical and Electronics Engineers (IEEE)
1. 48, Standard Test Procedures and Requirements for High-Voltage Alternating-Current Cable Terminations 2. 592, Standard for Exposed Semiconducting Shields on High Voltage Cable Joints and Separable Insulated Connectors
F. Insulated Cable Engineers Association (ICEA)
1. S-93-639/NEMA WC74, Shielded Power Cable 5-46kV 2. S-97-682, Utility Shielded Power Cable rated 5-46kV
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-1
3. T-25-425, Guide for Establishing Stability of Volume Resistivity for Conducting Polymeric Components of Power Cables
G. Underwriters Laboratories, Inc. (UL)
1. 1072, Medium-Voltage Solid Dielectric
1.3 SUBMITTALS
A. Test Reports
1. Certified copies of production sampling and completed cable test reports described in Paragraph 1.04 above of this Specification shall be submitted prior to shipping cable and shall be a legible and coherent format. This data should include the X-Y plot of the partial discharge test per ICEA. 2. Test reports shall be in a legible and coherent format and reported in accordance with AEIC CS6. 3. Catalog Data: Submit catalog data showing physical information, specifications used for manufacturing and materials used to manufacture cable.
B. Submittal Data Shall Include:
1. Letter stating cable meets specification and the date of cable manufacture 2. Conductor Size 3. Conductor Shield Materials 4. Insulation Material 5. Insulation Thickness 6. Diameter Over Insulation 7. Insulation Semi-conductor Thickness 8. Jacket Material 9. Jacket Thickness 10. Diameter of Cable 11. Weights per Length of Cable
C. Certification of the Qualifications of Medium-Voltage Cable Installers: The Contractor shall submit a certification of attendance to which contains the names of the Personnel who have successfully completed courses on the splicing and termination of medium-voltage cables approved for installation under this contract. The certification shall be accompanied by satisfactory proof of the training and experience of persons listed by the contractor as cable installers.
1.4 QUALITY ASSURANCE
A. Cable furnished under this specification shall conform to the latest edition of Insulated Cable Engineers Association (ICEA S-93-639) or its successors, except as specifically modified herein.
B. The completed cable shall meet or exceed all Insulated Cable Engineer's Association (ICEA), National Electrical Manufacturers Association (NEMA), and Association of Edison
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-2
Illuminating Companies (AEIC) physical and electrical tests. Tests shall be performed and frequency of sampling shall be in accordance with the latest edition of ICEA S-93-639 except as modified herein. All tests required by this specification, AEIC and ICEA shall be performed.
C. Cable shall be manufactured and tested using good care and workmanship.
D. EPR insulated cable shall be manufactured by a dry or steam curing process.
E. The conductor shield, the insulation, and the semiconducting insulation shield extrude in a triple tandem, dual tandem, or true triple process.
F. All Contractors shall require training on medium-voltage terminations. The contractor shall follow the manufacturer's recommended method for cable installation, and preparation of 15 KV tape shield EPR cable. This shall include the recommended tools and products for cable preparation.
G. AC Voltage Tests: Each factory reel length shall withstand AC voltage tests by the manufacturer at the factory in accordance with ICEA S-93-639.
PART 2 - PRODUCTS
2.1 GENERAL
A. All cable furnished shall be installed within 12 months of manufacture date. Labeling of cable shall be per NEMA and shall contain no less than the following information.
1. Name of Manufacturer 2. NEC Designation
B. Cable shall be operated at 60 Hertz, single or three phase at system voltage of up to 15 KV. Suitable installations include in conduit for wet or dry locations and in open air in sunlight.
2.2 CONDUCTOR
A. The conductor shall be Class B concentric lay stranding, un-coated copper in accordance with ASTM B3 and B8 and ICEA S-93-639 with the minimum number of wires noted below:
Conductor Size Number Range of Strands 8 - 2 7 1 - 4/0 19 250 - 500 37 501 - 1000 61
B. Conductor shall be free from moisture, corrosion and excessive drawing lubricant before conductor shielding is applied.
1. Paired, two pairs, No. 22 AWG, stranded (7x30) tinned-copper conductors. 2. Plastic insulation.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-3
2.3 CONDUCTOR SHIELD (STRAND SCREEN)
A. The strand screen shall consist of an extruded semi-conducting thermosetting compound applied over the conductor. It shall be of a material compatible with the thermal characteristics of this conductor metal and insulation, shall be uniformly and firmly bonded to the overlying insulation, and shall be free stripping from the conductor. A semi-conducting tape may be applied between the conductor and the extruded conductor screen. Okonite EPR based semiconductor is an approved exception.
B. The D-C volume resistivity of the extruded conductor shield shall not exceed 1000 meter-ohms at the maximum normal operating and emergency operating temperature accordance with ICEA Publication T-25-425.
C. The extruded strand shield shall have a minimum elongation of 100% after an air oven test at 121¡C for seven days and a brittleness temperature not warmer than -10¡C.
D. The contact area between the insulation and conductor shield shall not exhibit projections or irregularities which extend from the cylindrical surface of the conductor shield by more than 5 mils (.127 mm) toward the insulation or 10 mils (.254 mm) away from the insulation.
2.4 INSULATION
A. Insulation shall conform to ICEA S-93-639 except as modified herein and shall be the following, or a prior approved equal:
1. The insulation shall be a high quality heat, moisture, ozone, and corona resistant high dielectric strength ethylene propylene rubber compound. It shall be contrasting in color from the extruded strand and insulation screens. It shall contain less than 5% polyethylene, and the ethylene content of the elastomer shall not exceed 72.5% by weight of ethylene to limit susceptibility to treeing. 2. Insulation shall be for use in wet or dry locations at conductor temperatures not exceeding 105¡C for continuous operation, 140¡C emergency overload conditions, and 250¡C short circuit conditions.
B. The insulation shall have a minimum and maximum thickness for a 133% insulation level as specified in Table II below: TABLE II
Rated Circuit Conductor Minimum Maximum Voltage (kV) Size Insulation Insulation (Phase to Phase (AWG or kcmil) Thickness (mils) Thickness (mils) 5 8 - 1000 85 (2.16 mm) 120 (3.05 mm) 8 6 - 1000 135 (3.43 mm) 170 (4.32 mm) 15 2 - 1000 210 (5.33 mm) 250 (6.35 mm)
C. Insulation shall be homogeneous and free of gels or discolorations larger than 10 mils (.254 mm)
D. The insulation shall meet or exceed the requirements of all tests specified in ICEA S-93-639.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-4
E. The interface between the insulation and insulation shield shall be free of contaminants larger than 4 mils. The insulation shall be free from contaminants, gels and agglomerates larger than 10 mils.
2.5 INSULATION SHIELD (INSULATION SCREEN)
A. Insulation shield shall conform to ICEA S-93-639, except as modified herein.
B. The insulation screen shall consist of an extruded, semi-conducting thermosetting compound applied over and compatible with the insulation. It shall be of a material compatible with the thermal and chemical characteristics of the insulation and the overlaying metallic shield. Okonite EPR based semiconductor is an approved exception.
C. The thickness with corresponding minimum and maximum points shall be as specified in Table III:
TABLE III
Calculated Minimum Diameter Insulation Shield Insulation Shield over Insulation Minimum Point Maximum Point (inches) Thickness Thickness (mils) 0 - 1.000 24 60
1.001 - 1.500 32 60 1.501 - 2.000 40 75 2.001 & Larger 40 90
D. The insulation shield shall not alter its physical or electrical properties from exposure to sunlight or the elements.
1. The extruded insulation shield shall have a minimum elongation of 100% after an air oven test at 121¡C for 7 days and a brittleness temperature not warmer than -30¡ C.
E. The D-C volume resistivity of the extruded insulation shield shall not exceed 75 meter-ohms at 90¡C when tested in accordance with ICEA Publication T-25-425.
F. The insulation shield shall be free stripping from the insulation, and the tension necessary to remove the extruded insulation shield shall be 3 to 24 pounds (to 10.886 Kg) at room temperature when tested in accordance with ICEA S-93-639.
G. The contact area between the insulation and insulation shield shall not exhibit projections or irregularities, which into the insulation from the insulation shield more than 5 mils and into the insulation shield from the insulation more than 7 mils.
2.6 METAL TAPE SHIELD
A. Cable shall have a metal tape or metal tape with wire shield.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-5
B. A copper tape with nominal thickness of 0.005 inches (.127mm) shall be applied directly over the insulation shield. The tape shall be of suitable width and shall lap at least 12.5 percent of its width. The tape shall be free from burrs and, where jointed, shall be made electrically continuous. (If wire shield is used, it shall be mechanically and electrically comparable).
C. Application of tape shield or wire shield shall not deform the insulation.
2.7 JACKET
A. The jacket shall be black polyvinyl chloride compound meeting the requirements of ICEA S-93- 639.
B. The average thickness of the jacket shall be not less than the values specified in the following table. The minimum thickness of the jacket at any point shall be not less than 80 percent of the specified minimum average thickness.
TABLE IV
Calculated Diameter of Min. Thickness Cable under Jacket (inches) of Jacket (mils) 0.700 and Smaller 55 (1.40mm) 0.701 - 1.500 70 (1.78mm) 1.501 - 2.500 100 (2.54mm) 2.501 and Larger 125 (3.17mm)
C. Linear shrinkage of the jacket shall not exceed the linear shrinkage of the insulation.
D. The jacket shall be sunlight resistant in accordance with the requirements of UL 1072.
2.8 CABLE DIMENSIONS
A. Cable dimensions shall be in accordance with ICEA S-97-682
B. Diameters over insulation shall be in accordance with ICEA S-97-682
2.9 PACKAGING
A. The cable shall be placed on the shipping reel with both ends of cable accessible for proof testing in Appendix A. Ends of cable shall be sealed with weatherproof material prior to shipment.
2.10 MANUFACTURER
A. Primary EPR insulated power cables as manufactured by Okonite, Pirelli, General Cable, Keyrite, and Southwire or approved equal.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-6
B. The cable manufacturer shall have a minimum of 10 years proven and successful experience with the manufacturing of EPR insulated cables.
2.11 CABLE TERMINATIONS
A. Outdoor: Terminations that are exposed to the weather, such as riser poles.
1. Terminations of the shielded power cables shall be manufactured molded rubber terminations, IEEE 48, Class 1. Elastimold type 35MTG or approved equal with the grounding device for the metallic shield (Elastimold Type 20 MA for metallic type shield) and NEMA 2-hole, long-barrel terminal connector. The connector shall be listed for copper/aluminum applications.
B. Indoor: Terminations that are inside equipment or weatherproof compartments of outdoor equipment, such as transformers and switchgear.
1. Terminations of shielded power cables rated 15 kV or less shall be done with an IEEE Standard 48 Class 1 termination. It shall either be a one-piece design, where high- dielectric constant stress control is integrated within a skirted insulator made of silicone rubber, gray in color or provide for positive placement of the stress control with the installation of a stress patch. The termination shall not require heat or flame for installation. The terminations shall be 3M cold shrink Termination Kits, Raychem cold shrink Termination Kits, Elastimold cold shrink Termination Kits or approved equal. Only a NEMA 2-hole, long-barrel terminal connector shall be used. The connector shall be listed for copper/aluminum applications.
C. Cable terminations shall have voltage ratings of not less than 15,000 volts (ungrounded neutral). The standard withstand test voltage of the completed terminations shall conform to IEEE Standard No. 48.
2.12 SPLICES AND TAPS
A. Unless specified otherwise, all splices and taps shall be as per items B & C below. Only where hand-made splices are called out on the contract documents shall Item D apply. Unless specifically called out on drawings splices are not allowed.
B. In manholes, splices for feeders shall only be 600 Amp non-loadbreak power distribution connectors. Approved manufactures are Elastimold Catalog #K655BLR and Cooper Catalog #SSPL625AX* ( where *-X is replaced by number of T-bodies). Order manufactures’ corresponding cable adapter and compression connector sized per phase conductor. Elastimold or Cooper insulating plug, basic insulating plug and/or connecting plug shall be required for assembly. Manufacturer’s approved tape shield adaptors are required.
C. In above ground sectionalizing cabinets and transformers, taps shall be 600 Amp 15/25 KV Class Bol-T dead break connectors Cooper Cat# BT625-W-X-C2T or approved equal
1. * W is replaced by symbol per table in catalog for insulation diameter. Size for cable supplied.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-7
2. ** X is replaced by symbol per table in catalog for conductor size. Size for cable supplied.
D. Handmade splices to cable may be handmade from tape kits 3M 5700 series. Refer to manufacturer's catalog selection guide for voltage, conductor size and type information for ordering. Reference drawings for application of handmade splices.
2.13 CABLE IDENTIFICATION TAGS
A. The cables shall have identification tags in manholes (at conduit entrances and splices) and at equipment terminations indicating feeder number and routing (Example: Cable# 19M Routing: "To T15D”). The tags shall be one (1) inch polypropylene plastic (Almetek EZH9 or equal) affixed to cables with plastic or nylon ties (see Figure 1, Appendix B).
B. At underground riser poles where feeders make a transition from underground to overhead, the feeder number will be 2" x 2" (50.8 mm x 50.8 mm) black letters on yellow background adhesive-backed numbers. These numbers shall be attached to an aluminum strip nailed to wood or banded to steel pole above the cable terminator bracket.
PART 3 - EXECUTION
3.1 INSTALLATION
A. All work on primary conductors shall be done only when such conductors and equipment are de-energized. Unless otherwise noted on drawings, or directed, any tie-ins or connections to existing utilities or equipment that necessitate interruptions shall be performed when scheduled to be available by owner and utility. If this requires work on Saturday or Sunday it shall be without additional contract costs. The Contractor shall not interrupt any main electrical utility without a written request for an outage and a subsequent approval owner and or utility.
1. Written request for outages shall be submitted twenty-one (21) calendar days in advance of the outage date. This request will delineate the particular circuit or service interrupted and the approximate hours the utility shall be off. 2. The work to be performed during an interruption of electrical utilities will be preceded by all possible preparation and will be carefully coordinated to minimize the duration of the interruption and work will proceed continuously until the system is restored to normal. 3. Phasing of reconnected feeders shall be identical to the existing phasing.
B. Install and terminate primary cables in accordance with the manufacturer's approved recommendations and tools suggestions. The conductors shall be free of kinks and twists, and all bends shall be formed with smooth radius not smaller than twelve times the diameter of the cable nor smaller than the minimum radius recommended by the manufacturer, whichever is greater. All 600 Amp and 200 Amp terminations shall be mounted to avoid any stress on the terminations.
C. The two-hole cable connectors shall be crimped with only the manufacturer's approved tool recommendations.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-8
D. All cables in one conduit shall be pulled in together using a suitable patented grip on the conductors with a basket weave grip over the insulation, arranged so the stress of pulling is applied to the conductor and not the insulation.
E. Use a swivel between the cable grip and pulling rope:
F. Lubricate cables with Cablelube or Minnearallac cable pulling compound or the type approved by the cable manufacturer.
G. Maximum pull tensions shall not exceed values recommended by the cable manufacturer or as specified on the drawings. Pulls shall be made in the directions shown on the plans.
H. Install cables in manholes along wall as specified on drawing providing proper support. In manhole, route cables a minimum of 3/4 of manhole perimeter.
I. Cable shield shall be grounded with #6 bare copper to manhole ground at all terminations to provide permanent, low-resistance bond.
J. Seal all duct runs in manholes going inside buildings with a water-tight seal.
K. Cables of the same circuit shall be identified by tags in manholes (at conduit entrances and T- splice) and entrances into equipment. Information on tags shall include: circuit number and routing (circuit number will be confirmed at the outage coordination meeting). Tags shall be installed on each cable after fireproofing (see Part 2.14).
L. Cables of the same circuit shall have the phasing identified with color tape in manhole. Phase A with one wrap, Phase B with two wraps, Phase C with three wraps.
3.2 CABLE ENDS
A. After cutting, if cable ends are not to be terminated in same working day cut, immediately protect cable ends from damage or moisture by sealing with cable caps and silicone sealant. Provide stress relief at all terminations. Provide correct phasing of the conductors of each circuit at all terminations. Provide proper connections of tape shield or tape shield and drain wire to ground.
3.3 TESTS AND RECORDS
A. Prior to energizing the cable, testing of the cable shall be performed in the presence of the owners designated representative in accordance with Appendix A.
B. Exposed ends of cable shall be prepared and cleaned prior to testing in order to minimize any leakage current.
C. Cable circuit ends must be cleaned and guarded for personnel safety during cable testing. Circuits not under test in the immediate vicinity shall be grounded.
D. Exposed circuit ends under test require a minimum separation from all elements not subjected to a test of 1 inch (25.4 mm) per 10 kV of test potential. After testing, cables shall be grounded
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-9
for a minimum of 4 times (4X) as long as the test voltage was applied during the hi-potential tests to assure complete discharge.
E. When all cable, splices and terminations have been tested in accordance with Appendix A, and test results have been accepted by the designated representative, the cable system may be placed in service as per the outage procedure.
END OF SECTION 260513
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-10
SECTION 260513 – HIGH VOLTAGE D.C. TESTING APPENDIX A
After the installation of the primary cables the contractor shall test cables per this specification. The Contractor shall use calibrated test equipment for "Hi-potting" cables. The "Hi-pot" tests shall be performed at the times directed in this specification. The Contractor shall furnish all instruments and personnel required for the tests, and electrical power will be furnished to the contractor on an "as is available" basis; otherwise Contractor supplies generator. A Cable High Potential Test Certificate (blank form) will be furnished to the contractor. The contractor shall fill out the appropriate information on this form at the time of making the test for approval. See attached Forms A through D at the end of this appendix. APP1.01 TEST PROCEDURE
All medium voltage cables installed and existing cables spliced to the new cables shall be tested as follows, using D.C. hi-potential. (Note: This is not a grounding or switching procedure; see outage procedure for grounding and switching sequence).
A. Field Testing of New Cables After Installation: The cable shall be tested according to 1.01A after installation and installation of stress relief devices as in 1.01A. Both ends of the cable shall be isolated from air break switches, transformers, etc. Remove all grounds from cable to be "hi-potted". (Note: If conductors are left connected to the equipment, the hi-pot test shall not exceed the rating of the equipment). For cables terminated with a 200 Amp elbow connector, elbows shall be placed on an insulated parking bushing prior to test. For cables terminated with a 600 Amp T-splice connector, the T-splice shall be capped prior to test.
B. Field Testing of New Cables Jointed to Existing Cable
1. After acceptance tests for new cables, rated at 15KV, have been made and new cables are spliced to existing cables, a second test of the entire cable run, from termination to termination, shall be made. This is only applicable where an existing cable is introduced into the circuit.
2. The procedure for testing shall be the same as indicated in Paragraph 1.01 above, except that the test voltage will be reduced to the values indicated on the appropriate form. Appropriate records shall be made, as indicated on Forms A through D.
3. This test is also applicable for testing of existing 15 kV rated cable where it is important to test the integrity of the cable.
A. Dissipation of the charge build-up on the conductors shall be allowed to drain off through the test set and voltmeter circuit. After the potential drops below 95% of the test value, the conductor shall be solidly grounded. The grounds shall be left on all conductors for a minimum of 4 times (4X) as long as the test voltage was applied during hi-potential tests and/or as long as someone is handling the conductors.
APP1.02 FAULTY CABLE
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-11
Contractor Furnished: In the event that any new contractor-furnished cable fails to meet any of the above tests, the entire faulty cable shall be removed and new cable shall be installed and tested at no increase in the contract price.
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-12
PREPARED BY: FORM C
CHECKED BY: SPEC. NO.: 26122 CABLE HI POTENTIAL TEST DATE: REV. B CERTIFICATE, 15KV CLASS ELECTRICAL 10/01 NEW INSTALLATION
CONTRACT NO. ______DATE ______CABLE OR DESIGNATION ______LOCATION ______CABLE SIZE ______INSULATION AND JACKET TYPE ______LENGTH ______FT MAX. CURRENT AFTER 100% TEST VOLTAGE APPLIED ______
CABLE ACCEPTABLE ______NOT ACCEPTABLE ______TEST CONDUCTED BY: ______TEST WITNESSED BY: ______REMARKS: ______TEMPERATURE: ______¡F WEATHER CONDITIONS: ______5KV CABLE, HI-POTENTIAL TEST FOR INITIAL INSTALLATION TEST (NEW CABLE) VOLTAGE TIME MICRO POLARIZATION INDEX= = STEP 12 STEP LEVEL** DURATION ELAPSE AMPS * STEP 17 1 5 KV 1 Min. 1 Min. 2 10 KV 1 Min. 2 Min. 3 15 KV 1 Min. 3 Min. 4 20 KV 1 Min. 5 Min. 5 25 KV 1 Min. 7 Min. 6 30 KV 1 Min. 9 Min. 7 35 KV 1 Min. 11 Min. 8 40 KV 1 Min. 13 Min. 9 45 KV 1 Min. 15 Min. 10 50 KV 1 Min. 17 Min. 11 55 KV 1 Min. 19 Min. 12 60 KV 1 Min. 21 Min. ______13 60 KV 1 Min. 23 Min. 14 60 KV 1 Min. 25 Min. 15 60 KV 1 Min. 27 Min. 16 60 KV 1 Min. 29 Min. 17 60 KV 1 Min. 31 Min. ______= ______
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-13
* READING AT END OF 1-2 MIN. DURATION PRIOR TO RAISING VOLTAGE TO NEXT STEP. ** BETWEEN EACH STEP RAISE VOLTAGE UNIFORMLY. NOTE: STOP TEST IF CURRENT STEADILY INCREASES AT CONSTANT VOLTAGE. POLARIZATION RESULTS: IF 1.25 - 2.0 GOOD IF BELOW 1.0 FAILURE IF 1.0 - 1.25 MARGINAL
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-14
PREPARED BY: FORM D
CHECKED BY: SPEC. NO.: 26122 CABLE HI POTENTIAL TEST DATE: REV. B CERTIFICATE, 15KV CLASS ELECTRICAL 10/01 EXISTING INSTALLATION
CONTRACT NO. ______DATE ______CABLE OR DESIGNATION ______LOCATION ______CABLE SIZE ______INSULATION AND JACKET TYPE ______LENGTH ______FT MAX. CURRENT AFTER 100% TEST VOLTAGE APPLIED ______
CABLE ACCEPTABLE ______NOT ACCEPTABLE ______TEST CONDUCTED BY: ______TEST WITNESSED BY: ______REMARKS: ______TEMPERATURE: ______¡F WEATHER CONDITIONS: ______
5 KV CABLE, HI-POTENTIAL TEST FOR EXISTING CABLE AND FOR NEW CABLE SPLICED TO EXISTING CABLE VOLTAGE TIME MICRO POLARIZATION INDEX= = STEP 4 STEP LEVEL** DURATION ELAPSE AMPS * STEP 7 1 5 KV 1 Min. 1 Min. 2 10 KV 1 Min. 2 Min. 3 15 KV 1 Min. 3 Min. 4 20 KV 1 Min. 4 Min. ______5 20 KV 1 Min. 5 Min. 6 20 KV 1 Min. 6 Min. 6 20 KV 1 Min. 7 Min. 6 20 KV 1 Min. 8 Min. 7 20 KV 1 Min. 9 Min. ______= ______
* READING AT END OF 1 MIN. DURATION PRIOR TO RAISING VOLTAGE TO NEXT STEP. ** BETWEEN EACH STEP RAISE VOLTAGE UNIFORMLY. NOTE: STOP TEST IF CURRENT STEADILY INCREASES AT CONSTANT VOLTAGE. POLARIZATION RESULTS: IF 1.25 - 2.0 GOOD IF BELOW 1.0 FAILURE IF 1.0 - 1.25 MARGINAL
WRCRWA MEDIUM VOLTAGE CABLE PLANT EXPANSION PROJECT 260513-15
SECTION 260519 - LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes the following:
1. Building wires and cables rated 600 V and less. 2. Connectors, splices, and terminations rated 600 V and less.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control test reports.
1.4 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
B. Comply with NFPA 70.
PART 2 - PRODUCTS
2.1 CONDUCTORS AND CABLES
A. All conductors, conductor insulation and multiconductor cables shall comply with NEMA WC 70.
B. Wire sizes shall be American Wire Gauge (AWG) sizes with Class B stranded construction Number 2 AWG and smaller shall be factory color coded with a separate color for each phase and neutral, which shall be used consistently throughout the system. Larger cables shall be coded by the use of colored tape. Conductors #6 AWG or smaller shall be THWN-2 or XHHW-2. Number 4 and larger shall be XHHW-2.
C. Individual or multiple conductor cables for power, control, and alarm circuits of 480 volts or less shall be insulated for not less than 600V.
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 1
D. Where wire size is not indicated, they shall be of the size required by the NEC, except that no wire external to panels and motor control centers shall be less than #12 AWG, unless specifically noted on the Plans. Control wires shall be allowed to be #14 so long as there is appropriate protection (fuse or circuit breaker sized at 15A or less).
E. Multi-conductor tray cables shall be rated 600 volts, listed by UL as Type TC cable or ITC for instrumentation cable only per Article 340 of the NEC. The individual conductors shall be UL listed as Type XHHW, with a sunlight-resistant overall jacket. Conductor sizes shall be the same as for power and lighting wire and control wire above. Connectors/Terminators shall be water tight and manufactured of the same material as the cabling system referenced elsewhere in division 26.
F. Multi-conductor tray cables to be installed in classified areas shall be armored, rated 600 volts, listed by UL as Type MC-HL cable per Article 340 of the NEC. The individual conductors shall be UL listed as Type XHHW, with a sunlight-resistant overall jacket. Conductor sizes shall be the same as for power and lighting wire and control wire above. Connectors/terminators shall be rated for classified areas and submitted upon accordingly.
G. All wiring shall be as indicated on the Plans. Wires shall be new and shall be soft drawn copper with not less than 97 percent conductivity. The wire and cable shall have size, grade of insulation, voltage, and manufacturer's name permanently marked on the outer covering at not more than 2-foot intervals. All wires shall conform to the latest Standards of the ASTM, and ICEA, and shall be tested for their full length by these Standards. Insulation thickness shall be not less than that specified by the National Electrical Code.
H. VFD Cable:
1. Comply with UL 1277, UL 1685, and NFPA 70 for Type TC-ER cable. 2. Type TC-ER with oversized crosslinked polyethylene insulation, spiral-wrapped foil plus 85 percent coverage braided shields and insulated full-size ground wire, and sunlight- and oil-resistant outer PVC jacket. 3. Comply with UL requirements for cables in direct burial or Classes I and II, Division 2 hazardous location applications.
I. The following table describes the conductor color code that shall be followed:
120/208VAC 480VAC 12VDC 24VDC 24VAC Phase 1 Black Brown Phase 2 Red Orange Phase 3 Blue Yellow Neutrals/Commons White White Orange/White Blue/White Yellow/White Ground Green Green Green Green Green Control Red Orange Blue Yellow
J. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. American Insulated Wire Corporation
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 2
2. Cablec Corporation 3. Okonite Company 4. Southwire Company 5. Or Approved Equal
2.2 CONNECTORS AND SPLICES
A. Description: Factory-fabricated connectors and splices of size, ampacity rating, material, type, and class for application and service indicated.
B. Connectors and splices shall be rated at not less than 600 volts. Splicing shall join conductors mechanically and electrically to provide a complete circuit prior to installation of insulation.
C. Splices in wires No. 10 AWG and smaller shall be made with an insulated, solderless, pressure type connector, Type I, Class 1, Grade B, Style G, or Type II, Class 1 of FS W-S-610 and conforming to the applicable requirements of UL 486A.
D. Splices in wires No. 8 AWG and larger shall be made with noninsulated, solderless, pressure type connector, Type II, Class 2 of FS W-S-610, conforming to the applicable requirements of UL 486A and UL 486B. They shall then be covered with an insulation and jacket material equivalent to the conductor insulation and jacket.
E. Insulated conductor splices below grade or in wet locations shall be sealed type conforming to ANSI C119.1 or shall be waterproofed by a sealant-filled, thick wall, heat shrinkable, thermosetting tubing or by pouring a thermosetting resin into a mold that surrounds the joined conductors.
F. Bare conductor splices in wet locations or below grade shall be of the exothermic type.
G. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Hubbell Power Systems, Inc. 2. O-Z/Gedney; EGS Electrical Group LLC. 3. 3M; Electrical Products Division. 4. Or Approved Equal
2.3 PULLING LUBRICANT
A. All cables shall be properly coated with a water-based (wax-based is not acceptable) pulling compound before being pulled into conduits so as to prevent mechanical damage to the cables during installation. Lubricants shall be approved by the cable manufacturer for use with the cable being installed.
B. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Polywater 2. Ideal Aqua-Gel
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 3
3. Or Approved Equal
PART 3 - EXECUTION
3.1 CONDUCTOR MATERIAL APPLICATIONS
A. Feeders: Copper. Stranded for all sizes.
B. Branch Circuits: Copper. Stranded for all sizes.
3.2 CONDUCTOR INSULATION AND MULTICONDUCTOR CABLE APPLICATIONS AND WIRING METHODS
A. Service Entrance: Type XHHW-2, single conductors in raceway
B. Exposed Feeders and Branch Circuits: Type THWN-2 or XHHW-2 based on wire size requirements described in Part 2, single conductors in raceway. Multiconductor Tray Cable type TC shall be used where runs are to be in cable trays as shown on the drawings.
C. Feeders and Branch Circuits Concealed in Ceilings, Walls, Partitions, and Crawlspaces: Type THWN-2 or XHHW-2 based on wire size requirements described in Part 2, single conductors in raceway. Metal-clad cable, Type MC shall be allowed in ceilings that are considered dry and non-corrosive areas.
D. Feeders and Branch Circuits Concealed in Concrete, below Slabs-on-Grade, and Underground: Type THWN-2 or XHHW-2 based on wire size requirements described in Part 2, single conductors in raceway.
E. Cord Drops and Portable Appliance Connections: Type SO, hard service cord with stainless- steel, wire-mesh, strain relief device at terminations to suit application.
F. Class 1 Control Circuits: Type THWN-2, in raceway. Multiconductor Tray Cable type TC shall be used where runs are to be in cable trays as shown on the drawings.
G. Class 2 Control Circuits: Type THWN-2, in raceway. Power-limited tray cable shall be used where runs are to be in cable tray as shown on the drawings.
3.3 INSTALLATION OF CONDUCTORS AND CABLES
A. Conceal cables in finished walls, ceilings, and floors, unless otherwise indicated.
B. As far as practical, all circuits shall be continuous from origin to termination without splices in intermediate pull boxes. Sufficient slack shall be left at the termination to make proper connections. In no case shall a splice be pulled into the conduit. Conductor splicing shall not be permitted without the Engineer's approval. Conductor splices shall not be made in underground junction boxes or manholes unless specifically noted on the plans.
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 4
C. Each feeder and branch circuit shall be installed in its own individual conduit unless combining feeder and branch circuits is permitted as defined in the following:
1. As specifically indicated on the Plans. 2. For lighting, multiple branch circuits may be installed in a conduit as allowed by the NEC and with the wire ampacity de-rated in accordance with the requirements of the NEC. Conduit fill shall not exceed the limits established by the NEC. 3. When field conditions dictate and written permission is obtained from the Engineer.
D. Use manufacturer-approved pulling compound or lubricant when pulling conductors; compound used must not deteriorate conductor or insulation. Do not exceed manufacturer's recommended maximum pulling tensions and sidewall pressure values.
E. Feeder and branch circuits shall be isolated from each other and from all instrumentation and control circuits.
F. Control circuits shall be isolated from all other feeder, branch and instrumentation circuits, except as noted above. 12VDC, 24VDC and 48VDC control circuits may be combined into one conduit. 120/208/240VAC control circuits shall be isolated from all DC control circuits. 277/480VAC circuits shall be isolated from all other voltages.
G. Single conductor cable in cable trays shall be No. 1/0 or larger and shall be of a type listed and marked for use in cable trays. Tray cable smaller than 1/0 shall be multi-conductor, with outer jacket.
H. Use pulling means, including fish tape, cable, rope, and basket-weave wire/cable grips, that will not damage cables or raceway.
I. Install exposed cables parallel and perpendicular to surfaces of exposed structural members, and follow surface contours where possible.
J. Support cables according to Section 260529 "Hangers and Supports for Electrical Systems."
K. Identify and color-code conductors and cables according to Section 260553 "Identification for Electrical Systems."
L. Tighten electrical connectors and terminals according to manufacturer's published torque- tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B.
M. Make splices and taps that are compatible with conductor material and that possess equivalent or better mechanical strength and insulation ratings than unspliced conductors.
N. Wiring at Outlets and Switches: Install conductor at each outlet, with at least 6 inches (150 mm) of slack.
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 5
3.4 SLEEVE AND SLEEVE-SEAL INSTALLATION FOR ELECTRICAL PENETRATIONS
A. Install sleeves and sleeve seals at penetrations of exterior floor and wall assemblies. Comply with requirements in Section 260544 "Sleeves and Sleeve Seals for Electrical Raceways and Cabling."
3.5 FIRESTOPPING
A. Apply firestopping to electrical penetrations of fire-rated floor and wall assemblies to restore original fire-resistance rating of assembly according to Section 078413 "Penetration Firestopping."
3.6 FIELD QUALITY CONTROL
A. Perform tests and inspections and prepare test reports.
B. Tests and Inspections:
1. After installing conductors and cables and before electrical circuitry has been energized, test service entrance and feeder conductors, and conductors feeding the following critical equipment and services for compliance with requirements.
a. All conductors with voltages at 277V or higher and corresponding neutrals and grounds.
b. All conductors #8 and larger. c. All motor leads and corresponding grounds.
2. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 3. Infrared Scanning: After Substantial Completion, but not more than 60 days after Final Acceptance, perform an infrared scan of each splice in cables and conductors No. 3 AWG and larger. Remove box and equipment covers so splices are accessible to portable scanner.
a. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of each splice 11 months after date of Substantial Completion. b. Instrument: Use an infrared scanning device designed to measure temperature or to detect significant deviations from normal values. Provide calibration record for device. c. Record of Infrared Scanning: Prepare a certified report that identifies splices checked and that describes scanning results. Include notation of deficiencies detected, remedial action taken, and observations after remedial action.
C. Test Reports: Prepare a written report to record the following:
1. Test procedures used. 2. Test results that comply with requirements.
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 6
3. Test results that do not comply with requirements and corrective action taken to achieve compliance with requirements.
D. Remove and replace malfunctioning units and retest as specified above.
END OF SECTION 260519
LOW-VOLTAGE ELECTRICAL WRCRWA POWER CONDUCTORS AND CABLES PLANT EXPANSION PROJECT 260519 - 7
SECTION 260523 - CONTROL-VOLTAGE ELECTRICAL POWER CABLES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Instrumentation cabling. 2. Low-voltage control cabling. 3. Control-circuit conductors. 4. Identification products.
B. Related Sections
1. For structured cabling systems, including fiber optic cabling and CAT6 cabling refer to Section 409533.
1.2 DEFINITIONS
A. Low Voltage: As defined in NFPA 70 for circuits and equipment operating at less than 50 V or for remote-control and signaling power-limited circuits.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.4 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.5 QUALITY ASSURANCE
A. Testing Agency Qualifications: Member company of an NRTL.
B. Surface-Burning Characteristics: As determined by testing identical products according to ASTM E 84 by a qualified testing agency. Identify products with appropriate markings of applicable testing agency.
1. Flame-Spread Index: 25 or less. 2. Smoke-Developed Index: 50 or less.
C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-1
1.6 DELIVERY, STORAGE, AND HANDLING
A. Test cables upon receipt at Project site.
B. Test each pair of each cable for open and short circuits.
PART 2 - PRODUCTS
2.1 PATHWAYS
A. Conduit and Boxes: Comply with requirements in Section 260533 "Raceways and Boxes for Electrical Systems."
1. Outlet boxes shall be no smaller than 2 inches wide, 3 inches high, and 2-1/2 inches deep.
2.2 INSTRUMENTATION CABLE
A. Instrument cable shall be Type TC, and have the number of individually shielded twisted pairs indicated on the Plans and shall be insulated for not less than 600 volts. Unless otherwise indicated, conductor size shall be No. 18 AWG minimum. Shielded, grounded instrumentation cable shall be used for all analog and low voltage digital signals.
B. The jacket shall be flame retardant with 90 degrees C temperature rating. The cable shield shall be a minimum of 2.3 mil aluminum or copper tape overlapped to provide 100 percent coverage and a tinned copper drain wire.
C. The conductors shall be bare soft annealed copper, Class B, 7 strand minimum concentric lay with 15 mils nominal thickness, nylon jacket, 4 mil nominal thickness, 90 degrees C temperature rating. One conductor within each pair shall be numerically identified.
D. Pairs shall be assembled with a nominal 2-inch lay and shall then be group shielded with a minimum of 1.3 mil aluminum or copper tape overlapped to provide 100 percent coverage. All group shields shall be completely isolated from each other.
E. Pairs installed in a cable tray shall have a UV resistant jacket, and shall have a jacket intended for cable tray use.
2.3 RS-232 CABLE
A. Standard Cable: NFPA 70, Type CM.
1. Paired, two pairs, No. 22 AWG, stranded (7x30) tinned-copper conductors. 2. Polypropylene insulation. 3. Individual aluminum foil-polyester tape shielded pairs with 100 percent shield coverage. 4. PVC jacket. 5. Pairs are cabled on common axis with No. 24 AWG, stranded (7x32) tinned-copper drain wire. 6. Flame Resistance: Comply with UL 1581.
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-2
B. Plenum-Rated Cable: NFPA 70, Type CMP.
1. Paired, two pairs, No. 22 AWG, stranded (7x30) tinned-copper conductors. 2. Plastic insulation. 3. Individual aluminum foil-polyester tape shielded pairs with 100 percent shield coverage. 4. Plastic jacket. 5. Pairs are cabled on common axis with No. 24 AWG, stranded (7x32) tinned-copper drain wire. 6. Flame Resistance: Comply with NFPA 262.
2.4 RS-485 CABLE
A. Standard Cable: NFPA 70, Type CM.
1. Paired, two pairs, twisted, No. 22 AWG, stranded (7x30) tinned-copper conductors. 2. PVC insulation. 3. Unshielded. 4. PVC jacket. 5. Flame Resistance: Comply with UL 1581.
B. Plenum-Rated Cable: NFPA 70, Type CMP.
1. Paired, two pairs, No. 22 AWG, stranded (7x30) tinned-copper conductors. 2. Fluorinated ethylene propylene insulation. 3. Unshielded. 4. Fluorinated ethylene propylene jacket. 5. Flame Resistance: NFPA 262, Flame Test.
2.5 LOW-VOLTAGE CONTROL CABLE
A. Paired Cable: NFPA 70, Type CMG.
1. One pair, twisted, No. 16 AWG, stranded (19x29) tinned-copper conductors. 2. PVC insulation. 3. Unshielded. 4. PVC jacket. 5. Flame Resistance: Comply with UL 1581.
B. Plenum-Rated, Paired Cable: NFPA 70, Type CMP.
1. One pair, twisted, No. 16 AWG, stranded (19x29) tinned-copper conductors. 2. PVC insulation. 3. Unshielded. 4. PVC jacket. 5. Flame Resistance: Comply with NFPA 262.
C. Paired Cable: NFPA 70, Type CMG.
1. One pair, twisted, No. 18 AWG, stranded (19x30) tinned-copper conductors.
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-3
2. PVC insulation. 3. Unshielded. 4. PVC jacket. 5. Flame Resistance: Comply with UL 1581.
D. Plenum-Rated, Paired Cable: NFPA 70, Type CMP.
1. One pair, twisted, No. 18 AWG, stranded (19x30) tinned-copper conductors. 2. Fluorinated ethylene propylene insulation. 3. Unshielded. 4. Plastic jacket. 5. Flame Resistance: NFPA 262, Flame Test.
2.6 CONTROL-CIRCUIT CONDUCTORS
A. Class 1 Control Circuits: Stranded copper, Type THHN-THWN, in raceway, complying with UL 83.
B. Class 2 Control Circuits: Stranded copper, Type THHN-THWN, in raceway, complying with UL 83.
C. Class 3 Remote-Control and Signal Circuits: Stranded copper, Type TW or Type TF, complying with UL 83.
2.7 IDENTIFICATION PRODUCTS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Brady Corporation. 2. Panduit Corp. 3. Or Approved Equal.
B. Comply with UL 969 for a system of labeling materials, including label stocks, laminating adhesives, and inks used by label printers.
C. Comply with requirements in Section 260553 "Identification for Electrical Systems."
PART 3 - EXECUTION
3.1 INSTALLATION OF PATHWAYS
A. Comply with TIA/EIA-569-A for pull-box sizing and length of conduit and number of bends between pull points.
B. Comply with requirements in Section 260533 "Raceways and Boxes for Electrical Systems" for installation of conduits and wireways.
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-4
C. Install manufactured conduit sweeps and long-radius elbows if possible.
D. Pathway Installation in Equipment Rooms:
1. Position conduit ends adjacent to a corner on backboard if a single piece of plywood is installed or in the corner of room if multiple sheets of plywood are installed around perimeter walls of room. 2. Install cable trays to route cables if conduits cannot be located in these positions. 3. Secure conduits to backboard if entering room from overhead. 4. Extend conduits 3 inches above finished floor. 5. Install metal conduits with grounding bushings and connect with grounding conductor to grounding system.
E. Backboards: Install backboards with 96-inch dimension vertical. Butt adjacent sheets tightly and form smooth gap-free corners and joints.
3.2 INSTALLATION OF CONDUCTORS AND CABLES
A. Comply with NECA 1.
B. General Requirements for Cabling:
1. Comply with TIA/EIA-568-B.1. 2. Comply with BICSI ITSIM, Ch. 6, "Cable Termination Practices." 3. Terminate all conductors; no cable shall contain unterminated elements. Make terminations only at indicated outlets, terminals, and cross-connect and patch panels. 4. Cables may not be spliced. Secure and support cables at intervals not exceeding 30 inches and not more than 6 inches from cabinets, boxes, fittings, outlets, racks, frames, and terminals. 5. Bundle, lace, and train conductors to terminal points without exceeding manufacturer's limitations on bending radii, but not less than radii specified in BICSI ITSIM, "Cabling Termination Practices" Chapter. Install lacing bars and distribution spools. 6. Do not install bruised, kinked, scored, deformed, or abraded cable. Do not splice cable between termination, tap, or junction points. Remove and discard cable if damaged during installation and replace it with new cable. 7. Cold-Weather Installation: Bring cable to room temperature before dereeling. Heat lamps shall not be used for heating. 8. Pulling Cable: Comply with BICSI ITSIM, Ch. 4, "Pulling Cable." Monitor cable pull tensions.
C. Installation of Control-Circuit Conductors:
1. Install wiring in raceways. Comply with requirements specified in Section 260533 "Raceways and Boxes for Electrical Systems."
D. Open-Cable Installation:
1. Install cabling with horizontal and vertical cable guides in telecommunications spaces with terminating hardware and interconnection equipment.
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-5
2. Suspend copper cable not in a wireway or pathway a minimum of 8 inches above ceilings by cable supports not more than 60 inches apart. 3. Cable shall not be run through structural members or in contact with pipes, ducts, or other potentially damaging items.
E. Separation from EMI Sources:
1. Comply with BICSI TDMM and TIA/EIA-569-A recommendations for separating unshielded copper voice and data communication cable from potential EMI sources, including electrical power lines and equipment. 2. Separation between open communications cables or cables in nonmetallic raceways and unshielded power conductors and electrical equipment shall be as follows:
a. Electrical Equipment Rating Less Than 2 kVA: A minimum of 12 inches. b. Electrical Equipment Rating between 2 and 5 kVA: A minimum of 24 inches. c. Electrical Equipment Rating More Than 5 kVA: A minimum of 48 inches.
3. Separation between communications cables in grounded metallic raceways and unshielded power lines or electrical equipment shall be as follows:
a. Electrical Equipment Rating Less Than 2 kVA: A minimum of 6 inches. b. Electrical Equipment Rating between 2 and 5 kVA: A minimum of 12 inches. c. Electrical Equipment Rating More Than 5 kVA: A minimum of 24 inches.
4. Separation between communications cables in grounded metallic raceways and power lines and electrical equipment located in grounded metallic conduits or enclosures shall be as follows:
a. Electrical Equipment Rating Less Than 2 kVA: 3 inches. b. Electrical Equipment Rating between 2 and 5 kVA: A minimum of 6 inches. c. Electrical Equipment Rating More Than 5 kVA: A minimum of 12 inches.
5. Separation between Cables and Electrical Motors and Transformers: A minimum of 48 inches. 6. Separation between Cables and Fluorescent Fixtures: A minimum of 6 inches.
3.3 REMOVAL OF CONDUCTORS AND CABLES
A. Remove abandoned conductors and cables.
3.4 CONTROL-CIRCUIT CONDUCTORS
A. Minimum Conductor Sizes:
1. Class 1 remote-control and signal circuits, No. 14 AWG. 2. Class 2 low-energy, remote-control, and signal circuits, No. 16 AWG. 3. Class 3 low-energy, remote-control, alarm, and signal circuits, No 12 AWG.
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-6
3.5 GROUNDING
A. For data communications wiring, comply with ANSI-J-STD-607-A and with BICSI TDMM, "Grounding, Bonding, and Electrical Protection" Chapter.
B. For low-voltage wiring and cabling, comply with requirements in Section 260526 "Grounding and Bonding for Electrical Systems."
3.6 IDENTIFICATION
A. Identify system components, wiring, and cabling according to TIA/EIA-606-A. Comply with requirements for identification specified in Section 260553 "Identification for Electrical Systems."
3.7 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect cable placement, cable termination, grounding and bonding, equipment and patch cords, and labeling of all components.
B. Document data for each measurement. Print data for submittals in a summary report that is formatted using Table 10.1 in BICSI TDMM as a guide, or transfer the data from the instrument to the computer, save as text files, print, and submit.
C. End-to-end cabling will be considered defective if it does not pass tests and inspections.
D. Prepare test and inspection reports.
END OF SECTION 260523
WRCRWA CONTROL-VOLTAGE ELECTRICAL POWER CABLES PLANT EXPANSION PROJECT 260523-7
SECTION 260526 - GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: Grounding systems and equipment.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
B. Comply with UL 467 for grounding and bonding materials and equipment.
PART 2 - PRODUCTS
2.1 CONDUCTORS
A. Insulated Conductors: Copper wire or cable insulated for 600 V unless otherwise required by applicable Code or authorities having jurisdiction.
B. Bare Copper Conductors:
1. Stranded Conductors: ASTM B 8. 2. Tinned Conductors: ASTM B 33. 3. Bonding Cable: 28 kcmil, 14 strands of No. 17 AWG conductor, 1/4 inch in diameter. 4. Bonding Conductor: No. 4 or No. 6 AWG, stranded conductor. 5. Bonding Jumper: Copper tape, braided conductors terminated with copper ferrules; 1-5/8 inches wide and 1/16 inch thick. 6. Tinned Bonding Jumper: Tinned-copper tape, braided conductors terminated with copper ferrules; 1-5/8 inches wide and 1/16 inch thick.
WRCRWA GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260526-1
2.2 CONNECTORS
A. Listed and labeled by an NRTL acceptable to authorities having jurisdiction for applications in which used and for specific types, sizes, and combinations of conductors and other items connected.
B. Bolted Connectors for Conductors and Pipes: Copper or copper alloy, pressure type with at least two bolts.
1. Pipe Connectors: Clamp type, sized for pipe.
C. Welded Connectors: Exothermic-welding kits of types recommended by kit manufacturer for materials being joined and installation conditions.
2.3 GROUNDING ELECTRODES
A. Ground Rods: Copper-clad; 3/4 inch by 10 feet in diameter.
PART 3 - EXECUTION
3.1 APPLICATIONS
A. Conductors: Install stranded conductors all conductor sizes.
B. Underground Grounding Conductors: Install bare copper conductor, No. 4/0 AWG minimum. Bury at least 24 inches below grade.
C. Isolated Grounding Conductors: Green-colored insulation with continuous yellow stripe. On feeders with isolated ground, identify grounding conductor where visible to normal inspection, with alternating bands of green and yellow tape, with at least three bands of green and two bands of yellow.
D. Conductor Terminations and Connections:
1. Pipe and Equipment Grounding Conductor Terminations: Bolted connectors. 2. Underground Connections: Welded or approved compression connectors except at test wells and as otherwise indicated. 3. Connections to Ground Rods at Test Wells: Bolted connectors. 4. Connections to Structural Steel: Welded connectors.
3.2 EQUIPMENT GROUNDING
A. Install insulated equipment grounding conductors with the following items, in addition to those required by NFPA 70:
1. Feeders and branch circuits. 2. Lighting circuits. 3. Receptacle circuits.
WRCRWA GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260526-2
4. Single-phase motor and appliance branch circuits. 5. Three-phase motor and appliance branch circuits. 6. Flexible raceway runs. 7. Armored and metal-clad cable runs. 8. Busway Supply Circuits: Install insulated equipment grounding conductor from grounding bus in the switchgear, switchboard, or distribution panel to equipment grounding bar terminal on busway. 9. Computer and Rack-Mounted Electronic Equipment Circuits: Install insulated equipment grounding conductor in branch-circuit runs from equipment-area power panels and power-distribution units. 10. X-Ray Equipment Circuits: Install insulated equipment grounding conductor in circuits supplying x-ray equipment.
B. Air-Duct Equipment Circuits: Install insulated equipment grounding conductor to duct- mounted electrical devices operating at 120 V and more, including air cleaners, heaters, dampers, humidifiers, and other duct electrical equipment. Bond conductor to each unit and to air duct and connected metallic piping.
C. Water Heater, Heat-Tracing, and Antifrost Heating Cables: Install a separate insulated equipment grounding conductor to each electric water heater and heat-tracing cable. Bond conductor to heater units, piping, connected equipment, and components.
D. Signal and Communication Equipment: In addition to grounding and bonding required by NFPA 70, provide a separate grounding system complying with requirements in TIA/ATIS J- STD-607-A.
1. For telephone, alarm, voice and data, and other communication equipment, provide No. 4 AWG minimum insulated grounding conductor in raceway from grounding electrode system to each service location, terminal cabinet, wiring closet, and central equipment location. 2. Service and Central Equipment Locations and Wiring Closets: Terminate grounding conductor on a 1/4-by-4-by-12-inch grounding bus. 3. Terminal Cabinets: Terminate grounding conductor on cabinet grounding terminal.
E. Poles Supporting Outdoor Lighting Fixtures: Install grounding electrode and a separate insulated equipment grounding conductor in addition to grounding conductor installed with branch-circuit conductors.
3.3 INSTALLATION
A. Grounding Conductors: Route along shortest and straightest paths possible unless otherwise indicated or required by Code. Avoid obstructing access or placing conductors where they may be subjected to strain, impact, or damage.
B. Ground Rods: Drive rods until tops are 2 inches below finished floor or final grade unless otherwise indicated.
1. Interconnect ground rods with grounding electrode conductor below grade and as otherwise indicated. Make connections without exposing steel or damaging coating if any.
WRCRWA GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260526-3
2. For grounding electrode system, install at least three rods spaced at least one-rod length from each other and located at least the same distance from other grounding electrodes, and connect to the service grounding electrode conductor.
C. Test Wells: Ground rod driven through drilled hole in bottom of handhole. Handholes are specified in Section 260543 "Underground Ducts and Raceways for Electrical Systems," and shall be at least 12 inches deep, with cover.
1. Test Wells: Install at least two test wells for each service unless otherwise indicated. Install at the ground rods electrically closest to service entrance. Set top of test well flush with finished grade or floor.
D. Bonding Straps and Jumpers: Install in locations accessible for inspection and maintenance except where routed through short lengths of conduit.
1. Bonding to Structure: Bond straps directly to basic structure, taking care not to penetrate any adjacent parts. 2. Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports: Install bonding so vibration is not transmitted to rigidly mounted equipment. 3. Use exothermic-welded connectors for outdoor locations; if a disconnect-type connection is required, use a bolted clamp.
E. Grounding and Bonding for Piping:
1. Metal Water Service Pipe: Install insulated copper grounding conductors, in conduit, from building's main service equipment, or grounding bus, to main metal water service entrances to building. Connect grounding conductors to main metal water service pipes; use a bolted clamp connector or bolt a lug-type connector to a pipe flange using one of the lug bolts of the flange. Where a dielectric main water fitting is installed, connect grounding conductor on street side of fitting. Bond metal grounding conductor conduit or sleeve to conductor at each end. 2. Water Meter Piping: Use braided-type bonding jumpers to electrically bypass water meters. Connect to pipe with a bolted connector. 3. Bond each aboveground portion of gas piping system downstream from equipment shutoff valve.
F. Bonding Interior Metal Ducts: Bond metal air ducts to equipment grounding conductors of associated fans, blowers, electric heaters, and air cleaners. Install bonding jumper to bond across flexible duct connections to achieve continuity.
3.4 LABELING
A. Comply with requirements in Section 260553 "Identification for Electrical Systems" for instruction signs. The label or its text shall be green.
B. Install labels at the telecommunications bonding conductor and grounding equalizer.
1. Label Text: "If this connector or cable is loose or if it must be removed for any reason, notify the facility manager."
WRCRWA GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260526-4
3.5 FIELD QUALITY CONTROL
A. Perform the following tests and inspections and prepare test reports:
1. After installing grounding system but before permanent electrical circuits have been energized, test for compliance with requirements. 2. Inspect physical and mechanical condition. Verify tightness of accessible, bolted, electrical connections with a calibrated torque wrench according to manufacturer's written instructions. 3. Test completed grounding system at each location where a maximum ground-resistance level is specified, at service disconnect enclosure grounding terminal, and at ground test wells. Make tests at ground rods before any conductors are connected.
B. Report measured ground resistances that exceed the following values:
1. Power and Lighting Equipment or System with Capacity of 500 kVA and Less: 10 ohms. 2. Power and Lighting Equipment or System with Capacity of 500 to 1000 kVA: 5 ohms. 3. Power and Lighting Equipment or System with Capacity More Than 1000 kVA: 3 ohms. 4. Power Distribution Units or Panelboards Serving Electronic Equipment: 3 ohm(s).
C. Excessive Ground Resistance: If resistance to ground exceeds specified values, notify Engineer promptly and include recommendations to reduce ground resistance.
END OF SECTION 260526
WRCRWA GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260526-5
SECTION 260529 - HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. Supports, anchors, sleeves, and seals, are indicated on the Plans, schedules, and specified in other sections of these Specifications.
B. Types of supports, anchors, sleeves and seals specified in this section include the follow- ing:
1. One-hole Conduit Straps 2. One-Hole Conduit Straps with Clamp Backs 3. Two-Hole Conduit Straps 4. Conduit Hangers 5. I-beam Clamps 6. Channel Clamps 7. Round Steel Rods 8. Drop-in Anchors 9. Wedge Type Anchor Bolts 10. Lead Expansion Anchors 11. Toggle Bolts 12. Wall and Floor Seals 13. Cable Supports 14. U-Channel Strut System 15. Sleeves
1.2 SUBMITTALS
A. Products shall be submitted in accordance with Sections 013300 & 260000, and else- where in the Contract Documents, prior to installation.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Acceptable Manufacturers: Subject to compliance with requirements, manufacturers of- fering products which may be incorporated in the work include, but are not limited to, the following: Abbeon Cal Inc., Ackerman Johnson Fastening Systems Inc., Elcen Metal Products Co., Ideal Industries, Inc., Josyln Mfg and Supply Co., McGraw Edison Co., Rawlplug Co. Inc., Star Expansion Co., U.S. Expansion Bolt Co., Allied Tube and Con- duit Corp., B-Line Systems, Inc., Greenfield Mfg Co., Inc., Midland-Ross Corp., O- Z/Gedney Div; General Signal Corp., Power-Strut Div.; Van Huffel Tube Corp., and Unistrut Div; GTE Products Corp., and Robroy Industries.
2.2 GENERAL
WRCRWA HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260529-1
A. Provide supporting devices that comply with manufacturer standard materials, design, and construction, in accordance with published product information, and as required for complete installations, and as specified herein.
2.3 SUPPORTS
A. Provide supporting devices of types, sizes, and materials indicated, and having the fol- lowing construction features:
1. One-Hole Conduit Straps: For supporting electrical metallic tubing, and liquid tight flexible conduit; zinc plated steel, stainless steel or galvanized steel; snap-on, heavy duty. 2. One-Hole Conduit Straps with Clamp Backs: For supporting rigid metal conduit, and intermediate metal conduit; cast galvanized steel. 3. Two-Hole Conduit Straps: For supporting electrical metallic tubing, rigid metal con- duit, and intermediate metal conduit; zinc plated steel, stainless steel or galvanized steel. 4. Conduit Hangers: For supporting electrical metallic tubing, rigid metal conduit, and intermediate metal conduit; zinc plated steel, stainless steel or galvanized steel. 5. I-Beam Clamps: Electroplated zinc or hot dipped galvanized malleable iron. 6. Channel Clamps: Electroplated zinc or hot dipped galvanized steel. 7. Round Steel Rod: National coarse thread, electroplated.
2.4 ANCHORS
A. Provide anchors of types, sizes, and materials indicated, with the following construction features:
1. Lead Expansion Anchors: For CMU walls, 1/4”-20 threads, set tool required. 2. Toggle Bolts: Electroplated steel, size as required. 3. Drop-in Anchors: Stainless steel, size as required. 4. Anchor Bolts: Stainless steel, size as required. 5. Lag Bolts: Stainless steel, size as required. 6. Half-round head, non-removable anchor bolts shall not be used. 7. Self-Tapping screws shall not be used.
2.5 SEALS
A. Provide seals of types, sizes and materials indicated; with the following construction fea- tures:
1. Wall and Floor Seals: Provide factory-assembled watertight wall and floor seals, of types and sized indicated; suitable for sealing around conduit, pipe, or tubing passing through concrete floors and walls. Construct seals with steel sleeves, malleable iron body, neoprene sealing grommets and rings, metal pressure rings, pressure clamps, and cap screws. 2. Conduit sealing bushings shall be manufactured by O-Z/Gedney, Model CSMI, or equal. 3. The conductor sealing bushings shall be manufactured by O-Z/Gedney, Model CSBG, or equal.
WRCRWA HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260529-2
2.6 CONDUIT CABLE SUPPORTS
A. Provide cable supports with insulating wedging plug for non-armored type electrical ca- bles in risers; construct 2" rigid metal conduit; 3-wires, type wire as indicated; construct body of malleable-iron casting with hot-dip galvanized finish.
2.7 U-CHANNEL STRUT SYSTEM
A. Provide U-channel strut system for supporting electrical equipment, 12-gage hot-dip gal- vanized steel, of types and sizes indicated; construct with 9/16" dia. holes, 8" o.c. on top surface, with the following fittings that mate and match with U-Channel: 1. Fixture hangers 2. Channel hangers 3. End caps 4. Beam clamps 5. Wiring stud 6. Thinwall conduit clamps 7. Rigid conduit clamps 8. Post Bases 9. U-bolts B. Approved for use with the following types of conduit: 1. EMT 2. IMT 3. GRS 4. PVC (where above conduits are approved for the same location.)
2.8 PIPE SLEEVES
A. Provide pipe sleeves from the following:
1. Steel Pipe: Fabricate from Schedule 40 galvanized steel pipe; remove burrs.
2.9 PVC COATED U-CHANNEL STRUT SYSTEM
A. Provide PVC Coated U-channel strut system for supporting electrical equipment, 20 mil PVC coated steel, of types and sizes indicated; construct with 9/16" dia. holes, 8" o.c. on top surface, with all Stainless Steel hardware, and the following fittings that mate and match with PVC Coated U-Channel:
1. PVC Coated Strut nut 2. PVC Coated Pipe straps 3. Touch up compound (Gray)
B. Approved for use with the following types of conduit:
1. PVC Coated GRS 2. Aluminum 4. PVC
2.10 STAINLESS STEEL U-CHANNEL STRUT SYSTEM
WRCRWA HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260529-3
A. Provide Stainless Steel U-channel strut system for supporting electrical equipment, of types and sizes indicated; construct with 9/16" dia. holes, 8" o.c. on top surface, with all stainless steel hardware, and the following stainless steel fittings that mate and match with Stainless Steel U-Channel:
1. Fixture hangers 2. Channel hangers 3. End caps 4. Beam clamps 5. Wiring stud 6. Post bases 7. Rigid conduit clamps 8. U-bolts
B. Approved for use with the following types of conduit:
1. PVC Coated GRS 2. PVC
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install hangers, anchors, sleeves and seals as indicated, in accordance with manufacturer's written instructions and with recognized industry practices to insure supporting devices comply with requirements. Comply with requirements of NECA and NEC for installa- tion of supporting devices.
B. Coordinate with other electrical work, including raceway and wiring work, as necessary to interface installation of supporting devices with other work.
C. Install hangers, supports, clamps and attachments to support piping properly from build- ing structure. Arrange for grouping of 2 or more parallel runs of conduits to be supported together on channel type hangers where possible. Install supports with spacing indicated and in compliance with NEC requirements.
D. Torque sleeve seal nuts, complying with manufacturer recommended values. Ensure that sealing grommets expand to form watertight seal.
E. Comply with manufacturer’s recommendations for touch up of field cut ends or damaged PVC coated U-channel and fittings.
F. Remove burrs and apply a cold zinc galvanizing paint to field cut galvanized U-channel strut prior to installation.
G. Provide a minimum of two anchors per piece of u-channel. Maximum spacing of anchors shall be 12”.
WRCRWA HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260529-4
H. Ensure the anchoring system allows proper separation of the different raceway duties. Separation requirements are located in Specification 260533 Section 3.1
END OF SECTION 260529
WRCRWA HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260529-5
SECTION 260533 - RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. Furnish and install conduits as required, and as shown on the Plans. Materials employed shall be as shown on the Plans.
1.2 SUBMITTALS
A. Submit product literature including manufacturer part number, model number, material, size, and specifications. Material shall not be installed until the Engineer has reviewed the submittal data.
B. If changes from the Plan are proposed, shop drawings shall be submitted for review and acceptance showing routing, conduit size, and number and size of wires in each conduit before installation of conduit and any related work.
C. Conduit installation and routing submittal that is designed by a Licensed Professional Electrical Engineer in the state of California. The submittal shall be completed after con- duit installation and routing has been coordinated with the other disciplines working on site. Submittals may be submitted by construction area or by building after a yard layout and routing submittal has been approved. After submittal approval the Contractor’s Engi- neer shall stamp all details and layouts prior to installation. The submittal shall include the following:
1. Layout drawings done to scale showing the proposed routing and details of construc- tion of embedded conduits in walls, columns, slabs, duct banks etc. Layouts shall show proper separation between conduits and proper spacing from structural ele- ments, piping, re-bar, etc. Show the location of all elements on the layout. 2. Layouts drawings done to scale showing the proposed routing and details of con- struction of exposed conduits. Layouts shall show proper separation between con- duits, proper spacing from architectural elements, piping, HVAC, lighting, and loca- tion and types of supports that will be used. 3. Indicate on the layouts the location and construction details of openings in slabs and walls for raceway runs.
D. Identify conduit by tag number of equipment served or by circuit schedule number.
E. Refer to Section 26000 for further submittal requirements.
1.3 REFERENCES
A. American National Standards Institute (ANSI): C80.1, Rigid Steel Conduit - Zinc- Coated.
B. National Electric Manufacturers Association (NEMA): RN-1, Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit.
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-1
C. Underwriters Laboratories Inc. (UL): 1. 1, Flexible Metal Conduit. 2. 6, Rigid Metal Conduit. 3. 360, Liquid-Tight Flexible Steel Conduit. 4. 467, Grounding and Bonding Equipment. 5. 514, Nonmetallic Outlet Boxes, Flush-Device Boxes and Covers. 6. 651, Schedule 40 and 80 Rigid PVC Conduit. 7. 870, Wireways, Auxiliary Gutters, and Associated Fittings. 8. 884, Underfloor Raceways and Fittings. 9. 886, Outlet Boxes and Fittings for Use in Hazardous (Classified) Locations.
PART 2 - PRODUCTS
2.1 RACEWAYS
A. Exposed conduits in an unclassified or non-hazardous area shall be galvanized rigid steel (GRS) unless specifically indicated otherwise on the Plans. Conduits in corrosive, haz- ardous, or damp areas shall be PVC coated GRS unless otherwise indicated. Under- ground and/or concrete encased conduits shall be PVC, unless otherwise indicated. All conduits concealed in block walls or steel framing shall be EMT with compression fit- tings unless otherwise indicated. Set screw type fittings in EMT conduit will not be ac- cepted. All wiring, except as otherwise noted, shall be in conduit. Conduit size shall not be less than the National Electrical Code (NEC) size required for the conductors therein and shall not be smaller than 3/4-inch. No underground conduit shall be less than one inch.
B. Condulets type fittings shall be Crouse-Hinds, Appleton, or equal with wedge nut covers. All condulets located outdoors, damp or wet locations shall be weather tight.
C. In unclassified areas, flexible conduit shall be grounding type, weatherproof, corrosion resistant, and watertight.
D. Couplings, connectors, and fittings shall be standard types specifically designed and manufactured for the purpose. They shall be installed to provide a firm mechanical as- sembly and electrical conductivity throughout. Conduit systems shall be water tight.
E. Expansion fittings shall be OZ type AX with jumper for exposed locations and type DX at structural expansion joints, Spring City, or equal. Conduits shall have expansion fit- tings in accordance with NEC.
F. The conduits and fittings shall be supported per NEC requirements as a minimum.
G. Sealing fittings shall be provided for classified areas per the NEC requirements in haz- ardous or corrosive areas. Fittings shall be poured after the final walk-thru unless other- wise directed in writing by the engineer.
H. All raceways shall be listed and labeled as defined in NFPA 70 by a qualified testing agency and marked for intended location and application.
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-2
2.2 GALVANIZED RIGID STEEL (GRS)
A. Conduits and couplings shall be hot-dipped galvanized with zinc coated threads and outer coating of zinc bichromate, in accordance with ANSI C80.1 standards, as manufactured by Jones & Laughlin Steel Corporation, Allied Tube & Conduit Corporation, Triangle PWC, or equal.
B. Steel conduit shall not be buried in earth without concrete encasement and additional cor- rosion protection. A half lapped rapping of 20 mil PVC based corrosion protection tape shall be used.
2.3 PVC COATED GALVANIZED RIGID STEEL (PVC-GRS)
A. PVC coated GRS conduit shall be installed where shown on the Plans or elsewhere speci- fied and shall conform to NEMA RN-1 and ANSI C80.1 standards.
B. The zinc surface of the conduit shall remain intact and undisturbed on both the inside and the outside of the conduit throughout the preparation and application processing. A Pol- yvinyl Chloride (PVC) coating shall be bonded to the galvanized outer surface of the conduit. The bond between the PVC coating and the conduit surface shall be greater than the tensile strength of the plastic. The thickness of the PVC coating shall be a minimum of 0.040-inch (40 mil).
C. A loose coupling shall be furnished with each length of conduit. A PVC coating shall be bonded to the outer surface of the coupling and a PVC sleeve equal to the outside diame- ter of the uncoated conduit shall extend beyond both ends of the coupling approximately one pipe diameter or 1-1/2 inches, whichever is smaller. The wall thickness of the coat- ing on the coupling and the sleeve shall be a minimum of 0.055-inch (55 mil).
D. A PVC coating shall be bonded to the inner and outer surface of all conduit bodies and fittings and a PVC sleeve shall extend from all hubs. The wall thickness of the coating on conduit bodies and fittings and the sleeve walls shall be identical to those on couplings in length and thickness. The covers on all conduit bodies shall be coated on both sides and shall be designed to be completely interchangeable. The inside of conduit bodies shall remain undisturbed in the processing.
E. Type 304 stainless steel screws shall be furnished and used to attach the cover to the con- duit body. All coated material shall be installed and patched according to the manufac- turer's recommended installation and patching instructions.
F. Conduit straps shall be PVC coated or stainless steel.
G. PVC coated conduits and fittings shall be as manufactured by Kor Kap Corporation, Oc- cidental Coating Company, Rob-Roy, or equal.
H. PVC coated flexible conduits shall be liquid and vapor-tight and manufactured in accord- ance with UL 360 standards.
2.4 RIGID NONMETALLIC - PVC
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-3
A. Where specifically indicated on the Plans, or elsewhere specified, conduit may be high density Schedule 40, 90 degrees C, heavy-duty PVC. The conduit shall be manufactured from virgin polyvinyl chloride compound which meets ASTM D1784, NEMA TC-2, ANSI C33.91, and UL 651 standards. Smoke emissions shall be limited to less than 6 grams per 100 grams of material tested.
B. Solvent cements and adhesive primers shall have a VOC content of 510 and 550 g/L or less, respectively. Solvent cements and primers shall comply with the testing and product requirements of the California Department of Health Services “Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small-Scale Envi- ronmental Chambers”
C. Where conduit concrete encasement is indicated on the Plans, conduit supports shall be installed at five-foot intervals. PVC conduit shall be manufactured by Carlon, Triangle Conduit & Cable, or equal.
2.5 LIQUIDTIGHT FLEXIBLE METAL CONDUIT
A. Liquidtight flexible metal conduit shall be liquid and vapor-tight, oil and ultraviolet ray resistant and manufactured in accordance with UL 360 standards. Liquidtight flexible metal conduit shall be formed of a continuous, spiral wound, galvanized steel core with an extruded PVC jacket. The PVC jacket shall be rated for high ambient heat applica- tions, 90 degrees Celsius.
B. For corrosive locations, liquidtight flexible metal conduit shall be formed of a continu- ous, spiral wound, aluminum core with an extruded PVC jacket. The PVC jacket shall be impervious to corrosive liquids and vapors.
C. An external bonding conductor shall be required for flexible conduit connections contain- ing circuits rated at 60 amps or greater and for sizes 1 1/2 " or larger. Flexible conduits and connectors for 1 1/4 " and smaller shall be listed for grounding.
D. Connectors for liquidtight flexible conduit shall be galvanized, furnished with a sealing ring and locknut, and suitable for wet locations.
2.5 ELECTRICAL METALLIC TUBING (EMT)
A. Per UL Standard for Electrical Metallic Tubing No. 797. Galvanized mild steel with inte- rior coat of enamel.
B. Fittings shall be steel set-screw type. Cast type, indenter type or compression steel fit- tings are not acceptable.
C. Approved for plan specified locations only. Approved for conduits concealed in block walls and concealed in steel framed walls. Not approved for process areas where wash down or high humidity conditions exist.
2.6 ALUMINUM CONDUIT
A. Aluminum conduit is approved for wet and corrosive areas only. Prior approval from the engineer must be obtained when substituting for PVC coated.
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-4
B. Aluminum hardware and conduit shall be isolated from all dissimilar materials as appro- priate.
1. Isolation from dissimilar metals in channel or support by a single layer of scotch #33+ or approved equal. 2. Isolation from concrete shall be by neoprene gaskets. 3. Aluminum shall not be used for concrete penetrations.
C. Aluminum conduit shall contain less than 0.4% copper.
2.7 CABLE TRAY SYSTEM
A. Provide cable tray systems composed of straight sections, fittings, and accessories as de- fined in the latest NEMA Standards publication VE-1 - Ventilated Cable Tray.
1. Provide cable trays and fittings shall constructed of materials suited for the area clas- sification as noted below.
2. Provide cable trays shall be of the ladder type with availability of 6, 9, and 12-inch spacing.
3. Provide tray sizes with a 3, 4, 5, or 6-inch minimum usable load depth, as indicated on the drawings.
4. Provide loading capacities that meet the NEMA weight classification with a safety factor of 1.5.
5. In corrosive, damp, or Hazardous locations, provide cable trays manufactured of aluminum.
6. In non-classified areas provide cable trays manufactured of Hot Dipped galvanized materials. All cuts and welds shall be touched up with cold galvanizing spray per the raceway specification.
7. Separate power, control, signal and communications cables by grounded metallic di- viders or run in separate trays.
8. Manufacturer, or Approved Equal
a. Husky
b. B-Line
c. T.J. Cope
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-5
PART 3 - EXECUTION
3.1 INSTALLATION
A. Conduit runs are schematic only, and shall be modified as required to suit field condi- tions, subject to review and acceptance by the Engineer.
B. Conduit shall run continuously between outlets and shall be provided with junction boxes where connections are made. Couplings, connectors, and fittings shall be acceptable types designed and manufactured for the purpose, and shall provide a firm mechanical as- sembly, and electrical conductivity throughout.
C. Conduit runs shall be straight and true. Elbows, offsets, and bends shall be uniform and symmetrical. Changes in direction shall be made with long radius bends, or with fittings of the condulet type.
D. Conduit runs in buildings and structures shall be concealed where possible except as spe- cifically noted, or accepted by the Engineer.
E. Conduit runs shall not interfere with the proper and safe operation of equipment, and shall not block or interfere with ingress or egress, including equipment removal hatches.
F. Exposed conduits shall be securely fastened with clamps, or straps, intended for conduit use. All exposed conduit shall be run on the walls and ceiling only and shall be parallel to the planes of the walls or ceiling. No diagonal runs will be permitted. Flexible conduit shall be used only for short lengths required to facilitate connections between rigid con- duit to vibrating equipment such as motors, fans, and transformers. The maximum length of flexible conduit shall be 3 feet, unless approved in writing by engineer. Flexible con- duit shall not be used for electricians convenience where rigid conduit could be used.
G. Conduit runs on water-bearing walls shall be supported one inch away from the wall on an accepted channel. When channel galvanizing, or other coating, is cut or otherwise damaged, it shall be field coated to original condition. No conduit shall be run in wa- ter-bearing walls, unless specifically designated otherwise.
H. Conduit shall be thoroughly reamed to remove burrs. IMC or GRS shall be reamed dur- ing the threading process, and Rigid Nonmetallic PVC shall be reamed before applying fittings. A zinc rich cold galvanizing shall be used to restore corrosion protection on field cut threads.
I. Bushings and lock nuts or hubs shall be used at conduit terminations. Conduit, bushings, locknuts, and enclosures shall be fastened to the conduit system prior to pulling wire. Splitting the bushings for installation will not be accepted. Hubs shall be used in all pro- cess areas outside of electrical rooms unless otherwise specified. The total number of bends in any run between pull points shall not exceed 360 degrees. Junction boxes and pull boxes shall be installed at points acceptable to the Engineer. Conduit ends shall be plugged to prevent the entrance of moisture or debris during construction. All spare con- duits shall be adequately capped and shall contain a suitable pull string. Splices shall be made in junction boxes only. Splices in conduit bodies will not be accepted.
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-6
J. Joints shall be set up tight. Hangers and fastenings shall be secure, and of a type appro- priate in design, and dimensions, for the particular application.
K. Conduit runs shall be cleaned and internally sized (obstruction tested) so that no foreign objects, or obstructions remain in the conduit prior to pulling in conductors.
L. After installation of complete conduit runs 2 inches and larger, conduits shall be snaked with a conduit cleaner equipped with a cylindrical mandrel of a diameter not less than 85 percent of the nominal diameter of the conduit. Conduits through which the mandrel will not pass shall not be used. Test results should be submitted to the engineer.
M. Expansion fittings shall be installed across all expansion joints and at other locations where necessary to compensate for thermal expansion and contraction.
N. Provide trenching, backfill, and compaction for conduits installed underground.
O. Raceways running parallel to hot water or steam piping shall maintain a distance of 6 inches from the piping.
P. Raceways crossing steam or liquid filling piping shall cross above the piping.
Q. In slab conduits shall be covered by a minimum of 2 inches of concrete.
R. Conduits of the same duty (480V Power, 120V Power, 120V Controls and signals) shall have a minimum separation of 2” between conduits.
S. Conduits and raceways carrying signal wiring shall have a minimum separation of 12 inches from 480V power raceways, 6 inches from 120V power raceways, and 4 inches from 120V control raceways.
T. Raceways with 120V Control shall maintain a distance of 12 inches from 480V power raceways, 6 inches from 120V power raceways.
U. Raceways with 120V power shall maintain a distance of 6 inches from 480V power raceways.
3.2 CABLE TRAYS
A. Provide cable trays in strict accordance with the manufacturer's printed instructions.
B. Allowable cable fill areas shall meet NEC Article 392 - Cable Trays requirements.
C. Verify cable tray fills prior to installation based on cables and trays actually provided.
D. Maintain continuous grounding of cable trays including bonding jumpers in accordance with the requirements of NEC Article 392.
E. Install cable trays using hangers and supports on 8-foot centers, maximum.
F. Install cable trays to walls as the primary method of support where possible.
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-7
G. If support from the ceiling is the only alternative, use hangers and supports on 6-foot cen- ters, maximum
H. Ensure that proper separation between duties as detailed in 3.1.
END OF SECTION 260533
WRCRWA RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260533-8
SECTION 260534 – ENCLOSURES
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This specification includes enclosures to house electrical controls, instruments, terminal blocks, and serve a junction boxes where shown on the Plans.
1.2 RELATED SECTIONS
A. For Raceways and Boxes for Electrical Systems see Section 260533.
1.3 SUBMITTALS
A. Products shall be submitted in accordance with Section 26000, and elsewhere in the Con- tract Documents, prior to installation.
1.4 MANUFACTURERS
A. Enclosures shall be manufactured by Hoffman, Rittal, or equal.
PART 2 - PRODUCTS
2.1 STEEL
A. Enclosures shall be fabricated from 14 gauge steel with seams that are continuously welded. Doors shall have full length piano hinges with the door removable by pulling the hinge pin.
B. A rolled lip shall be provided around three sides of the door and around all sides of the enclosure opening. The gasket shall be attached with oil-resistant adhesive and held in place with steel retaining strips. Exterior hardware, such as clamps, screws, and hinge pins, shall be of stainless steel for outdoor installations. A hasp and staple shall be pro- vided for padlocking. Each enclosure shall have a print pocket. All wires entering or leaving the enclosure shall terminate on terminal strips. All wires and terminals shall be clearly identified as specified elsewhere in these specifications.
C. Finish shall be white enamel interior, light gray enamel, ANSI 61 exterior, over phospha- tized surfaces. Special finishes and colors shall be furnished for wet locations. Plans should be checked for special conditions.
2.2 NEMA RATING
A. Unless otherwise indicated on the Plans, enclosures shall be NEMA 12 for indoors, NEMA 4X for corrosive areas, and NEMA 4 for outdoor installations. NEMA 4X enclo- sures shall be stainless steel, unless noted otherwise. NEMA 4X enclosures shall also be used in wet, or wash down areas.
WRCRWA ENCLOSURES PLANT EXPANSION PROJECT 260534-1
B. All enclosures used in classified areas shall be NEMA 7.
C. In Waste Water facilities all enclosures in process areas shall be NEMA 4X stainless steel. Enclosures in electrical rooms, meeting rooms, offices and shops shall be NEMA 12 unless otherwise specified.
D. Areas not specified in Water Treatment, Wastewater, or other water related facilities shall be approved by the engineer for NEMA type prior to installation.
2.3 FIBERGLASS
A. Enclosures shall be heavy-duty, compression molded, fiberglass reinforced polyester, high impact, heat resistant, NEMA 4X.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Enclosures shall be installed as indicated on the Plans, and according to manufacturer's instructions.
B. Enclosures shall be properly grounded, and shall include ground straps connected to hinged doors and accessories.
END OF SECTION 260534
WRCRWA ENCLOSURES PLANT EXPANSION PROJECT 260534-2
SECTION 260548 - VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes: 1. Channel support systems. 2. Restraint cables. 3. Hanger rod stiffeners. 4. Anchorage bushings and washers.
1.2 PERFORMANCE REQUIREMENTS
A. Seismic-Restraint Loading:
1. Site class, building code and Design Spectral Response Acceleration as defined on the Contract Drawings.
1.3 ACTION SUBMITTALS
A. Product Data: For the following:
1. Include rated load, rated deflection, and overload capacity for each vibration isolation device. 2. Illustrate and indicate style, material, strength, fastening provision, and finish for each type and size of seismic-restraint component used.
a. Tabulate types and sizes of seismic restraints, complete with report numbers and rated strength in tension and shear as evaluated by an agency acceptable to authorities having jurisdiction. b. Annotate to indicate application of each product submitted and compliance with requirements.
3. Restrained-Isolation Devices: Include ratings for horizontal, vertical, and combined loads.
B. Delegated-Design Submittal: For seismic-restraint details indicated to comply with performance requirements and design criteria, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.
1. Design Calculations: Calculate static and dynamic loading due to equipment weight and operation, seismic forces required to select vibration isolators and seismic restraints.
a. Coordinate design calculations with wind-load calculations required for equipment mounted outdoors. Comply with requirements in other electrical Sections for equipment mounted outdoors.
WRCRWA VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260548 - 1
2. Indicate materials and dimensions and identify hardware, including attachment and anchorage devices. 3. Field-fabricated supports. 4. Seismic-Restraint Details:
a. Design Analysis: To support selection and arrangement of seismic restraints. Include calculations of combined tensile and shear loads. b. Details: Indicate fabrication and arrangement. Detail attachments of restraints to the restrained items and to the structure. Show attachment locations, methods, and spacings. Identify components, list their strengths, and indicate directions and values of forces transmitted to the structure during seismic events. c. Preapproval and Evaluation Documentation: By an agency acceptable to authorities having jurisdiction, showing maximum ratings of restraint items and the basis for approval (tests or calculations).
1.4 INFORMATIONAL SUBMITTALS
A. Welding certificates.
B. Field quality-control test reports.
1.5 QUALITY ASSURANCE
A. Comply with seismic-restraint requirements in the IBC unless requirements in this Section are more stringent.
B. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."
C. Seismic-restraint devices shall have horizontal and vertical load testing and analysis and shall bear anchorage preapproval OPA number from OSHPD, preapproval by ICC-ES, or preapproval by another agency acceptable to authorities having jurisdiction, showing maximum seismic-restraint ratings. Ratings based on independent testing are preferred to ratings based on calculations. If preapproved ratings are not available, submittals based on independent testing are preferred. Calculations (including combining shear and tensile loads) to support seismic- restraint designs must be signed and sealed by a qualified professional engineer.
D. Comply with NFPA 70.
PART 2 - PRODUCTS
2.1 SEISMIC-RESTRAINT DEVICES
A. Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
1. Amber/Booth Company, Inc. 2. California Dynamics Corporation.
WRCRWA VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260548 - 2
3. Cooper B-Line, Inc.; a division of Cooper Industries. 4. Hilti Inc. 5. Loos & Co.; Seismic Earthquake Division. 6. Mason Industries. 7. TOLCO Incorporated; a brand of NIBCO INC. 8. Unistrut; Tyco International, Ltd.
B. General Requirements for Restraint Components: Rated strengths, features, and application requirements shall be as defined in reports by an agency acceptable to authorities having jurisdiction.
1. Structural Safety Factor: Allowable strength in tension, shear, and pullout force of components shall be at least four times the maximum seismic forces to which they will be subjected.
C. Channel Support System: MFMA-3, shop- or field-fabricated support assembly made of slotted steel channels with accessories for attachment to braced component at one end and to building structure at the other end and other matching components and with corrosion-resistant coating; and rated in tension, compression, and torsion forces.
D. Hanger Rod Stiffener: Reinforcing steel angle clamped to hanger rod. Do not weld stiffeners to rods.
E. Bushings for Floor-Mounted Equipment Anchor: Neoprene bushings designed for rigid equipment mountings, and matched to type and size of anchors and studs.
F. Bushing Assemblies for Wall-Mounted Equipment Anchorage: Assemblies of neoprene elements and steel sleeves designed for rigid equipment mountings, and matched to type and size of attachment devices.
G. Resilient Isolation Washers and Bushings: One-piece, molded, oil- and water-resistant neoprene, with a flat washer face.
H. Mechanical Anchor: Drilled-in and stud-wedge or female-wedge type in zinc-coated steel for interior applications and stainless steel for exterior applications. Select anchors with strength required for anchor and as tested according to ASTM E 488. Minimum length of eight times diameter.
I. Adhesive Anchor: Drilled-in and capsule anchor system containing polyvinyl or urethane methacrylate-based resin and accelerator, or injected polymer or hybrid mortar adhesive. Provide anchor bolts and hardware with zinc-coated steel for interior applications and stainless steel for exterior applications. Select anchor bolts with strength required for anchor and as tested according to ASTM E 488.
WRCRWA VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260548 - 3
PART 3 - EXECUTION
3.1 APPLICATIONS
A. Multiple Raceways or Cables: Secure raceways and cables to trapeze member with clamps approved for application by an agency acceptable to authorities having jurisdiction.
B. Hanger Rod Stiffeners: Install hanger rod stiffeners where indicated or scheduled on Drawings to receive them and where required to prevent buckling of hanger rods due to seismic forces.
C. Strength of Support and Seismic-Restraint Assemblies: Where not indicated, select sizes of components so strength will be adequate to carry present and future static and seismic loads within specified loading limits.
3.2 SEISMIC-RESTRAINT DEVICE INSTALLATION
A. Equipment and Hanger Restraints:
1. Install restrained isolators on electrical equipment. 2. Install resilient, bolt-isolation washers on equipment anchor bolts where clearance between anchor and adjacent surface exceeds 0.125 inch. 3. Install seismic-restraint devices using methods approved by an agency acceptable to authorities having jurisdiction providing required submittals for component.
B. Install bushing assemblies for mounting bolts for wall-mounted equipment, arranged to provide resilient media where equipment or equipment-mounting channels are attached to wall.
C. Attachment to Structure: If specific attachment is not indicated, anchor bracing to structure at flanges of beams, at upper truss chords of bar joists, or at concrete members.
D. Drilled-in Anchors:
1. Identify position of reinforcing steel and other embedded items prior to drilling holes for anchors. Do not damage existing reinforcing or embedded items during coring or drilling. Notify the structural engineer if reinforcing steel or other embedded items are encountered during drilling. Locate and avoid prestressed tendons, electrical and telecommunications conduit, and gas lines. 2. Do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength. 3. Wedge Anchors: Protect threads from damage during anchor installation. Heavy-duty sleeve anchors shall be installed with sleeve fully engaged in the structural element to which anchor is to be fastened. 4. Adhesive Anchors: Clean holes to remove loose material and drilling dust prior to installation of adhesive. Place adhesive in holes proceeding from the bottom of the hole and progressing toward the surface in such a manner as to avoid introduction of air pockets in the adhesive. 5. Set anchors to manufacturer's recommended torque, using a torque wrench. 6. Install zinc-coated steel anchors for interior and stainless-steel anchors for exterior applications.
WRCRWA VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260548 - 4
3.3 ACCOMMODATION OF DIFFERENTIAL SEISMIC MOTION
A. Install flexible connections in runs of raceways, cables, wireways, cable trays, and busways where they cross seismic joints, where adjacent sections or branches are supported by different structural elements, and where they terminate with connection to equipment that is anchored to a different structural element from the one supporting them as they approach equipment.
3.4 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Obtain Engineer's approval before transmitting test loads to structure. Provide temporary load-spreading members. 2. Test at least four of each type and size of installed anchors and fasteners selected by Engineer. 3. Test to 90 percent of rated proof load of device. 4. If a device fails test, modify all installations of same type and retest until satisfactory results are achieved.
B. Remove and replace malfunctioning units and retest as specified above.
C. Prepare test and inspection reports.
3.5 ADJUSTING
A. Adjust isolators after isolated equipment is at operating weight.
B. Adjust limit stops on restrained spring isolators to mount equipment at normal operating height. After equipment installation is complete, adjust limit stops so they are out of contact during normal operation.
C. Adjust active height of spring isolators.
D. Adjust restraints to permit free movement of equipment within normal mode of operation.
END OF SECTION 260548
WRCRWA VIBRATION AND SEISMIC CONTROLS FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260548 - 5
SECTION 260553 - IDENTIFICATION FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Identification for raceways. 2. Identification of power and control cables. 3. Identification for conductors. 4. Underground-line warning tape. 5. Warning labels and signs. 6. Instruction signs. 7. Equipment identification labels. 8. Miscellaneous identification products.
1.2 ACTION SUBMITTALS
A. Product Data: For each electrical identification product indicated.
B. Samples of each color, lettering style and other graphic representation required for each identification material or system.
C. Table or list of equipment, panel and disconnect switch labels.
1.3 QUALITY ASSURANCE
A. Comply with ANSI A13.1.
B. Comply with NFPA 70.
C. Comply with 29 CFR 1910.144 and 29 CFR 1910.145.
D. Comply with ANSI Z535.4 for safety signs and labels.
E. Adhesive-attached labeling materials, including label stocks, laminating adhesives, and inks used by label printers, shall comply with UL 969.
PART 2 - PRODUCTS
2.1 POWER RACEWAY IDENTIFICATION MATERIALS
A. Comply with ANSI A13.1 for minimum size of letters for legend and for minimum length of color field for each raceway size.
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 1
B. Colors for Raceways Carrying Circuits at 600 V or Less:
1. Black letters on an orange field. 2. Legend: Indicate voltage and system or service type.
C. Self-Adhesive Vinyl Labels for Raceways Carrying Circuits at 600 V or Less: Preprinted, flexible label laminated with a clear, weather- and chemical-resistant coating and matching wraparound adhesive tape for securing ends of legend label.
D. Snap-Around Labels for Raceways Carrying Circuits at 600 V or Less: Slit, pretensioned, flexible, preprinted, color-coded acrylic sleeve, with diameter sized to suit diameter of raceway or cable it identifies and to stay in place by gripping action.
E. Snap-Around, Color-Coding Bands for Raceways Carrying Circuits at 600 V or Less: Slit, pretensioned, flexible, solid-colored acrylic sleeve, 2 inches long, with diameter sized to suit diameter of raceway or cable it identifies and to stay in place by gripping action.
F. Write-On Tags shall not be allowed.
2.2 ARMORED AND METAL-CLAD CABLE IDENTIFICATION MATERIALS
A. Comply with ANSI A13.1 for minimum size of letters for legend and for minimum length of color field for each raceway and cable size.
B. Colors for Raceways Carrying Circuits at 600 V and Less:
1. Black letters on an orange field. 2. Legend: Indicate voltage and system or service type.
C. Self-Adhesive Vinyl Labels: Preprinted, flexible label laminated with a clear, weather- and chemical-resistant coating and matching wraparound adhesive tape for securing ends of legend label.
D. Self-Adhesive Vinyl Tape: Colored, heavy duty, waterproof, fade resistant; 2 inches wide; compounded for outdoor use.
2.3 POWER AND CONTROL CABLE IDENTIFICATION MATERIALS
A. Comply with ANSI A13.1 for minimum size of letters for legend and for minimum length of color field for each raceway and cable size.
B. Self-Adhesive Vinyl Labels: Preprinted, flexible label laminated with a clear, weather- and chemical-resistant coating and matching wraparound adhesive tape for securing ends of legend label. Heat shrink tubing, or sleeve type wire markers are also acceptable.
A. Write-On Tags shall not be allowed.
B. Snap-Around Labels: Slit, pretensioned, flexible, preprinted, color-coded acrylic sleeve, with diameter sized to suit diameter of raceway or cable it identifies and to stay in place by gripping action.
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 2
C. Snap-Around, Color-Coding Bands: Slit, pretensioned, flexible, solid-colored acrylic sleeve, 2 inches long, with diameter sized to suit diameter of raceway or cable it identifies and to stay in place by gripping action.
2.4 CONDUCTOR IDENTIFICATION MATERIALS
A. Color-Coding Conductor Tape: Colored, self-adhesive vinyl tape not less than 3 mils thick by 1 to 2 inches wide.
B. Self-Adhesive Vinyl Labels: Preprinted, flexible label laminated with a clear, weather- and chemical-resistant coating and matching wraparound adhesive tape for securing ends of legend label. Heat shrink tubing, or sleeve type wire markers are also acceptable.
C. Marker Tapes: Vinyl or vinyl-cloth, self-adhesive wraparound type, with circuit identification legend machine printed by thermal transfer or equivalent process.
D. Write-On Tags shall not be allowed.
2.5 FLOOR MARKING TAPE
A. 2-inch-wide, 5-mil pressure-sensitive vinyl tape, with black and white stripes and clear vinyl overlay.
2.6 UNDERGROUND-LINE WARNING TAPE
A. Tape:
1. Recommended by manufacturer for the method of installation and suitable to identify and locate underground electrical and communications utility lines. 2. Printing on tape shall be permanent and shall not be damaged by burial operations. 3. Tape material and ink shall be chemically inert, and not subject to degrading when exposed to acids, alkalis, and other destructive substances commonly found in soils.
B. Color and Printing:
1. Comply with ANSI Z535.1 through ANSI Z535.5. 2. Inscriptions for Red-Colored Tapes: ELECTRIC LINE, HIGH VOLTAGE. 3. Inscriptions for Orange-Colored Tapes: TELEPHONE CABLE, CATV CABLE, COMMUNICATIONS CABLE, OPTICAL FIBER CABLE.
C. Tag: Type I:
1. Pigmented polyolefin, bright-colored, compounded for direct-burial service. 2. Thickness: 4 mils. 3. Weight: 18.5 lb/1000 sq. ft. 4. 3-Inch Tensile According to ASTM D 882: 30 lbf, and 2500 psi.
D. Tag: Type ID:
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 3
1. Detectable three-layer laminate, consisting of a printed pigmented polyolefin film, a solid aluminum-foil core, and a clear protective film that allows inspection of the continuity of the conductive core, bright-colored, compounded for direct-burial service. 2. Overall Thickness: 5 mils. 3. Foil Core Thickness: 0.35 mil. 4. Weight: 28 lb/1000 sq. ft. 5. 3-Inch Tensile According to ASTM D 882: 70 lbf, and 4600 psi.
2.7 WARNING LABELS AND SIGNS
A. Comply with NFPA 70 and 29 CFR 1910.145.
B. Self-Adhesive Warning Labels: Factory-printed, multicolor, pressure-sensitive adhesive labels, configured for display on front cover, door, or other access to equipment unless otherwise indicated.
C. Baked-Enamel Warning Signs:
1. Preprinted aluminum signs, punched or drilled for fasteners, with colors, legend, and size required for application. 2. 1/4-inch grommets in corners for mounting. 3. Nominal size, 7 by 10 inches.
D. Metal-Backed, Butyrate Warning Signs:
1. Weather-resistant, nonfading, preprinted, cellulose-acetate butyrate signs with 0.0396- inch galvanized-steel backing; and with colors, legend, and size required for application. 2. 1/4-inch grommets in corners for mounting. 3. Nominal size, 10 by 14 inches.
E. Warning label and sign shall include, but are not limited to, the following legends:
1. Multiple Power Source Warning: "DANGER - ELECTRICAL SHOCK HAZARD - EQUIPMENT HAS MULTIPLE POWER SOURCES." 2. Workspace Clearance Warning: "WARNING - OSHA REGULATION - AREA IN FRONT OF ELECTRICAL EQUIPMENT MUST BE KEPT CLEAR FOR 36 INCHES."
2.8 INSTRUCTION SIGNS
A. Engraved, laminated acrylic or melamine plastic, minimum 1/16 inch thick for signs up to 20 sq. inches and 1/8 inch thick for larger sizes.
1. Engraved legend with black letters on white face. 2. Punched or drilled for mechanical fasteners. 3. Framed with mitered acrylic molding and arranged for attachment at applicable equipment.
B. Adhesive Film Label: Machine printed, in black, by thermal transfer or equivalent process. Minimum letter height shall be 3/8 inch.
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 4
C. Adhesive Film Label with Clear Protective Overlay: Machine printed, in black, by thermal transfer or equivalent process. Minimum letter height shall be 3/8 inch. Overlay shall provide a weatherproof and UV-resistant seal for label.
2.9 EQUIPMENT IDENTIFICATION LABELS
A. Adhesive Film Label with Clear Protective Overlay: Machine printed, in black, by thermal transfer or equivalent process. Minimum letter height shall be 3/8 inch. Overlay shall provide a weatherproof and UV-resistant seal for label.
B. Self-Adhesive, Engraved, Laminated Acrylic or Melamine Label: Adhesive backed, with black letters on a white background. Minimum letter height shall be 3/8 inch.
C. Stenciled Legend: In nonfading, waterproof, black ink or paint. Minimum letter height shall be 1 inch.
2.10 MISCELLANEOUS IDENTIFICATION PRODUCTS
A. Paint: Comply with requirements in painting Sections for paint materials and application requirements. Select paint system applicable for surface material and location (exterior or interior).
B. Fasteners for Labels and Signs: Self-tapping, stainless-steel screws or stainless-steel machine screws with nuts and flat and lock washers.
PART 3 - EXECUTION
3.1 CONDUCTOR LABELING SCHEME
A. All control and instrumentation conductors shall be labeled with a “To/From” labeling scheme. Each conductor label shall have two lines of text. The first line of text shall indicate the enclosure and terminal where the wire is to terminate on the other end. The second line of text shall indicate the enclosure and terminal where the wire is to terminate on this end. The following example illustrates the “To/From” labeling scheme: 1. A wire is connected between a VFD and an LCP. The VFD equipment tag is VFD-100 and the LCP equipment tag is LCP-100. The connecting terminal at the VFD enclosure is terminal “5”. The connecting terminal at the LCP is terminal “7”. This wire would have the following labels: a. The wire label at the VFD end: Top Line: “LCP-100 : 7” Bottom Line: “VFD-100 : 5” b. The wire label at the LCP end: Top Line: “VFD-100 : 5” Bottom Line: “LCP-100 : 7”
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 5
3.2 INSTALLATION
A. Location: Install identification materials and devices at locations for most convenient viewing without interference with operation and maintenance of equipment.
B. Apply identification devices to surfaces that require finish after completing finish work.
C. Self-Adhesive Identification Products: Clean surfaces before application, using materials and methods recommended by manufacturer of identification device.
D. Attach signs and plastic labels that are not self-adhesive type with mechanical fasteners appropriate to the location and substrate.
E. System Identification Color-Coding Bands for Raceways and Cables: Each color-coding band shall completely encircle cable or conduit. Place adjacent bands of two-color markings in contact, side by side. Locate bands at changes in direction, at penetrations of walls and floors, at 50-foot maximum intervals in straight runs, and at 25-foot maximum intervals in congested areas.
F. Underground-Line Warning Tape: During backfilling of trenches install continuous underground-line warning tape directly above line at 6 to 8 inches below finished grade. Use multiple tapes where width of multiple lines installed in a common trench or concrete envelope exceeds 16 inches overall.
G. Painted Identification: Comply with requirements in painting Sections for surface preparation and paint application.
3.3 IDENTIFICATION SCHEDULE
A. Accessible Raceways and Metal-Clad Cables, 600 V or Less, for Service, Feeder, and Branch Circuits More Than 30A, and 120V to ground: Install labels at 10-foot maximum intervals.
B. Accessible Raceways and Cables within Buildings: Identify the covers of each junction and pull box of the following systems with self-adhesive vinyl labels with the wiring system legend and system voltage. System legends shall be as follows:
1. Emergency Power. 2. Power. 3. UPS.
C. Power-Circuit Conductor Identification, 600 V or Less: For conductors in vaults, pull and junction boxes, manholes, and handholes, use color-coding conductor tape to identify the phase.
1. Color-Coding for Phase Identification, 600 V or Less: Use colors listed below for ungrounded service, feeder and branch-circuit conductors.
a. Colors for 208/120-V Circuits:
1) Phase A: Black. 2) Phase B: Red.
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 6
3) Phase C: Blue.
b. Colors for 480/277-V Circuits:
1) Phase A: Brown. 2) Phase B: Orange. 3) Phase C: Yellow.
c. Field-Applied, Color-Coding Conductor Tape: Apply in half-lapped turns for a minimum distance of 6 inches from terminal points and in boxes where splices or taps are made. Apply last two turns of tape with no tension to prevent possible unwinding. Locate bands to avoid obscuring factory cable markings.
D. Install instructional sign including the color-code for grounded and ungrounded conductors using adhesive-film-type labels.
E. Conductors to Be Extended in the Future: Attach marker tape to conductors and list source.
F. Auxiliary Electrical Systems Conductor Identification: Identify field-installed alarm, control, and signal connections.
1. Identify conductors, cables, and terminals in enclosures and at junctions, terminals, and pull points. Identify by system and circuit designation. 2. Use system of marker tape designations that is uniform and consistent with system used by manufacturer for factory-installed connections. 3. Coordinate identification with Project Drawings, manufacturer's wiring diagrams, and the Operation and Maintenance Manual.
G. Locations of Underground Lines: Identify with underground-line warning tape for power, lighting, communication, and control wiring and optical fiber cable.
1. Limit use of underground-line warning tape to direct-buried cables. 2. Install underground-line warning tape for both direct-buried cables and cables in raceway.
H. Workspace Indication: Install floor marking tape to show working clearances in the direction of access to live parts. Workspace shall be as required by NFPA 70 and 29 CFR 1926.403 unless otherwise indicated. Do not install at flush-mounted panelboards and similar equipment in finished spaces.
I. Warning Labels for Indoor Cabinets, Boxes, and Enclosures for Power and Lighting: Self- adhesive warning labels.
1. Comply with 29 CFR 1910.145. 2. Identify system voltage with black letters on an orange background. 3. Apply to exterior of door, cover, or other access. 4. For equipment with multiple power or control sources, apply to door or cover of equipment including, but not limited to, the following:
a. Power transfer switches. b. Controls with external control power connections.
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 7
J. Operating Instruction Signs: Install instruction signs to facilitate proper operation and maintenance of electrical systems and items to which they connect. Install instruction signs with approved legend where instructions are needed for system or equipment operation.
K. Emergency Operating Instruction Signs: Install instruction signs with white legend on a red background with minimum 3/8-inch-high letters for emergency instructions at equipment used for power transfer.
L. Equipment Identification Labels: On each unit of equipment, install unique designation label that is consistent with wiring diagrams, schedules, and the Operation and Maintenance Manual. Apply labels to disconnect switches and protection equipment, central or master units, control panels, control stations, terminal cabinets, and racks of each system. Systems include power, lighting, control, communication, signal, monitoring, and alarm systems unless equipment is provided with its own identification.
1. Labeling Instructions:
a. Indoor Equipment: Self-adhesive, engraved, laminated acrylic or melamine label. Unless otherwise indicated, provide a single line of text with 1/2-inch-high letters on 1-1/2-inch-high label; where two lines of text are required, use labels 2 inches high. b. Outdoor Equipment: Engraved, laminated acrylic or melamine label. c. Elevated Components: Increase sizes of labels and letters to those appropriate for viewing from the floor. d. Unless provided with self-adhesive means of attachment, fasten labels with appropriate mechanical fasteners that do not change the NEMA or NRTL rating of the enclosure.
END OF SECTION 260553
WRCRWA IDENTIFICATION FOR ELECTRICAL SYSTEMS PLANT EXPANSION PROJECT 260553 - 8
SECTION 260573 – ELECTRICAL TESTING WITH COORDINATION STUDY
PART 1 – GENERAL
1.1 SCOPE
A. The contractor shall furnish short-circuit and protective device coordination studies as prepared by the electrical equipment manufacturer or an approved engineering firm.
B. The contractor shall furnish an Arc Flash Hazard Analysis Study per the requirements set forth in NFPA 70E. The arc flash hazard analysis shall be performed according to the IEEE 1583 equations that are presented in NFPA 70E-2004, Annex D.
C. The scope of the studies shall include all new distribution equipment supplied by the equipment Manufacturer under this contract as well as all existing distribution equipment at the customer facility.
D. The contractor shall perform electrical tests as described in Part 3 of this document.
1.2 REFERENCES
A. The following is a list of standards which may be referenced in this section:
1. American National Standards Institute (ANSI):
a. 450, Recommended Practice for Maintenance, Testing, and Replacement of Large Lead Storage Batteries for Generator Stations and Substations. b. C2, National Electric Safety Code. c. C37.13, Standard for Low Voltage AC Power Circuit Breakers Used in Enclo- sures d. C37.20.1, Metal-Enclosed Low Voltage Power Circuit Breaker Switchgear. e. C37.20.2, Metal-Clad and Station-Type Cubicle Switchgear. f. C37.20.3, Metal-Enclosed Interrupter Switchgear. g. C57.12.00, Standard General Requirements for Liquid-Immersed Distribution, Power and Regulating Transformers h. C62.33, Standard Test Specifications for Varistor Surge Protective Devices.
2. American Society for Testing and Materials (ASTM):
a. D665, Standard Test Method for Rust Preventing Characteristics of Inhibited Mineral Oil in the Presence of Water. b. D877, Standard Test Method for Dielectric Breakdown Voltage of Insulating Liquids Using Disk Electrodes. c. D923, Standard Test Method for Sampling Electrical Insulating Liquids. d. D924, Standard Test Methods for A-Class Characteristics and Relative Permittiv- ity (Dielectric Constant) of Electrical Insulating Liquids. e. D971, Standard Test Method for Interfacial Tension of 0.1 against Water by the Ring Method.
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-1
f. D974, Standard Test Method for Acid and Base Number by Color-Indicator Ti- tration. g. D1298, Standard Test Method for Density, Relative Density (Specific Gravity), or API Gravity of Crude Petroleum and Liquid Petroleum Products by Hydrome- ter Method. h. D1500, Standard Test Method for ASTM Color of Petroleum Products. i. D1524, Standard Test Method for Visual Examination of Used Electrical Insulat- ing Oils of Petroleum Origin in the Field. j. D1533, Standard Test Methods for Water in Insulating Liquids. k. D1816, Standard Test Method for Dielectric Breakdown Voltage on Insulating Oils of Petroleum Origin Using VDE Electrodes. l. D2285, Standard Test Method for Interfacial Tension of Electrical Insulating Oils of Petroleum Origin against Water by the Drop-Weight Method.
3. Institute of Electrical and Electronics Engineers (IEEE):
a. 43, Recommended Practice for Testing Insulating Resistance of Rotating Ma- chinery. b. 48, Standard Test Procedures and Requirements for High-Voltage Alternating- Current Cable Terminators. c. 81, Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System. d. 95, Recommended Practice for Insulation Testing of Large AC Rotating Machin- ery with High Direct Voltage. e. 118, Standard Test Code for Resistance Measurement. f. 141, Recommended Practice for Electric Power Distribution and Coordination of Industrial Power Systems. g. 242, Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems h. 399, Recommended Practice for Industrial and Commercial Power System Anal- ysis i. 400, Guide for Making High-Direct-Voltage Tests on Power Cable Systems in the Field. j. 1015, Recommended Practice for Apply Low-Voltage Circuit Breakers Used in Industrial and Commercial Power Systems k. 1584, Guide for Performing Arc-Flash Hazard Calculations
4. National Electrical Manufacturers Association (NEMA):
a. AB 4, Guideline for Inspection and Preventive Maintenance of Molded Case Cir- cuit Breakers Used in Commercial and Industrial Applications. b. PB 2, Deadfront Distribution Switchboards. c. WC 7, Cross-Linked-Thermosetting-Polyethylene-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy. d. WC 8, Ethylene-Propylene-Rubber-Insulated Wire and Cable for the Transmis- sion and Distribution of Electrical Energy.
5. International Electrical Testing Association (NETA): ATS, Acceptance Testing Spec- ifications for Electrical Power Distribution Equipment and Systems.
6. National Fire Protection Association (NFPA):
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-2
a. 70, National Electrical Code (NEC). b. 70E, Standard for Electrical Safety Requirements for Employee Workplaces.
1.3 SUBMITTALS
A. Analysis Studies Submittal: Submit prior to receiving final approval of the distribution equipment submittal and prior to release of equipment manufacturing. If formal comple- tion of the studies may cause delay in equipment manufacturing, approval may be ob- tained from the Engineer may be obtained for preliminary submittal of sufficient study data to ensure that the selection of device and characteristics will be satisfactory.
1. The results of the short-circuit, protective device coordination and arc flash hazard analysis studies shall be summarized in a final report and submitted to the Design Engineer 2. The report shall include the following sections:. a. Executive Summary b. Descriptions, purpose, basis and scope of the study c. Tabulations of circuit breaker, fuse and other protective device ratings versus short circuit duties d. Protective device time versus current coordination curves, tabulations of relay and circuit breaker trips unit settings, fuse selection e. Fault current calculations including a definition of terms and guide for interpreta- tion of the computer printout\ f. Details of the incident energy and flash protection boundary calculations g. Recommendations for system improvements, where needed h. One-line diagram 3. Arc flash labels shall be provided in hard copy only 4. Sample copy of individual device test form. 5. Sample copy of individual system test form.
B. Administrative Submittals: Submit 30 days prior to performing inspections or tests:
1. Schedule for performing inspection and tests. 2. List of references to be used for each test. 3. Sample copy of equipment and materials inspection form(s). 4. Sample copy of individual device test form. 5. Sample copy of individual system test form.
C. Quality Control Submittals: Submit within 14 days after completion of test:
1. Test or inspection reports and certificates for each electrical item tested.
D. Contract Closeout Submittals:
1. Operation and Maintenance Data: a. In accordance with references elsewhere in these specifications. b. After test of inspection reports and certificates have been reviewed by ENGINEER and returned, insert a copy of each in operation and maintenance manual.
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1.4 QUALIFICATIONS
A. The short-circuit, protective device coordination and arc flash hazard analysis studies shall be conducted under the supervision and approval of a Registered Professional Elec- trical Engineer skilled in performing and interpreting the power system studies.
B. The Engineer shall be a full-time employee of the equipment manufacturer or an ap- proved engineering firm.
C. The Engineer shall have a minimum of five (5) years of experience in performing power system studies.
D. The Engineer shall submit references of at least ten actual short-circuit, protective device coordination and arc flash hazard analysis studies performed over the last five years.
1.5 QUALITY ASSURANCE
A. Test equipment shall have an operating accuracy equal to, or greater than, requirements established by NETA ATS.
B. Test instrument calibration shall be in accordance with NETA ATS.
1.6 SEQUENCING AND SCHEDULING
A. Perform short-circuit, protective device coordination and arc flash hazard analysis studies prior to final approval of distribution equipment submittal
B. Perform inspection and electrical tests after equipment has been installed.
C. Perform tests with apparatus de-energized whenever feasible.
D. Inspection and electrical tests on energized equipment are to be: 1. Scheduled with OWNER prior to de-energization. 2. Minimized to avoid extended period of interruption to the operating plant equipment.
E. Notify OWNER at least 24 hours prior to performing tests on energized electrical equip- ment.
PART 2 – PRODUCTS
2.1 STUDIES
A. Contractor is to furnish short-circuit and protective device coordination studies as pre- pared by equipment manufacturer or an approved engineering firm.
B. The contractor shall furnish an Arc Flash Hazard Analysis Study per NFPA 70E Article 130.3 and Annex D.
2.2 DATA COLLECTION
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-4
A. Contractor shall furnish all data as required by the power system studies. The Engineer performing the short-circuit, protective device coordination and arc flash hazard analysis studies shall furnish the Contractor with a listing of required data immediately after award of the contract. The Contractor shall expedite collection of the data to assure com- pletion of the studies as required for final approval of the distribution equipment shop drawings and/or prior to the release of the equipment for manufacturing.
B. Source combination may include present and future motors and generators
C. Load data utilized may include existing and proposed loads obtained from Contract Doc- uments provided by Owner or Contractor
2.3 SHORT-CIRCUIT AND PROTECTIVE DEVICE EVALUATION STUDY
A. Use actual conductor impedances if known. If unknown, use typical conductor imped- ances based on IEEE Standard 141-1993.
B. Transformer design impedances shall be used when test impedances are not available.
C. Provide the following: 1. Calculation methods and assumptions 2. One-line diagram of the system being evaluated 3. Source impedance data, including utility system and motor fault contribution charac- teristics 4. Tabulations of calculated quantities 5. Results, conclusions, and recommendations.
D. Calculate short-circuit momentary and interrupting duties for a three-phase bolted fault at each: 1. Electric utility’s supply termination point 2. Incoming switchgear 3. Unit substation primary and secondary terminals 4. Low voltage switchgear 5. Motor control centers 6. Standby generators and automatic transfer switches 7. Branch circuit panelboards 8. Other significant locations throughout the system
E. For grounded systems, provide a bolted line-to-ground fault current study for areas as de- fined for the three-phase bolted fault short-circuit study.
F. Protective Device Evaluation 1. Evaluate equipment and protective devices and compare to short circuit ratings 2. Adequacy of switchgear, motor control centers, and panelboard bus bars to withstand short-circuit stresses 3. Notify Owner in writing, of existing, circuit protective devices improperly rated for the calculated available fault current.
2.4 PROTECTIVE DEVICE COORDINATION STUDY
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-5
A. Proposed protective device coordination time-current curves (TCC) shall be displayed on log-log scale graphs
B. Include on each TCC graph, a complete title and one-line diagram with legend identify- ing the specific portion of the system covered.
C. Terminate device characteristic curves at a point reflecting maximum symmetrical or asymmetrical fault current to which the device is exposed.
D. Identify the device associated with each curve by manufacturer type, function, and, if ap- plicable, tap, time delay, and instantaneous settings recommended.
E. Plot the following characteristics on the TCC graphs, where applicable: 1. Electric utility’s overcurrent protective device 2. Medium voltage equipment overcurrent relays 3. Medium and low voltage fuses including manufacturer’s minimum melt, total clear- ing, tolerance, and damage bands 4. Low voltage equipment circuit breaker trip devices, including manufacturer’s toler- ance bands 5. Transformer full-load current, magnetizing inrush current, and ANSI through-fault protection curves 6. Conductor damage curves 7. Ground fault protective devices, as applicable 8. Pertinent motor starting characteristics and motor damage points, where applicable 9. Pertinent generator short-circuit decrement curve and generator damage point 10. The largest feeder circuit breaker in each motor control center and applicable panel- board
F. Provide adequate time margins between device characteristics such that selective opera- tion is provided, while providing proper protection.
2.5 ARC FLASH HAZARD ANALYSIS
A. The arc flash hazard analysis shall be performed according to the IEEE 1584 equations that are presented in NFPA70E-2004, Annex D.
B. The flash protection boundary and the incident energy shall be calculated at all signifi- cant locations in the electrical distribution system (switchboards, switchgear, motor- control centers, panelboards, busway and splitters) where work could be performed on energized parts.
C. The Arc-Flash Hazard Analysis shall include all significant locations in 240 volt and 208 volt systems fed from transformers equal to or greater than 125 kVA where work could be performed on energized parts.
D. Safe working distances shall be based upon the calculated arc flash boundary considering an incident energy of 1.2 cal/cm2.
E. When appropriate, the short circuit calculations and the clearing times of the phase over- current devices will be retrieved from the short-circuit and coordination study model.
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Ground overcurrent relays should not be taken into consideration when determining the clearing time when performing incident energy calculations.
F. The short-circuit calculations and the corresponding incident energy calculations for mul- tiple system scenarios must be compared and the greatest incident energy must be uniquely reported for each equipment location. Calculations must be performed to repre- sent the maximum and minimum contributions of fault current magnitude for all normal and emergency operating conditions. The minimum calculation will assume that the utili- ty contribution is at a minimum and will assume a minimum motor contribution (all mo- tors off). Conversely, the maximum calculation will assume a maximum contribution from the utility and will assume the maximum amount of motors to be operating. Calcu- lations shall take into consideration the parallel operation of synchronous generators with the electric utility, where applicable.
G. The incident energy calculations must consider the accumulation of energy over time when performing arc flash calculations on buses with multiple sources. Iterative calcula- tions must take into account the changing current contributions, as the sources are inter- rupted or decremented with time. Fault contribution from motors and generators should be decremented as follows: 1. Fault contribution from induction motors should not be considered beyond 3-5 cy- cles. 2. Fault contribution from synchronous motors and generators should be decayed to match the actual decrement of each as closely as possible (e.g. contributions from permanent magnet generators will typically decay from 10 per unit to 3 per unit after 10 cycles).
H. For each equipment location with a separately enclosed main device (where there is ade- quate separation between the line side terminals of the main protective device and the work location), calculations for incident energy and flash protection boundary shall in- clude both the line and load side of the main breaker.
I. When performing incident energy calculations on the line side of a main breaker (as re- quired per above), the line side and load side contributions must be included in the fault calculation.
J. Mis-coordination should be checked amongst all devices within the branch containing the immediate protective device upstream of the calculation location and the calculation should utilize the fastest device to compute the incident energy for the corresponding lo- cation.
K. Arc Flash calculations shall be based on actual overcurrent protective device clearing time. Maximum clearing time will be capped at 2 seconds based on IEEE 1584-2002 section B.1.2. Where it is not physically possible to move outside of the flash protection boundary in less than 2 seconds during an arc flash event, a maximum clearing time based on the specific location shall be utilized.
2.6 REPORT SECTIONS
A. Input data shall include, but not be limited to the following:
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-7
1. Feeder input data including feeder type (cable or bus), size, length, number per phase, conduit type (magnetic or non-magnetic) and conductor material (copper or alumi- num). 2. Transformer input data, including winding connections, secondary neutral-ground connection, primary and secondary voltage ratings, kVA rating, impedance, % taps and phase shift. 3. Reactor data, including voltage rating, and impedance. 4. Generation contribution data, (synchronous generators and Utility), including short- circuit reactance (X”d), rated MVA, rated voltage, three-phase and single line-ground contribution (for Utility sources) and X/R ratio. 5. Motor contribution data (induction motors and synchronous motors), including shortcircuit reactance, rated horsepower or kVA, rated voltage, and X/R ratio.
B. Short-Circuit Output Data shall include, but not be limited to the following reports: 1. Low Voltage Fault Report shall include a section for three-phase and unbalanced fault calculations and shall show the following information for each applicable loca- tion: a. Voltage b. Calculated fault current magnitude and angle c. Fault point X/R ratio d. Equivalent impedance 2. Momentary Duty Report shall include a section for three-phase and unbalanced fault calculations and shall show the following information for each applicable location: a. Voltage b. Calculated symmetrical fault current magnitude and angle c. Fault point X/R ratio d. Calculated asymmetrical fault currents e. Equivalent impedance 3. Interrupting Duty Report shall include a section for three-phase and unbalanced fault calculations and shall show the following information for each applicable location: a. Voltage b. Calculated symmetrical fault current magnitude and angle c. Fault point X/R ratio d. No AC Decrement (NACD) Ratio e. Equivalent impedance f. Multiplying factors for 2, 3, 5 and 8 cycle circuit breakers
C. Recommended Protective Device Settings: 1. Phase and Ground Relays: a. Current transformer ratio b. Current setting c. Time setting d. Instantaneous setting e. Recommendations on improved relaying systems, if applicable. 2. Circuit Breakers: a. Adjustable pickups and time delays (long time, short time, ground) b. Adjustable time-current characteristic c. Adjustable instantaneous pickup d. Recommendations on improved trip systems, if applicable.
D. Incident energy and flash protection boundary calculations
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-8
1. Arcing fault magnitude 2. Protective device clearing time 3. Duration of arc 4. Arc flash boundary 5. Working distance 6. Incident energy 7. Hazard Risk Category 8. Recommendations for arc flash energy reduction
PART 3 – EXECUTION
3.1 GENERAL
A. Tests specified in this section are to be performed in accordance with the requirements else- where in these specifications.
B. Coordination with local Utilities to obtain necessary information to perform the tests speci- fied in this section is the responsibility of the Contractor. All costs incurred in obtaining re- quired information shall be borne by the Contractor.
B. Tests and inspection shall establish that:
1. Electrical equipment is operational within industry and manufacturer’s tolerances. 2. All trip units are adjusted to avoid erroneous tripping of circuit breakers. 2. Installation operates properly. 3. Equipment is suitable for energization. 4. Installation conforms to requirements of Contract Documents and NFPA 70, NFPA 70E, and ANSI C2.
C. Perform inspection and testing in accordance with NETA ATS, industry standards, and manufacturer’s recommendations.
D. Adjust mechanisms and moving parts for free mechanical movement.
E. Adjust adjustable relays and sensors to correspond to operating conditions, or as recom- mended by manufacturer.
F. Verify nameplate data for conformance to Contract Documents.
G. Realign equipment not properly aligned and correct un-levelness.
H. Properly anchor electrical equipment found to be inadequately anchored.
I. Tighten accessible bolted connections, including wiring connections, with calibrated torque wrench to manufacturer’s recommendations, or as otherwise specified.
J. Clean contaminated surfaces with cleaning solvents as recommended by manufacturer.
K. Provide proper lubrication of applicable moving parts.
L. Inform OWNER of working clearances not in accordance with NFPA 70.
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-9
M. Investigate and repair or replace:
1. Electrical items that fail tests. 2. Active components not operating in accordance with manufacturer’s instructions. 3. Damaged electrical equipment.
N. Electrical Enclosures:
1. Remove foreign material and moisture from enclosure interior. 2. Vacuum and wipe clean enclosure interior. 3. Remove corrosion found on metal surfaces. 4. Repair or replace, as determined by OWNER, door and panel sections having dented surfaces. 5. Repair or replace, as determined by OWNER, poor fitting doors and panel sections. 6. Repair or replace improperly operating latching, locking, or interlocking devices. 7. Replace missing or damaged hardware. 8. Finish: a. Provide matching paint and touch up scratches and mars. b. If required due to extensive damage, as determined by OWNER, refinish the en- tire assembly.
O. Replace fuses and circuit breakers that do not conform to size and type required by the Contract Documents.
3.2 COORDINATION STUDY FIELD ADJUSTMENT
A. Adjust relay and protective device settings according to the recommended settings table provided by the coordination study.
B. Make minor modifications to equipment as required to accomplish conformance with short circuit and protective device coordination studies.
C. Notify Owner in writing of any required major equipment modifications.
3.3 ARC FLASH WARNING LABELS
A. The contractor of the Arc Flash Hazard Analysis shall provide a 3.5 in. x 5 in. thermal transfer type label of high adhesion polyester for each work location analyzed.
B. All labels will be based on recommended overcurrent device settings and will be provid- ed after the results of the analysis have been presented to the owner and after any system changes, upgrades or modifications have been incorporated in the system.
C. The label shall include the following information, at a minimum: 1. Location designation 2. Nominal voltage 3. Flash protection boundary 4. Hazard risk category 5. Incident energy 6. Working distance
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D. Labels shall be machine printed, with no field markings.
E. Arc flash labels shall be provided in the following manner and all labels shall be based on recommended overcurrent device settings. 1. For each 600, 480 and applicable 208 volt panelboard, one arc flash label shall be provided. 2. For each motor control center, one arc flash label shall be provided. 3. For each low voltage switchboard, one arc flash label shall be provided. 4. For each switchgear, one flash label shall be provided. 5. For medium voltage switches one arc flash label shall be provided
3.4 LOW VOLTAGE CABLES, 600 VOLTS MAXIMUM
A. Visual and Mechanical Inspection:
1. Inspect Each Individual Exposed Power Cable No. 4 and Larger For: a. Physical damage. b. Proper connections in accordance with single-line diagram. c. Cable bends that do not conform with manufacturer’s minimum allowable bend- ing radius where applicable. d. Color coding conformance with specifications. e. Proper circuit identification. 2. Mechanical Connections For: a. Proper lug type for conductor material. b. Proper lug installation. c. Bolt torque level in accordance with NETA ATS, Table 10.1, unless otherwise specified by manufacturer. 3. Shielded Instrumentation Cables For: a. Proper Shield grounding. b. Proper terminations. c. Proper circuit identification. 4 Control Cables For: a. Proper termination. b. Proper circuit identification. 5. Cables Terminated Through Window Type CTs: Verify that neutrals and grounds are terminated for correct operation of protective devices.
B. Electrical Tests:
1. Insulation Resistance Tests: a. Applied megohm-meter dc voltage in accordance with NETA ATS, Table 10.2. b. Phase-to-phase and phase-to-ground for 1 minute on each pole. c. Insulation resistance values equal to, or greater than ohm values established by manufacturer. d. Provide test reports to Engineer and Owner that show where test measurements were taken and the results 2. Contact Resistance Tests: a. Contact resistance in micro-ohms across each switch blade and fuse holder. b. Investigate deviation of 50% or more form adjacent poles or similar switches.
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-11
3.5 MOLDED CASE CIRCUIT BREAKERS
A. General: Inspection and testing limited to circuit breakers rated 400 amperes and larger.
B. Visual and Mechanical Inspection:
1. Proper mounting. 2. Proper conductor size. 3. Feeder designation according to nameplate and one-line diagram. 4. Cracked casings. 5. Connection bolt torque level in accordance with NETA ATS, Table 10.1. 6. Operate frame size and trip setting with circuit breaker schedules or one-line dia- gram. 7. Compare frame size and trip setting with circuit breaker schedules or one-line dia- gram. 8. Verify that terminals are suitable for 75 degrees C rated insulated conductors.
C. Electrical Tests:
1. Insulation Resistance Tests: a. Utilize 1,000-volt dc megohm-meter for 480- and 600-volt circuit breakers. b. Pole-to-pole and pole-to-ground with breaker contacts opened for 1 minute. c. Pole-to-pole and pole-to-ground with breaker contacts closed for 1 minute. d. Test values to comply with NETA ATS, Table 10.2. 2. Contact Resistance Tests: a. Contact resistance in micro-ohms across each pole. b. Investigate deviation of 50% or more from adjacent poles and similar breakers. 3. Trip Coordination Study: a. Provide coordination study of all new and existing equipment in the facililty. b. Adjust all circuit breaker settings per the coordination study.
3.6 INSTRUMENT TRANSFORMERS
A. Visual and Mechanical Inspection:
1. Visually Check Current, Potential, and Control Transformers for: a. Cracked insulation. b. Broken leads or defective wiring. c. Proper connections d. Adequate clearances between primary and secondary circuit wiring. 2. Verify Mechanically that: a. Grounding and shorting connections have good contact. b. Withdrawal mechanism and grounding operation, when applicable, operate properly. 3. Insulation resistance measurement on instrument transformer shall not be less than that shown in NETA ATS, Table 7.1.1.
3.7 METERING
A. Visual and Mechanical Inspection:
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-12
1. Verify meter connections in accordance with appropriate diagrams. 2. Verify meter multipliers. 3. Verify that meter types and scales conform to Contract Documents. 4. Check calibration of meters at cardinal points. 5. Check calibration of electrical transducers.
3.8 GROUNDING SYSTEMS
A. Visual and Mechanical Inspection:
1. Equipment and circuit grounds in motor control centers and panelboards assemblies for proper connection and tightness. 2. Ground bus connections in motor control centers and panelboards assemblies for proper termination and tightness. 3. Effective transformer core and equipment grounding. 4. Accessible connections to grounding electrodes for proper fit and tightness. 5. Accessible exothermic-weld grounding connections to verify that molds were fully filled and proper bonding was obtained. 6. Test ground system using 3 point fall of potential test equipment. Ground system must provide less than 5 ohms to ground resistance. Provide test reports to Engineer and Owner that show where test measurements were taken and the results. System must be tested at all ground rods, concrete encased electrodes, ground busses and service entrance locations.
3.9 AC INDUCTION MOTORS
A. General: Inspection and testing limited to motors rated 10 hp and larger.
B. Visual and Mechanical Inspection:
1. Proper electrical and grounding connections. 2. Shaft alignment. 3. Blockage of ventilating air passageways. 4. Operate Motor and Check for: a. Excessive mechanical and electrical noise. b. Overheating. c. Correct rotation. d. Check vibration detectors, resistance temperature detectors, or motor inherent protectors for proper operation. e. Excessive vibration. 5. Check operation of space heaters.
C. Electrical Tests:
1. Insulation Resistance Tests: a. In accordance with IEEE 43 at test voltages established by NETA ATS, Table 10.2 for: 1) Motors above 200 hp for 10-minute duration with resistances tabulated at 30 seconds, 1 minute, and 10 minutes.
WRCRWA ELECTRICAL TESTING WITH COORDINATION STUDY PLANT EXPANSION PROJECT 260573-13
2) Motors 200 hp and less for 1-minute duration with resistances tabulated at 30 and 60 seconds. b. Insulation resistance values equal to, or greater than, ohm values established by manufacturers. 2. Calculate polarization index ratios for motors above 200 hp. Investigate index ratios less than 1.5 for Class A insulation and 2.0 for Class B insulation. 3. Insulation resistance test on insulated bearings in accordance with manufacturer’s in- structions. 4. Measure running current and voltage, and evaluate relative to load conditions and nameplate full-load amperes. 5. Provide test reports to Engineer and Owner that show where test measurements were taken and the results
3.10 LOW VOLTAGE MOTOR CONTROL
A. Visual and Mechanical Inspection:
1. Proper barrier and shutter installation and operation. 2. Proper operation of indicating and monitoring devices. 3. Proper overload protection for each motor. 4. Improper blockage of air cooling passages. 5. Proper operation of draw out elements. 6. Integrity and contamination of us insulation system. 7. Check Door and Device Interlocking System By: a. Closure attempt of device when door is in OFF or OPEN position. b. Opening attempt of door when device is in ON or CLOSED position. 8. Check Nameplates for Proper Identification Of: a. Equipment title and tag number with latest one-line diagram. b. Pushbuttons. c. Control switches. d. Pilot lights. e. Control relays. f. Circuit breakers. g. Indicating meters. 9. Verify that fuse and circuit breaker sizes and types conform to Contract Documents. 10. Verify that current and potential transformer ratios conform to Contract Documents. 11. Check Bus Connections for High Resistance by Low Resistance Ohmmeter and Cali- brated Torque Wrench Applied to Bolted Joints: a. Ohm value to be zero. b. Bolt torque level in accordance with NETA ATS, Table 10.1, unless otherwise specified by manufacturer. 12. Check Operation and Sequencing of Electrical and Mechanical Interlock Systems by: a. Closure attempt for locked open devices. b. Opening attempt for locked closed devices. 13. Verify performance of each control device and feature furnished as part of the motor control center. 14. Control Wiring: a. Compare wiring to local and remote control, and protective devices with elemen- tary diagrams. b. Check for proper conductor lacing and bundling. c. Check for proper conductor identification.
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d. Check for proper conductor lugs and connections. 15. Exercise active components. 16. Inspect Contactors For: a. Correct mechanical operations. b. Correct contact gap, wipe, alignment, and pressure. c. Correct torque of all connections. 17. Compare overload heater rating with full-load current for proper size. 18. Compare fuse, motor protector, and circuit breaker with motor characteristics for proper size. 19. Perform phasing check on double-ended motor control centers to ensure proper bus phasing from each source.
B. Electrical Tests:
1. Insulation Resistance Tests: a. Applied megohm-meter dc voltage in accordance with NETA ATS, Table 10.2. b. Bus section phase-to-phase and phase-to-ground for 1 minute on each phase. c. Contactor phase-to-ground and across open contacts for 1 minute on each phase. d. Starter section phase-to-phase and phase-to-ground on each phase with starter contacts closed and protective devices open. e. Test values to comply with NETA ATS, Table 10.2. 2. Current Injection through Overload Unit at 300% of Motor Full-Load Current and Monitor Trip Time: a. Trip time in accordance with manufacturer’s published data. b. Investigate values in excess of 120 seconds. 3. Control Wiring Tests: a. Apply secondary voltage to control power and potential circuits. b. Check voltage levels at each point on terminal boards and each device terminal. c. Insulation resistance test at 1,000 volts dc on control wiring except that connect- ed to solid state components. 1) Insulation resistance to be 1 megohm minimum. 4. Operational test by initiating control devices to affect proper operation. 5. Provide test reports to Engineer and Owner that show where test measurements were taken and the results
END OF SECTION 260753
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SECTION 261213 - LIQUID-FILLED MEDIUM-VOLTAGE TRANFORMERS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This section covers pad mount liquid immersed transformers with medium voltage primary, low voltage secondary, three phase, power distribution.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with Section 013300 “Contractor Submittals” and Section 26000 “General Electrical Requirements” prior to installation. As a minimum the contractor shall submit the following information: a. Dimensional Drawings b. Weight c. Voltage ratings of both the primary and secondary including taps d. KVA rating e. % impedance f. Insulation class g. Wiring Diagrams h. Installation Instructions
1.3 QUALITY ASSURANCE
A. ANSI C57.12.00, liquid-immersed transformers
B. ANSI C57.12.26, dead front transformers
C. ANSI C57.12.28, enclosure integrity
D. ANSI C57.12.34 Pad Mounted, Compartmental type transformers
E. ANSI C57.12.90, testing
F. ANSI C57.91 Loading Guide
G. NEMA TR1 Transformers, Regulators, and Reactors
H. ANSI C2 National Electrical Safety Code
I. NFPA 70 National Electrical Code
J. State and Local Codes as Required by Local Authorities.
PART 2 - PRODUCTS
2.1 MEDIUM VOLTAGE PRIMARY, LOW VOLTAGE SECONDARY
WRCRWA LIQUID-FILLED MEDIUM-VOLTAGE TRANSFORMERS PLANT EXPANSION PROJECT 261213 - 1
A. Transformer voltage and KVA ratings shall be as shown on the plans and rated or de-rated as necessary based on the site elevation and conditions.
B. Transformers shall be rated premium high efficiency. Transformer efficiency shall be no less than 99% at any load above 25%. Transformers shall meet DOE 2010 efficiency Standards.
C. The primary winding of the transformers shall have two 2-1/2 percent taps above, and below normal.
D. Transformers shall have a BIL of 95 KV primary and 45 KV secondary.
E. Transformers shall be configured for radial feed, dead front with primary bayonet style fusing.
F. Transformer windings shall be copper.
G. Transformer insulating liquid shall be new. It shall contain no PCBs. It shall be mineral oil, silicon or R'Temp fluids.
H. Transformers shall have separate high voltage and low voltage compartments. Connection compartments shall be lockable.
I. Transformer tanks shall be steel all welded construction.
J. Transformers shall have the following accessories:
a. Dial type thermometer b. Liquid level gauge c. Pressure vacuum gauge d. One Inch Upper Fill and Filter Press Connection e. Combination Drain and Filtering Valve with Sampling Valve f. Pressure Relief Device g. De-energized HV Tap Changer h. Tank Lifting Provisions i. Ground Pads in each connection compartment j. Stainless Steel Nameplate
K. Transformers shall be Class OA with a rated temperature rise of 55 deg C. Cooling fans shall not be used.
L. Transformers shall have a nominal impedance of 5.75%, maximum impedance of 6.5% and a minimum impedance of 5%.
M. Grounding lugs shall be provided inside both the connection compartments and externally on the tank.
N. A sufficient number of lugging holes shall be provided on the secondary bushings for secondary cables to carry the full load current of the Transformer. The number of holes required shall be calculated on the basis of 350 MCM conductors and NEC article 310. There shall be support brackets installed in the secondary of the transformer to help support the weight of the cables so that the bushings are not supporting the total weight of the secondary cables.
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O. The transformer shall be provided with three (3) high voltage bushings in accordance with ANSI C57.12.34 for radial feed configurations. The bushing heights shall be in accordance with ANSI C57.12.34.
P. Wye secondary transformers shall have a separate isolated neutral bushing in the low voltage compartment for the Wye point. The wye point shall be electrically isolated and not be internally grounded.
Q. MANUFACTURERS
a. ABB b. General Electric c. Square D d. Westinghouse e. Approved Equal
PART 3 - EXECUTION
3.1 INSTALLATION
A. Transformers shall be installed as indicated on the Contract Drawings, and in accordance with the manufacturer’s instructions and recommendations.
B. Grounding shall be provided per NEC, and Section 260526 – “Grounding and Bonding for Electrical Systems” and manufacturer’s recommendations.
C. Transformers shall be bolted in place using appropriately sized anchor bolts per the manufacturer’s recommendations.
3.2 FIELD QUALITY CONTROL
A. Test dielectric liquid to ASTM D877, using 25,000 volts minimum breakdown voltage, after installation and before being energized.
B. Test transformer to ANSI/IEEE C57.12.90.
C. Provide the Engineer with five (5) certified copies of all field test reports.
3.3 ADJUSTING
A. Adjust primary taps so that secondary voltage is within two (2) percent of rated voltage.
END OF SECTION 261213
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SECTION 261300 - MEDIUM-VOLTAGE SWITCHGEAR
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Special Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes metal-enclosed interrupter switchgear with the following optional components, features, and accessories:
1. Copper, tin-plated main bus. 2. Communication modules. 3. Analog instruments. 4. Relays. 5. Surge arresters. 6. Provisions for future devices. 7. Fungus proofing. 8. Control battery system. 9. Mimic bus.
1.3 DEFINITIONS
A. ATS: Acceptance Testing Specifications.
B. GFCI: Ground-Fault Circuit Interrupter.
1.4 SUBMITTALS
A. Product Data: For each type of switchgear and related equipment, include the following:
1. Rated capacities, operating characteristics, furnished specialties, and accessories for individual interrupter switches. 2. Time-current characteristic curves for overcurrent protective devices, including fusible devices.
B. Shop Drawings: For each type of switchgear and related equipment, include the following:
1. Dimensioned plans, elevations, sections, and details, including required clearances and service space around equipment. Show method of field assembly and location and size of each field connection. Include the following:
a. Tabulation of installed devices with features and ratings.
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b. Outline and general arrangement drawing showing dimensions, shipping sections, and weights of each assembled section. c. Drawing of cable termination compartments showing preferred locations for conduits and indicating space available for cable terminations. d. Floor plan drawing showing locations for anchor bolts. e. Current ratings of buses. f. Short-time and short-circuit ratings of switchgear assembly. g. Nameplate legends. h. Mimic-bus diagram. i. Utility company's metering provisions with indication of approval by utility company.
2. Design Calculations: Signed and sealed by a qualified professional engineer. Calculate requirements for selecting seismic restraints. 3. Wiring Diagrams: For each type of switchgear and related equipment, include the following:
a. Power, signal, and control wiring. b. Three-line diagrams of current and future secondary circuits showing device terminal numbers and internal diagrams. c. Schematic control diagrams. d. Diagrams showing connections of component devices and equipment. e. Schematic diagrams showing connections to remote devices.
C. Coordination Drawings: Floor plans showing dimensioned layout, required working clearances, and required area above and around switchgear where piping and ducts are prohibited. Show switchgear layout and relationships between components and adjacent structural and mechanical elements. Show support locations, type of support, and weight on each support. Identify field measurements.
D. Samples: Representative portion of mimic bus with specified finish. Manufacturer's color charts showing colors available for mimic bus.
E. Manufacturer Seismic Qualification Certification: Submit certification that switchgear, accessories, and components will withstand seismic forces defined in Division 26 Section "Vibration and Seismic Controls for Electrical Systems." Include the following:
1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation.
a. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified." b. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event."
2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions. 3. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements.
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F. Qualification Data: For professional engineer.
G. Source quality-control test reports.
H. Field quality-control test reports.
I. Operation and Maintenance Data: For switchgear and switchgear components to include in emergency, operation, and maintenance manuals. In addition to items specified in Division 01 Section "Operation and Maintenance Data," include the following:
1. Manufacturer's written instructions for testing and adjusting overcurrent protective devices. 2. Time-current curves, including selectable ranges for each type of overcurrent protective device.
1.5 QUALITY ASSURANCE
A. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a member company of the InterNational Electrical Testing Association or is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7, and that is acceptable to authorities having jurisdiction.
1. Testing Agency's Field Supervisor: Person currently certified by the InterNational Electrical Testing Association or the National Institute for Certification in Engineering Technologies to supervise on-site testing specified in Part 3.
B. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7.
C. Source Limitations: Obtain each type of switchgear and associated components through one source from a single manufacturer.
D. Product Options: Drawings indicate size, profiles, and dimensional requirements of switchgear and are based on the specific system indicated. Refer to Division 01 Section "Product Requirements."
E. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
F. Comply with IEEE C2.
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver in sections of lengths that can be moved past obstructions in delivery path as indicated.
B. Store switchgear indoors in clean dry space with uniform temperature to prevent condensation. Protect switchgear from exposure to dirt, fumes, water, corrosive substances, and physical damage.
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C. If stored in areas subjected to weather, cover switchgear to provide protection from weather, dirt, dust, corrosive substances, and physical damage. Remove loose packing and flammable materials from inside switchgear; install electric heating (250 W per section) to prevent condensation.
1.7 PROJECT CONDITIONS
A. Environmental Limitations: Rate equipment for continuous operation at indicated ampere ratings for the following conditions:
1. Ambient temperature not exceeding 122 deg F (50 deg C). 2. Altitude of 800 ft above sea level. 3. Outdoor installation
B. Installation Pathway: Remove and replace building components and structures to provide pathway for moving switchgear into place.
C. Product Selection for Restricted Space: Drawings indicate maximum dimensions for switchgear, including clearances between switchgear and adjacent surfaces and other items. Comply with indicated maximum dimensions.
D. Interruption of Existing Electrical Service: Do not interrupt electrical service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary electrical service according to requirements indicated:
1. Notify Construction Manager and Owner no fewer than five days in advance of proposed interruption of electrical service. 2. Do not proceed with interruption of electrical service without Owner's written permission.
1.8 COORDINATION
A. Coordinate layout and installation of switchgear and components with other construction including conduit, piping, equipment, and adjacent surfaces. Maintain required clearances for workspace and equipment access doors and panels.
B. Coordinate size and location of concrete bases. Concrete, reinforcement, and formwork requirements are specified in Division 03.
1.9 EXTRA MATERIALS
A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.
1. Fuses: Six of each type and rating used. Include spares for future transformers, control power circuits, and fusible devices. 2. Indicating Lights: Six of each type installed. 3. Touchup Paint: Two containers of paint matching enclosure finish, each 0.5 pint.
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B. Maintenance Tools: Furnish tools and miscellaneous items required for interrupter switchgear test, inspection, maintenance, and operation. Include the following:
1. Fuse-handling tool. 2. Extension rails, lifting device, transport or dockable dolly or mobile lift, and all other items necessary to remove circuit breaker from housing and transport to remote location. 3. Racking handle to move circuit breaker manually between connected and disconnected positions, and a secondary test coupler to permit testing of circuit breaker without removal from switchgear.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:
1. Manufacturers: Subject to compliance with requirements, provide products by one of the manufacturers specified.
2.2 MANUFACTURED UNITS
A. Description: Factory assembled and tested, and complying with IEEE C37.20.1.
B. Ratings: Suitable for application in 3-phase, 60-Hz, solidly grounded-neutral system.
C. System Voltage: 12.47 kV nominal; 15 kV maximum.
2.3 METAL-ENCLOSED INTERRUPTER SWITCHGEAR
A. Available Manufacturers:
1. Square D; Schneider Electric.
B. Comply with IEEE C37.20.3.
C. Comply with IEEE C37.20.7. Provide arc-resistant switchgear, Type 1C.
D. Design Level of Available-Source Fault Current: Integrated short-circuit rating consistent with value of fault current indicated.
E. Ratings: Comply with standard ratings designated in IEEE C37.20.3 for maximum-rated voltage specified.
1. Main-Bus Rating: 1200 A, continuous.
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F. Interrupter Switches: Stationary, gang operated, and suitable for application at maximum short- circuit rating of integrated switchgear assembly.
1. Rating: 600-A continuous duty and load break. 2. Duty-Cycle, Fault Closing: 25,000 asymmetrical A. 3. Switch Action: No external arc and no significant quantities of ionized gas released into the enclosure. 4. Switch Construction: Supported entirely by interior framework of structure, with copper switchblades and stored-energy operating mechanism. 5. Phase Barriers: Full length of switchblades and fuses for each pole; designed for easy removal; allow visual inspection of switch components if barrier is in place. 6. Protective Shields: Cover live components and terminals. 7. Fuses: De-energized if switch is open.
G. Mechanical Interlock: Prevent opening switch compartment door unless switchblades are open, and prevent closing switch if door is open.
H. Window: Permit viewing switchblade positions if door is closed.
I. Power Fuses: Comply with the following and with applicable requirements in NEMA SG 2:
1. Indicator: Integral with each fuse to indicate when it has blown. 2. Mounting: Positively held in position with provision for easy removal and replacement from front without special tools. 3. Current-Limiting Fuses: Full-range, fast-replaceable, current-limiting type that will operate without explosive noise or expulsion of gas, vapor, or foreign matter from tube. 4. Expulsion Fuses: Furnished in disconnect-type mountings and renewable with replacement fuse units. Gases emitted on interruption are controlled and silenced by chambers designed for that purpose.
2.4 FABRICATION
A. Indoor Enclosure: Steel.
B. Outdoor Enclosure: Galvanized steel, weatherproof construction; integral structural-steel base frame with factory-applied asphaltic undercoating. NEMA 3R rating.
1. Each compartment shall have the following features:
a. Structural design and anchorage adequate to resist loads imposed by 125-mph (200-km/h) wind. b. Space heater operating at one-half or less of rated voltage, sized to prevent condensation. c. Louvers equipped with insect and rodent screen and filter, and arranged to permit air circulation while excluding rodents and exterior dust. d. Hinged front door with locking provisions. e. Interior light with switch. f. Weatherproof GFCI duplex receptacle. g. Power for heaters, lights, and receptacles to be provided by control power transformer.
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2. Weatherproof internal aisle construction shall have the following features:
a. Common internal aisle of sufficient width to permit protective-device withdrawal, disassembly, and servicing in aisle. b. Aisle access doors at each end with exterior locking provisions and interior panic latches. c. Aisle space heaters operating at one-half or less of rated voltage, thermostatically controlled. d. Vaporproof fluorescent aisle lights with low-temperature ballasts, controlled by wall switch at each entrance. e. GFCI duplex receptacles, a minimum of two, located in aisle. f. Aisle ventilation louvers equipped with insect and rodent screen and filter, and arranged to permit air circulation while excluding rodents and exterior dust.
C. Finish: Manufacturer's standard gray finish over rust-inhibiting primer on phosphatizing-treated metal surfaces.
D. Bus Transition Unit: Arranged to suit bus and adjacent units.
E. Incoming-Line Unit: Arranged to suit incoming line.
F. Outgoing Feeder Units: Arranged to suit distribution feeders.
G. Auxiliary Compartments: Arranged to suit house meters, relays, controls, and auxiliary equipment; isolated from medium-voltage components.
H. Key Interlocks: Arranged to effect interlocking schemes indicated.
I. Provisions for Future Key Interlocks: Mountings and hardware required for future installation of locks, where indicated.
2.5 COMPONENTS
A. Main Bus: Copper, tin plated; full length of switchgear.
B. Ground Bus: Copper, or copper, tin plated; minimum size 1/4 by 2 inches (6 by 50 mm); full length of switchgear.
C. Bus Insulation: Covered with flame-retardant insulation.
D. Instrument Transformers: Comply with IEEE C57.13.
1. Potential Transformers: Secondary voltage rating of 120 V and NEMA accuracy class of 0.3 with burdens of W, X, and Y. 2. Current Transformers: Burden and accuracy class suitable for connected relays, meters, and instruments.
E. Multifunction Digital-Metering Monitor: Microprocessor-based unit suitable for three- or four- wire systems, listed and labeled by an NRTL, and with the following features:
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1. Inputs from sensors or 5-A current-transformer secondaries, and potential terminals rated to 600 V. 2. Switch-selectable digital display with the following features:
a. Phase Currents, Each Phase: Plus or minus 1 percent. b. Phase-to-Phase Voltages, Three Phase: Plus or minus 1 percent. c. Phase-to-Neutral Voltages, Three Phase: Plus or minus 1 percent. d. Three-Phase Real Power: Plus or minus 2 percent. e. Three-Phase Reactive Power: Plus or minus 2 percent. f. Power Factor: Plus or minus 2 percent. g. Frequency: Plus or minus 0.5 percent. h. Integrated Demand, with Demand Interval Selectable from 5 to 60 Minutes: Plus or minus 2 percent. i. Accumulated energy, in megawatt hours (joules), plus or minus 2 percent; stored values unaffected by power outages for up to 72 hours.
3. Communications module suitable for remote monitoring of meter quantities and functions. Interface communication and metering requirements according to Division 26 Section "Electrical Power Monitoring and Control." 4. Mounting: Display and control unit that is flush or semiflush mounted in instrument compartment door.
F. Analog Instruments: Rectangular, 4-1/2 inches (115 mm) square, 1 percent accuracy, semiflush mounting, with antiparallax 250-degree scale and external zero adjustment, and complying with ANSI C39.1.
1. Voltmeters: Cover an expanded scale range of normal voltage plus 10 percent. 2. Voltmeter Selector Switch: Rotary type with off position to provide readings of phase- to-phase voltages. 3. Ammeters: Cover an expanded scale range of bus rating plus 10 percent. 4. Ammeter Selector Switch: Permits current reading in each phase and keeps current- transformer secondary circuits closed in off position. 5. Locate meter and selector switch on circuit-breaker compartment door for indicated feeder circuits only. 6. Watt-Hour Meters: Flush- or semiflush-mounting type, 5 A, 120 V, 3 phase, 3 wire; with 3 elements, 15-minute indicating demand register, and provision for testing and adding pulse initiation. 7. Recording Demand Meter: Usable as totalizing relay or indicating and recording maximum demand meter with 15-minute interval.
a. Operation: Counts and records a succession of pulses entering two channels. b. Housing: Drawout, back-connected case arranged for semiflush mounting.
G. Relays: Comply with IEEE C37.90, integrated digital type; with test blocks and plugs.
H. Surge Arresters: Distribution class, metal-oxide-varistor type. Comply with NEMA LA 1.
1. Install in cable termination compartments in each phase of circuit. 2. Coordinate rating with circuit voltage.
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I. Provision for Future Devices: Equip compartments with rails, mounting brackets, supports, necessary appurtenances, and bus connections.
J. Fungus Proofing: Permanent fungicidal treatment for switchgear interior, including instruments and instrument transformers.
K. Control Power Supply: DC battery system.
L. Control Power Supply: Control power transformer supplies 120-V control circuits through secondary disconnect devices. Include the following features:
1. Dry-type transformers, in separate compartments for units larger than 3 kVA, including primary and secondary fuses. 2. Two control power transformers in separate compartments with necessary interlocking relays; each transformer connected to line side of associated main circuit breaker.
a. Secondary windings connected through relay(s) to control bus to affect an automatic transfer scheme. b. Secondary windings connected through an internal automatic transfer switch to switchgear control power bus.
3. Control Power Fuses: Primary and secondary fuses provide current-limiting and overload protection.
M. Control Wiring: Factory installed, complete with bundling, lacing, and protection; and complying with the following:
1. Flexible conductors for No. 8 AWG and smaller, for conductors across hinges, and for conductors for interconnections between shipping units. 2. Conductors sized according to NFPA 70 for duty required.
2.6 CONTROL BATTERY SYSTEM
A. System Requirements: Battery shall have number of cells and ampere-hour capacity based on an initial specific gravity of 1.210 at 25 deg C with electrolyte at normal level and minimum ambient temperature of 13 deg C. Cycle battery before shipment to guarantee rated capacity on installation. Arrange battery to operate ungrounded.
B. Battery: Lead-calcium type in sealed, clear plastic or glass containers, complete with electrolyte, fully charged and arranged for shipment with electrolyte in cells. Limit weight of each container to not more than 70 lb and cells per container to not more than 3. System batteries shall be suitable for service at an ambient temperature ranging from minus 18 to 25 deg C. Limit variation of current output to 0.8 percent for each degree below 25 deg C down to minus 8 deg C.
C. Rack: Two-step rack with electrical connections between battery cells and between rows of cells; include two flexible connectors with bolted-type terminals for output leads. Rate battery rack, cell supports, and anchorage for seismic requirements.
D. Accessories:
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1. Thermometers with specific-gravity correction scales. 2. Hydrometer syringes. 3. Set of socket wrenches and other tools required for battery maintenance. 4. Wall-mounting, nonmetallic storage rack fitted to store above items. 5. Set of cell numerals.
E. Charger: Static-type silicon rectifier equipped with automatic regulation and provision for manual and automatic adjustment of charging rate. Unit shall automatically maintain output voltage within 0.5 percent from no load to rated charger output current, with ac input-voltage variation of plus or minus 10 percent and input-frequency variation of plus or minus 3 Hz. Other features of charger include the following:
1. DC ammeter. 2. DC Voltmeter: Maximum error of 5 percent at full-charge voltage; operates with toggle switch to select between battery and charger voltages. 3. Ground Indication: Two appropriately labeled lights to indicate circuit ground, connected in series between negative and positive terminals, with midpoint junction connected to ground by normally open push-button contact. 4. Capacity: Sufficient to supply steady load, float-charge battery between 2.20 and 2.25 V per cell and equalizing charge at 2.33 V per cell. 5. Charging-Rate Switch: Manually operated switch provides for transferring to higher charging rate. Charger operates automatically after switch operation until manually reset. 6. AC power supply is 120 V, 60 Hz, subject to plus or minus 10 percent variation in voltage and plus or minus 3-Hz variation in frequency. After loss of ac power supply for any interval, charger automatically resumes charging battery. Charger regulates rate of charge to prevent damage due to overload and to prevent fuses or circuit breakers from opening. 7. Protective Feature: Current-limiting device or circuit, which limits output current to rating of charger but does not disconnect charger from either battery or ac supply; to protect charger from damage due to overload, including short circuit on output terminals. 8. Electrical Filtering: Reduces charger's audible noise to less than 26 dB.
2.7 IDENTIFICATION
A. Materials: Refer to Division 26 Section "Identification for Electrical Systems." Identify units, devices, controls, and wiring.
B. Mimic Bus: Continuous mimic bus applied to front of switchgear, arranged in single-line diagram format, using symbols and lettered designations consistent with approved final mimic- bus diagram.
1. Mimic-bus segments coordinated with devices in switchgear sections to which applied, to produce a concise visual presentation of principal switchgear components and connections. 2. Medium: Painted graphics, as approved. 3. Color: Contrasting with factory-finish background; selected by Architect.
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2.8 SOURCE QUALITY CONTROL
A. Before shipment of equipment, perform the following tests and prepare test reports:
1. Production tests on circuit breakers according to ANSI C37.09. 2. Production tests on completed switchgear assembly according to IEEE C37.20.2.
B. Assemble switchgear and equipment in manufacturer's plant and perform the following:
1. Functional tests of all relays, instruments, meters, and control devices by application of secondary three-phase voltage to voltage circuits and injection of current in current transformer secondary circuits. 2. Functional test of all control and trip circuits. Connect test devices into circuits to simulate operation of controlled remote equipment such as circuit-breaker trip coils, close coils, and auxiliary contacts. Test proper operation of relay targets.
C. Prepare equipment for shipment.
1. Provide suitable crating, blocking, and supports so equipment will withstand expected domestic shipping and handling shocks and vibration. 2. Weatherproof equipment for shipment. Close connection openings to prevent entrance of foreign material during shipment and storage.
2.9 FACTORY FINISHES
A. Finish: Manufacturer's standard color finish applied to equipment before shipping.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine elements and surfaces to receive switchgear for compliance with requirements for installation tolerances, required clearances, and other conditions affecting performance.
1. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Anchor switchgear assembly to 4-inch channel-iron sill embedded in concrete base and attach by bolting.
1. Sills: Select to suit switchgear; level and grout flush into concrete base. 2. Design each fastener and support to carry load indicated by seismic requirements and according to seismic-restraint details. See Division 26 Section "Vibration and Seismic Controls for Electrical Systems" for seismic-restraint requirements. 3. Concrete Bases: 4 inches high, reinforced, with chamfered edges. Extend base no less than 3 inches in all directions beyond the maximum dimensions of switchgear, unless
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otherwise indicated or unless required for seismic anchor support. Construct concrete bases according to Division 26 Section "Hangers and Supports for Electrical Systems."
B. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from switchgear units and components.
3.3 IDENTIFICATION
A. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs as specified in Division 26 Section "Identification for Electrical Systems."
B. Diagram and Instructions:
1. Frame under clear acrylic plastic on front of switchgear.
a. Operating Instructions: Printed basic instructions for switchgear, including control and key-interlock sequences and emergency procedures. b. System Power Riser Diagrams: Depict power sources, feeders, distribution components, and major loads.
2. Storage for Maintenance: Include a rack or holder, near the operating instructions, for a copy of maintenance manual.
3.4 CONNECTIONS
A. Cable terminations at switchgear are specified in Division 26 Section "Medium-Voltage Cables."
B. Tighten bus joints, electrical connectors, and terminals according to manufacturer's published torque-tightening values.
C. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems."
D. Connect wiring according to Division 26 Sections "Low-Voltage Electrical Power Conductors and Cables" and "Medium-Voltage Cables."
3.5 FIELD QUALITY CONTROL
A. Prepare for acceptance tests as follows:
1. Test insulation resistance for each switchgear bus, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit.
B. Manufacturer's Field Service: Engage a factory-authorized service representative to perform the following:
1. Inspect switchgear, wiring, components, connections, and equipment installation.
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2. Assist in field testing of equipment. 3. Report results in writing.
C. Perform the following field tests and inspections and prepare test reports:
1. Perform each electrical test and visual and mechanical inspection stated in NETA ATS. Certify compliance with test parameters. Perform NETA tests and inspections for each of the following NETA categories:
a. Switchgear. b. Circuit breakers. c. Protective relays. d. Instrument transformers. e. Metering and instrumentation. f. Ground-fault systems. g. Battery systems. h. Surge arresters. i. Capacitors.
D. Remove and replace malfunctioning units and retest as specified above.
E. Infrared Scanning: After Substantial Completion, but not more than 60 days after Final Acceptance, perform infrared scan of each switchgear. Remove front and rear panels so joints and connections are accessible to portable scanner.
1. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of each switchgear 11 months after date of Substantial Completion. 2. Instrument: Use an infrared-scanning device designed to measure temperature or to detect significant deviations from normal values. Provide calibration record for device. 3. Record of Infrared Scanning: Prepare a certified report that identifies switchgear checked and that describes infrared-scanning results. Include notation of deficiencies detected, remedial action taken, and observations after remedial action.
3.6 ADJUSTING
A. Set field-adjustable, protective-relay trip characteristics according to results in Division 26 Section "Overcurrent Protective Device Coordination Study".
3.7 CLEANING
A. On completion of installation, inspect interior and exterior of switchgear. Vacuum dirt and debris; do not use compressed air to assist in cleaning. Repair damaged finishes.
3.8 PROTECTION
A. Temporary Heating: Apply temporary heat to switchgear, according to manufacturer's written instructions, throughout periods when switchgear environment is not controlled for temperature and humidity within manufacturer's stipulated service conditions.
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3.9 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain switchgear. Refer to Division 01 Section "Demonstration and Training."
END OF SECTION
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SECTION 262200 - LOW-VOLTAGE TRANSFORMERS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This section covers dry type transformers used for low voltage, single and three phase, power distribution and lighting.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with Section 26000, and elsewhere in the Contract Documents, prior to installation. As a minimum the contractor shall submit the following in- formation: a. Dimensional Drawings b. Weight c. Voltage ratings of both the primary and secondary including taps d. KVA rating e. % impedance f. Insulation class g. Sound level h. Wiring Diagrams i. Installation Instructions
1.3 QUALITY ASSURANCE
A. ANSI C57.12.01, dry-type transformers
B. ANSI C89.2, dry-type transformers
C. NEMA ST-20, dry-type transformers
D. UL-506, specialty transformers
E. NEMA TP-1-2002
F. National Electric Code (NEC)
G. International Building code (IBC)
PART 2 - PRODUCTS
2.1 DISTRIBUTION - LOW VOLTAGE LIGHTING AND POWER
A. Transformers shall be premium high efficiency quiet type, and shall be installed where indicated on the Plans. The primary winding of the transformers shall have two 2-1/2 percent taps above, and below normal.
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B. The transformers shall have a BIL of 10 KV with a temperature class of 185 degrees C for transformers up to 25 KVA, and a temperature class of 220 degrees C for larger transformers.
D. The sound level shall not exceed 44 dBa measured at 5 feet from the transformer after installation. Core and coil assemblies 30 KVA and larger, shall be mounted on rubber vibration isolators, designed to reduce harmonics generated noise.
E. Transformers shall be types manufactured by Square D, Cutler-Hammer, General Electric, Siemens, or equal.
F. Transformers shall conform with Seismic restraint requirements per the IBC and specification 26000.
G. Transformers shall be constructed using copper windings.
H. Transformers shall be ventilating type with NEMA 3R kit if installation is outdoors.
I. Transformer shall be rated for a continuous duty cycle.
2.2 FERRO RESONANT ISOLATION TRANSFORMERS
A. Ferro resonant isolation transformers shall be provided where indicated on the Plans. Regulation shall be + 3% for an input range of + 10%. Common mode noise rejection shall be better than 120 dB with transverse mode noise rejection better than 60 dB. Voltage spike attenuation shall be better than 250:1.
B. Isolation transformers shall be as manufactured by Shape Magnetronics, Control Concepts, Inc., or equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Transformers shall be installed as indicated on the Plans, and in accordance with the manufacturer’s instructions and recommendations.
B. Contractor shall provide painted metal wall brackets, when required.
C. Grounding shall be provided per NEC, and Section 260526.
END OF SECTION 262200
WRCRWA LOW-VOLTAGE TRANSFORMERS PLANT EXPANSION PROJECT 262200-2
SECTION 262416 – PANELBOARDS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This section covers electrical panelboards.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with Section 26000, and the Contract Documents, prior to installation.
B. Panel layout with alphanumeric designation, branch circuit breaker sizes and types, AIC rating, bus sizes, bus material and other characteristics.
1.3 QUALITY ASSURANCE
A. NEMA PB-1, Panelboards
B. NEC
C. UL67, Panelboards
PART 2 - PRODUCTS
2.1 PANELBOARDS
A. Dead-front panelboards, including lighting distribution and control panels, shall be furnished and installed as indicated on the Plans. Buses shall be copper. If shown on the drawings as 4 wire neutral shall be 100% rated. Mounting and type of enclosures shall be as indicated on the Plans. Where not indicated, indoor enclosures shall be NEMA 12 and outdoor enclosures shall be NEMA 4. The minimum interrupting capacity of any device shall be 22 KAIC unless otherwise indicated on the Plans.
B. Protective devices shall be replaceable without disturbing adjacent units, and shall be of the bolt-on type. Snap in protective devices will not be accepted. Wire connectors shall be suitable for wire sizes indicated. Branch circuits shall be numbered as indicated on the Plans, and a complete typed circuit schedule shall be furnished under a transparent cover, and affixed to the inside of the panel access door. Phase busing shall be full height without reduction. Full size neutral and ground bars shall be included, and shall have suitable lugs for each outgoing circuit requiring connection. Spaces for future protective devices provided in lighting panels shall be bused for the maximum device that can be fitted into them.
C. Panelboards shall be finished with a primer, rust resistant phosphate undercoat and two coats of oven baked enamel with finish ANSI grey. They shall be sized to provide a minimum of 4 inches of gutter space on all sides. Doors shall not uncover any live parts, and shall be hinged and have latches that require no tool to operate. Panelboard doors shall be lockable. Lock and two keys shall be furnished.
WRCRWA PANELBOARDS PLANT EXPANSION PROJECT 262416-1
D. Each panelboard shall have, on the outside of the door, a lamicoid nameplate with 3/4 inch letters as specified elsewhere in these Contract Documents.
E. Panelboards shall be as manufactured by Square D, General Electric, Eaton / Cutler Hammer, or equal.
F. Panelboards shall be service entrance rated where required, and as shown on the Plans.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Panelboards shall be installed as indicated on the plans and according to manufacturer's instructions.
B. Provide grounding per NEC, and Section 260526.
C. Contractor shall verify all NEC clearance requirements prior to installation.
END OF SECTION 262416
WRCRWA PANELBOARDS PLANT EXPANSION PROJECT 262416-2
SECTION 262419 - MOTOR-CONTROL CENTERS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. The Contractor shall furnish and install, ready to use, intelligent motor control centers for use as indicated on the Plans and specified herein.
B. Circuit breaker ratings, and modifications, shall be as indicated on the Plans.
C. MCP ratings, and modification, shall be as indicated on the Plans.
1.2 SUBMITTALS
A. The motor control centers shall meet the requirements of the latest edition of Standards for Industrial Control No. ICS published by the National Electrical Manufacturers Asso- ciation. The following minimum information and drawings shall be submitted for review:
1. Plan, front, side views and overall dimension of each motor control center. 2. Weight. 3. Internal wiring diagram of each plug-in unit. 4. Internal wiring diagram of the motor control centers. 5. External connection diagram showing the wiring to the external controls and devices associated with the motor control center. 6. One-line and schematic diagram for each motor control center. 7. Bill of material list and Manufacturer's Product Data. 8. Installation instructions including seismic installation. 9. Manufacturer's certification that the following items are capable of interrupting and/or withstanding the specified short circuit condition: a. Bus bar bracing b. Feeder tap units c. Starter units
B. Product information shall be submitted in accordance with Section 26000, and elsewhere in the Contract Documents.
PART 2 - PRODUCTS
2.1 MOTOR CONTROL CENTERS (MCC)
A. The motor control center fabricator shall be the manufacturer of the major components therein, such as circuit breakers, VFD’s and starters. Engineered motor control centers shall be by the component and housing manufacturer. The manufacturer shall comply with equipment specifications contained elsewhere in these Contract Documents.
B. The motor control center shall be intelligent, in that all VFD’s, starters/electronic over- loads and power monitors shall be equipped with an Ethernet port that provides an Ether-
WRCRWA MOTOR-CONTROL CENTERS PLANT EXPANSION PROJECT 262419-1
net/IP connection to the plant SCADA network. This connection will allow for monitor- ing and controlling the device as depicted by the Contract Documents. The intelligent MCC with Ethernet/IP shall be factory tested and validated with all devices pre- configured with IP addressing that has been assigned by the Owner’s System Integrator. No device level Ethernet rings shall be allowed but instead all devices shall be home run to an Ethernet, managed, industrial switch or switches. The managed industrial switch or switches shall be built up as part of the MCC assembly and shall be powered by a 24VDC power supply that is also part of the MCC assembly.
C. Each component, as well as the complete assembly, shall be constructed and tested in ac- cordance with latest NEMA Standards for Industrial Control. The type of construction of the control centers shall be NEMA Class II, Type B. Lifting eyes shall be provided on each section to facilitate handling.
D. Unit doors shall be mounted on the stationary structure and hinged on the side away from the vertical wireway. They shall be held closed with slotted thumbscrews.
E. Unit doors shall have positive action linkage with disconnect operating mechanism. Mechanism shall be designed so that it can be locked in the OFF position with up to 3 padlocks. When the handle is not padlocked, it shall be possible to open the door by re- leasing the door interlock with a small screwdriver. The control units shall be of the plug-in type. When doors are closed, the operating mechanism shall clearly indicate the ON or OFF position of the disconnect, and the door interlock mechanism shall engage. The disconnect operating mechanism shall be designed against inadvertent operation when the door is open. Each plug-in unit door shall be provided with a nameplate, speci- fied elsewhere herein, that indicates the circuit number and circuit name. The nameplate shall be attached to the door with brass or stainless steel screws. Each motor starter door shall be provided with an externally operated manual reset pushbutton for the overload relay.
F. It shall be possible to install up to 6 NEMA size one units in one vertical section. Units shall be completely enclosed with sheet steel. A small wireway shall be provided inside the unit, so all wiring can be laid in place without removing barriers or plates. Each ver- tical section that holds the units shall be rigidly formed of minimum 12 gauge, cold-rolled sheet steel. The vertical front-of-board-construction shall be supplied with minimum 20-inch depth.
G. Continuous horizontal wiring troughs shall be provided at both top and bottom of each section. These troughs shall line up to form a continuous wireway for the full length of the MCC. A large continuous, full-height vertical wiring trough shall be provided in the right side of each section.
H. All starter wiring, control, and power shall be terminated in terminal strips in this trough for size 2 and smaller starters. Size 3 and larger starters shall have control leads terminat- ing on the terminal strips in the trough. Terminal strips shall be split-type to facilitate wiring connections without disconnecting factory or field conductors. Terminal strips shall be rated to accept conductor sizes as indicated on the Plans.
I. All bus bars shall be tin plated copper, and shall be of the ampacity indicated on the Plans. Unit bus bar stabs shall insure high contact pressure. The vertical bus bars shall be effectively isolated from accidental contact by plastic insulating medium.
WRCRWA MOTOR-CONTROL CENTERS PLANT EXPANSION PROJECT 262419-2
J. Bus bar supports shall be of high impact strength non-carbonizing insulating material mounted on padded steel brackets and shall provide adequate dielectric strength and creepage distance. The bus structure shall be capable of withstanding short circuit current in accordance with NEMA standards, and as indicated on the Plans.
K. Each section shall be equipped with horizontal ground bus that shall be continuous across the MCC.
L. The MCCs shall be supplied as indicated on the Plans, and as specified herein and in ac- cordance with NEMA Standard Pub. IS 1.1, latest edition. The MCCs shall be enclosed in NEMA Type 1 gasketed industrial use enclosures, unless otherwise shown. NEMA 3R enclosures shall provide sufficient depth for air conditioning units to be mounted on the end of the structures. If the MCCs contain VFDs or Solid State Starters that require cool- ing, their respective sections shall be louvered top and bottom, and fans shall remove heat from within the sections.
M. All metal surfaces and structural parts shall be given a phosphatizing, or equal, treatment prior to painting. The control centers shall then be given a gun-metal gray undercoat which is equal to zinc chromate. The exterior of the enclosure shall be finished in stand- ard ANSI Grey.
N. Spaces for future combination starters shall have all the hardware necessary so that a fu- ture plug-in control unit can be installed without having to modify the vertical sections. The number of spaces for future control units shall be as indicated on the Plans.
O. Devices, such as, but not limited to, starters, circuit breaker, relays, timers, conductors, shall conform to other sections of these Contract Documents.
P. Provide customer metering instruments, as indicated on the Plans. Unless otherwise indi- cated on the Plans, metering units shall be electronic, capable of displaying volts line-to- line and line-to-neutral, and amps per phase.
Q. Each section shall be equipped with horizontal neutral bus that shall be continuous across the MCC if the MCC is designated as 277/480 volt 4 wire.
R. MCCs shall be as manufactured by Allen-Bradley or approved equal.
PART 3 - EXECUTION
3.1 GENERAL
A. The MCCs shall be erected in accordance with the recommendations of the manufacturer and with the details specified herein.
B. Cables larger than No. 6 AWG, which hang from their vertical connections, shall be sup- ported within 2 feet of the connection.
C. The motor overload relays shall be provided and sized based on the actual full load am- peres of the motor connected to the starter.
WRCRWA MOTOR-CONTROL CENTERS PLANT EXPANSION PROJECT 262419-3
D. The motor circuit protectors shall be adjusted to the lowest settings that do not cause false tripping.
E. Motor control centers shall be installed for seismic requirements as required in division 26000.
F. Motor Control Centers shall be provided in accordance with all applicable sections of di- vision 26000.
3.2 FIELD TESTS
A. MCCs shall be tested in accordance with Section 26000.
END OF SECTION 262419
WRCRWA MOTOR-CONTROL CENTERS PLANT EXPANSION PROJECT 262419-4
SECTION 262726 - WIRING DEVICES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Receptacles, receptacles with integral GFCI, and associated device plates. 2. Weather-resistant receptacles. 3. Snap switches and wall-box dimmers. 4. Solid-state fan speed controls. 5. Wall-switch and exterior occupancy sensors. 6. Communications outlets.
1.2 ADMINISTRATIVE REQUIREMENTS
A. Coordination:
1. Receptacles for Owner-Furnished Equipment: Match plug configurations.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product.
B. Shop Drawings: List of legends and description of materials and process used for premarking wall plates.
1.4 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.5 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers' Names: Shortened versions (shown in parentheses) of the following manufacturers' names are used in other Part 2 articles:
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-1
1. Appleton Electric Co. (Appleton). 2. Cooper Wiring Devices; Division of Cooper Industries, Inc. (Cooper). 3. Cooper Crouse-Hinds (Crouse-Hinds). 4. Hubbell Incorporated; Wiring Device-Kellems (Hubbell). 5. Killark. 6. Leviton Mfg. Company Inc. (Leviton). 7. Pass & Seymour/Legrand (Pass & Seymour).
B. Source Limitations: Obtain each type of wiring device and associated wall plate from single source from single manufacturer.
2.2 GENERAL WIRING-DEVICE REQUIREMENTS
A. Wiring Devices, Components, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
B. Comply with NFPA 70.
C. Devices that are manufactured for use with modular plug-in connectors may be substituted under the following conditions:
1. Connectors shall comply with UL 2459 and shall be made with stranding building wire. 2. Devices shall comply with the requirements in this Section.
2.3 STRAIGHT-BLADE RECEPTACLES FOR UNCLASSIFIED AREAS
A. General Description
1. Convenience Receptacles, 125 V, 20 A 2. Comply with NEMA WD 1, NEMA WD 6 Configuration 5-20R, UL 498, and FS W-C- 596. 3. Straight blade, grounding type, specification grade. 4. Color: White unless Owner or Engineer specifies otherwise. Ivory for weather resistant receptacles. Yellow for corrosion resistant receptacles. 5. Provide weather resistant receptacles for damp and wet areas (including all process areas or areas that may be sprayed down). 6. Provide corrosion resistant receptacles for corrosive areas.
B. Products: Subject to compliance with requirements, provide the following:
1. Dry, non-corrosive locations: a. Hubbell; HBL5361 (single), HBL5362 (duplex). b. Or Approved Equal. 2. Damp or wet locations: a. Hubbell; HBL5361WR (single), HBL5362WR (duplex). b. Or Approved Equal. 3. Corrosive locations: a. Hubbell; HBL53CM61 (single), HBL53CM62 (duplex). b. Or Approved Equal.
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-2
2.4 RECEPTACLES FOR CLASSIFIED AREAS
A. General Description
1. Explosion proof, UL Listed for Class 1 Division I and II Groups C & D 2. Rated for 125 V, 20 A 3. Corrosion Resistant with malleable iron mounting box. 4. “Dead-front” construction requiring plug to be inserted and rotated to activate receptacle. 5. Factory Sealed so that seal-offs are not required at the receptacle. 6. If receptacles are to have GFCI, this shall be achieved at the branch circuit overcurrent protective device (typically a lighting panel) in an unclassified space.
B. Products: Subject to compliance with requirements, provide the following:
1. Appleton U-Line Contender series. 2. Crouse-Hinds Arktite Series. 3. Or Approved Equal.
2.5 GFCI RECEPTACLES FOR UNCLASSIFIED AREAS
A. General Description:
1. Duplex GFCI Convenience Receptacles, 125 V, 20 A. 2. Straight blade, feed-through type. 3. Comply with NEMA WD 1, NEMA WD 6, UL 498, UL 943 Class A, and FS W-C-596. 4. Include indicator light that shows when the GFCI has malfunctioned and no longer provides proper GFCI protection. 5. Receptacles shall be tamper and weather resistant.
B. Products: Subject to compliance with requirements, provide the following:
1. Hubbell; GFR5362TR. 2. Or Approved Equal.
2.6 TOGGLE SWITCHES FOR UNCLASSIFIED AREAS
A. General Description:
1. Toggle Switches, 120/277 V, 20A 2. Comply with NEMA WD 1, UL 20, and FS W-S-896. 3. Toggle type, quiet action, specification grade with grounding terminal. 4. Back and side wired, silver alloy contacts. 5. Color: White unless Owner or Engineer specifies otherwise. 6. For corrosive or wet areas, provide a NEMA 4X watertight, dust-tight and corrosion resistant cover.
B. Switches:
1. Products: Subject to compliance with requirements, provide the following:
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-3
a. Switches, 120/277 V, 20 A: 1) Hubbell; HBL1221 (Single Pole); HBL1222 (Double Pole); HBL1223 (Three Way); HBL1224 (Four Way). 2) Or Approved Equal.
b. Illuminated Switches (illuminated when switch is “off”: 1) Hubbell; HBL1221IL (Single Pole); HBL1223IL (Three Way). 2) Or Approved Equal.
c. Key-Operated Switches (with factory supplied key): 1) Hubbell; HBL1221L 2) Or Approved Equal.
2.7 TOGGLE SWITCHES FOR CLASSIFIED AREAS
A. General Description:
1. Explosion proof, UL Listed for Class 1 Division I and II Groups C & D 2. Rated for 125 V, 20 A 3. Corrosion Resistant with malleable iron body and cover. 4. Factory Sealed so that seal-offs are not required at the receptacle. 5. Front operated handle with stainless steel shaft. 6. With grounding screw.
B. Products: Subject to compliance with requirements, provide the following:
1. Appleton Contender series. 2. Crouse-Hinds EDS Series. 3. Or Approved Equal.
2.8 WALL-BOX DIMMERS
A. Dimmer Switches: Modular, full-wave, solid-state units with integral, quiet on-off switches, with audible frequency and EMI/RFI suppression filters.
B. Control: Continuously adjustable slider; with single-pole or three-way switching. Comply with UL 1472.
C. Incandescent Lamp Dimmers: 120 V; control shall follow square-law dimming curve. On-off switch positions shall bypass dimmer module.
1. 600 W; dimmers shall require no derating when ganged with other devices. Illuminated when "off." Load shall not exceed 80% of dimmer rating.
D. Fluorescent Lamp Dimmer Switches: Modular; compatible with dimmer ballasts; trim potentiometer to adjust low-end dimming; dimmer-ballast combination capable of consistent dimming with low end not greater than 20 percent of full brightness.
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-4
2.9 WALL PLATES
A. Single and combination types shall match corresponding wiring devices.
1. Plate-Securing Screws: Metal with head color to match plate finish except for stainless steel wall plates whose screws shall be stainless steel. 2. Material for Finished Office Spaces: Smooth, high-impact thermoplastic, color to match device color. 3. Material for Finished Spaces: Type 304 stainless steel. 4. Material for Unfinished Spaces: Type 304 stainless steel. 5. Material for Damp and corrosive Locations: Cast aluminum with spring-loaded lift cover, and listed and labeled for use in wet and damp locations.
B. Wet-Location, Weatherproof Cover Plates: NEMA 250, complying with Type 3R, weather- resistant, die-cast aluminum with lockable cover.
C. Weatherproof, While-In-Use Covers: Where receptacles are required to be weatherproof and physically protected while in use or idle or where shown on the drawings, weatherproof, while- in-use covers shall be used in lieu of other covers. The cover shall have the following features:
1. General Description:
a. Suitable style receptacle plate with a hinged cover. b. Cord port(s) capable of allowing an appropriate size electrical cord(s) to pass through when the cover is closed. c. Latching mechanism to allow the enclosure to maintain weatherproof integrity. The latch shall be a tamper resistant (locking/security) style in areas where security is needed. d. Sufficiently deep to allow full closure with plug(s) in use. e. UL listed per UL Standard 514C and conform to NEC Article 410.57 paragraphs a and b, Article 110.3 and Article 110.11. f. Body materials shall be of a flame resistant, self-extinguishing, UV inhibiting, impact resistant, polycarbonate resin. Materials must meet UL Standard 94 HF1. g. Mounting screws shall be stainless steel and of sufficient length to properly secure the device and ensure seal to mounting surface.
2. Products: Subject to compliance with requirements, provide the following:
a. Cooper; TP74 Series. b. Or Approved Equal.
2.10 FINISHES
A. Device Color:
1. Wiring Devices Connected to Normal Power System: White unless Owner or Engineer specifies otherwise or otherwise indicated or required by NFPA 70 or device listing. 2. Wiring Devices Connected to UPS or Emergency Power System: Red. 3. TVSS Devices: Blue.
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-5
B. Wall Plate Color: For plastic covers, match device color.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Comply with NECA 1, including mounting heights listed in that standard, unless otherwise indicated.
B. Coordination with Other Trades:
1. Protect installed devices and their boxes. Do not place wall finish materials over device boxes and do not cut holes for boxes with routers that are guided by riding against outside of boxes. 2. Keep outlet boxes free of plaster, drywall joint compound, mortar, cement, concrete, dust, paint, and other material that may contaminate the raceway system, conductors, and cables. 3. Install device boxes in brick or block walls so that the cover plate does not cross a joint unless the joint is troweled flush with the face of the wall. 4. Install wiring devices after all wall preparation, including painting, is complete.
C. Conductors:
1. Do not strip insulation from conductors until right before they are spliced or terminated on devices. 2. Strip insulation evenly around the conductor using tools designed for the purpose. Avoid scoring or nicking of solid wire or cutting strands from stranded wire. 3. The length of free conductors at outlets for devices shall meet provisions of NFPA 70, Article 300, without pigtails. 4. Existing Conductors:
a. Cut back and pigtail, or replace all damaged conductors. b. Straighten conductors that remain and remove corrosion and foreign matter. c. Pigtailing existing conductors is permitted, provided the outlet box is large enough.
D. Device Installation:
1. Wherever possible, wiring devices shall be recess mounted with switches, receptacles and wall plates flush with the wall or surface. 2. Replace devices that have been in temporary use during construction and that were installed before building finishing operations were complete. 3. Keep each wiring device in its package or otherwise protected until it is time to connect conductors. 4. Do not remove surface protection, such as plastic film and smudge covers, until the last possible moment. 5. Connect devices to branch circuits using pigtails that are not less than 6 inches in length. 6. When there is a choice, use side wiring with binding-head screw terminals. Wrap solid conductor tightly clockwise, two-thirds to three-fourths of the way around terminal screw.
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-6
7. Use a torque screwdriver when a torque is recommended or required by manufacturer. 8. When conductors larger than No. 12 AWG are installed on 15- or 20-A circuits, splice No. 12 AWG pigtails for device connections. 9. Tighten unused terminal screws on the device. 10. When mounting into metal boxes, remove the fiber or plastic washers used to hold device-mounting screws in yokes, allowing metal-to-metal contact.
E. Receptacle Orientation:
1. Install ground pin of vertically mounted receptacles down, and on horizontally mounted receptacles to the left. 2. Where more than one receptacle is installed in a room, they shall be symmetrically arranged. 3. Set switches and receptacles plumb and vertical to the floor. 4. Set recess-mounted switches and receptacles flush with face of walls.
F. Device Plates: Do not use oversized or extra-deep plates. Repair wall finishes and remount outlet boxes when standard device plates do not fit flush or do not cover rough wall opening. Provide blank plates for empty boxes.
G. Dimmers:
1. Install dimmers within terms of their listing. 2. Verify that dimmers used for fan speed control are listed for that application. 3. Install unshared neutral conductors on line and load side of dimmers according to manufacturers' device listing conditions in the written instructions. 4. Do not connect dimmers to loads in excess of 80% of the rating of the dimmer.
H. Arrangement of Devices: Unless otherwise indicated, mount flush, with long dimension vertical and with grounding terminal of receptacles on top. Group adjacent switches under single, multigang wall plates.
I. Adjust locations of service poles to suit arrangement of partitions and furnishings.
3.2 GFCI RECEPTACLES
A. Install non-feed-through-type GFCI receptacles where protection of downstream receptacles is not required.
3.3 FIELD QUALITY CONTROL
A. Perform the following tests and inspections:
1. Test Instruments: Use instruments that comply with UL 1436. 2. Test Instrument for Convenience Receptacles: Digital wiring analyzer with digital readout or illuminated digital-display indicators of measurement.
B. Tests for Convenience Receptacles:
1. Line Voltage: Acceptable range is 105 to 132 V.
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-7
2. Percent Voltage Drop under 15-A Load: A value of 6 percent or higher is unacceptable. 3. Ground Impedance: Values of up to 2 ohms are acceptable. 4. GFCI Trip: Test for tripping values specified in UL 1436 and UL 943. 5. Using the test plug, verify that the device and its outlet box are securely mounted. 6. Tests shall be diagnostic, indicating damaged conductors, high resistance at the circuit breaker, poor connections, inadequate fault current path, defective devices, or similar problems. Correct circuit conditions, remove malfunctioning units and replace with new ones, and retest as specified above.
C. Wiring device will be considered defective if it does not pass tests and inspections.
D. Prepare test and inspection reports.
END OF SECTION 262726
WRCRWA WIRING DEVICES PLANT EXPANSION PROJECT 262726-8
SECTION 262813 – FUSES
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. Extent of fuse work required by this section is indicated by drawings, and by requirements of this section.
B. Types of fuses specified in this section include the following: 1. Class L time-delay. 2. Class L fast-acting. 3. Class RK1 time-delay. 4. Class RK1 and Class J current limiting. 5. Class RK5 time-delay. 6. Class K5 time-delay, non-current limiting. 7. Class T current-limiting.
1.2 QUALITY ASSURANCE
A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of fuses of types and sizes required, whose products have been in satisfactory use in similar service for not less than 5 years.
1.3 CODES AND STANDARDS
A. UL Compliance and Labeling: Comply with applicable provisions of UL 198D, "High- Interrupting-Capacity Class K Fuses". Provide over-current protective devices which are UL-listed and labeled.
B. NEC Compliance: Comply with NEC as applicable to construction and installation of fusible devices.
C. ANSI Compliance: Comply with applicable requirements of ANSI C97.1 "Low-Voltage Cartridge Fuses 600 Volts or Less".
1.4 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data on fuses, including specifications, electrical characteristics, installation instructions, furnished specialties and accessories in accordance with Section 26000, and the Contract Documents. In addition, include voltages and current ratings, interrupting ratings, current limitation ratings, time- current trip characteristic curves, and mounting requirements.
1.5 MANUFACTURERS
A. Subject to compliance with requirements, manufacturers offering fusible devices which may be incorporated in the work include, but are not limited to, the following: Bussmann, Gould-Shawmut, Reliance, or equal.
WRCRWA FUSES PLANT EXPANSION PROJECT 262813-1
PART 2 - PRODUCTS
2.1 GENERAL
A. Except as otherwise indicated, provide fuses of types, sizes, ratings, and average time- current and peak let-through current characteristics indicated, which comply with manufacturer's standard design, materials, and constructed in accordance with published product information, and with industry standards and configurations.
2.2 Class L Time-Delay Fuses
A. Provide UL Class L time-delay fuses rated 600-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating for protecting transformers, motors, and circuit- breakers.
2.3 Class L Fast-Acting Fuses
A. Provide UL Class L fast-acting fuses rated 600-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating for protecting service entrances and main feeder circuit-breakers.
2.4 Class RK1 Time-Delay Fuses
A. Provide UL Class RK1 time-delay fuses rated 600-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating for protecting motors and circuit-breakers.
2.5 Class RK1 Current-Limiting Fuses
A. Provide UL Class RK1 current-limiting fuses rated 250-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating for protecting circuit-breakers.
2.6 Class J Current-Limiting Fuses
A. Provide UL Class J current-limiting fuses rated 600-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating.
2.7 Class RK5 Time-Delay Fuses
A. Provide UL Class RK5 time-delay fuses rated 600-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating for protecting motors.
2.8 Class K5 One-Time Fuses
A. Provide UL Class K5 one-time fuses rated 250-volts, 60 Hz, with 100,000 RMS symmetrical interrupting current rating for protecting non-inductive loads.
2.9 Class T Fuses
WRCRWA FUSES PLANT EXPANSION PROJECT 262813-2
A. Provide UL Class T fuses rated 600-volts, 60 Hz, with 200,000 RMS symmetrical interrupting current rating for protection of physically small devices.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Fuse types and sizes shall be as indicated on the Plans. Fuses shall be installed in accordance with the National Electric Code (NEC) requirements and the manufacturer’s written instructions.
B. Install fuses in proper fuse holders.
C. Where fuses are installed in the motor starters, fuses shall be sized to match the actual motor full load current.
D. Where fuses are installed in disconnect switches at HVAC units, the fuse sizes shall be sized to meet the HVAC manufacturer’s requirements.
E. Fuses for control transformers shall be sized in accordance with the National Electrical Code.
F. Fuses shall be installed with the labels clearly visible.
3.2 FIELD QUALITY CONTROL
A. Prior to energizing fusible devices, test devices for circuit continuity and for short-circuits.
3.3 SPARE PARTS
A. Furnish 10% of installed fuses or 3 sets whichever is greater for each type and ampere rating. The set shall equal the number of poles in the appropriate equipment.
B. Furnish a spare fuse cabinet equal to Bussmann for storing spare fuses. Mount on wall in Electrical room as directed by the Engineer.
END OF SECTION 262813
WRCRWA FUSES PLANT EXPANSION PROJECT 262813-3
SECTION 262816 - ENCLOSED SWITCHES AND CIRCUIT BREAKERS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. The Contractor shall furnish and install, low voltage circuit breakers, as indicated on the Drawings and specified herein.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with Section 26000, and elsewhere in the Con- tract Documents, prior to installation.
1.3 QUALITY ASSURANCE
A. The breaker manufacturer’s facilities shall be ISO 9001 certified.
PART 2 - PRODUCTS
2.1 GENERAL
A. Circuit breakers shall be as manufactured by Square D, Cutler-Hammer, Allen-Bradley, General Electric, or equal.
B. Circuit breaker frame, trip, short circuit, and interruption ratings shall be as indicated on the Drawings, except that they shall be coordinated with the ratings of the equipment ac- tually furnished, and shall be modified where necessary to suit the equipment. Circuit breakers to be used in motor control centers shall be as indicated on the Drawings. Where no indication of type is given on the Drawings circuit breakers protecting motors shall be motor circuit protectors, and other circuit breakers shall be molded case type.
C. Circuit breaker for mounting in motor control centers, or for separate mounting shall be of the air-break type, quick-make and quick-break, 600 volt, with number of poles as in- dicated on the Drawings.
D. Each pole of the circuit breaker shall provide inverse time delay, and instantaneous cir- cuit protection.
E. The breakers shall be operated by a handle, and shall have a switching mechanism that is mechanically trip free from the handle, so that the contacts cannot be held closed against short circuits, and abnormal currents. Tripping due to overload, or short circuit shall be clearly indicated by the handle automatically assuming a position between the manual ON and OFF positions. Latch surfaces shall be ground and polished. Poles shall be con- structed so that they open, close, and trip simultaneously.
F. Breakers must be completely enclosed in a molded case. Non-interchangeable trip breakers shall have their covers sealed; interchangeable trip breakers shall have the trip unit sealed to prevent tampering. Ampere ratings shall be clearly visible. Contacts shall
WRCRWA ENCLOSED SWITCHES AND CIRCUIT BREAKERS PLANT EXPANSION PROJECT 262816-1
be non-welding silver alloy. Arc extinction must be accomplished by means of arc chutes. The minimum interrupting ratings of the circuit breakers shall be at least equal to the available short circuit current at the line terminals.
G. Circuit breakers shall conform to the applicable requirements of NEMA Standards Publi- cation No. AB1.
H. Molded case circuit breakers shall be ambient temperature compensating that provides inverse time delay overload and instantaneous short circuit protection by means of a thermal magnetic element. Compensation shall be accomplished by a secondary bi-metal that will allow the breaker to carry rated current between 25 degrees C and 50 degrees C with tripping characteristics that are approximately the same throughout this temperature range.
I. On breakers with interchangeable, thermal, adjustable magnetic trip, the accessibility and position of the adjustment knob shall not be changed from those on the standard breaker.
J. Unless mounted in a switchboard, or panelboard, circuit breakers shall be housed in a NEMA rated enclosure as described elsewhere in these specifications.
K. Provide circuit breakers with shunt trip mechanisms where shown on the Drawings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Circuit breakers shall be installed as indicated on the Drawings and per manufacturer's instructions.
END OF SECTION 262816
WRCRWA ENCLOSED SWITCHES AND CIRCUIT BREAKERS PLANT EXPANSION PROJECT 262816-2
SECTION 262819 – DISCONNECT SWITCHES
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This section covers electrical disconnecting switches.
1.2 RELATED SECTIONS
A. For Enclosed Switches and Circuit Breakers see Section 262816.
1.3 SUBMITTALS
A. Products shall be submitted in accordance with Section 26000, and elsewhere in the Con- tract Documents, prior to installation.
PART 2 - PRODUCTS
2.1 DISCONNECT SWITCHES
A. Disconnect switches shall be heavy-duty safety switches with a quick-make, quick-break operating mechanism, with full cover interlock, and indicator handle.
B. Where specified as fused disconnect switches, disconnects shall be furnished with fuses of the size indicated on the Plans. One set of spare fuses shall be furnished for each fused disconnect switch.
C. Disconnect switches shall be NEMA type HD heavy duty construction, UL 98 listed.
D. Enclosures shall be rated NEMA 12 for indoor use, and NEMA 3R for outdoor use, un- less otherwise indicated on the Plans.
E. Disconnect switch handle shall be padlockable.
F. Disconnect switches in damp, wet or corrosive areas as indicated on the Plans, shall be NEMA 4X, 304 stainless steel. All disconnect switches in wastewater applications shall be NEMA 4X unless otherwise noted on the plans.
G. Disconnect switches located in hazardous locations shall be rated NEMA 7.
G. Disconnect switches shall be as manufactured by Square D, Cutler-Hammer, Allen- Bradley, or equal.
PART 3 - EXECUTION
3.1 INSTALLATION
WRCRWA DISCONNECT SWITCHES PLANT EXPANSION PROJECT 262819-1
A. Disconnect switches shall be installed as indicated on the Plans.
B. Provide grounding per NEC, and Section 260526.
END OF SECTION 262819
WRCRWA DISCONNECT SWITCHES PLANT EXPANSION PROJECT 262819-2
SECTION 262913 – ENCLOSED CONTROLLERS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. A motor controller is any device or group of devices normally used to start and stop a motor by making and breaking the motor circuit current. The motor controller and devic- es that make up the motor controller shall be governed by items indicated on the Plans, or elsewhere within these specifications.
B. Types of motor controllers specified in this section include the following:
1. Combination. 2. Fractional HP manual. 3. Solid-state reduced voltage. 4. Autotransformer reduced voltage. 5. Variable Frequency Drive (See also VFD Specification)
C. This section applies to motor controllers rated 480 V and below.
1.2 CODE AND STANDARDS
A. Electrical Code Compliance: Comply with applicable local electrical code requirements of the authority having jurisdiction and NEC Articles 220, 250, and 430, as applicable to installation, and construction of motor controllers.
B. NFPA Compliance: Comply with applicable requirements of NFPA 70E, "Standard for Electrical Safety requirements for Employee Workplaces."
C. UL Compliance: Comply with applicable requirements of UL 486A and B, and UL 508, pertaining to installation of motor controllers. Provide controllers and components which are UL-listed and labeled.
D. IEEE Compliance: Comply with recommended practices contained in IEEE Standard 241, "Recommended Practice for Electrical Power Systems in Commercial Buildings," pertaining to motor controllers.
E. NEMA Compliance: Comply with applicable requirements of NEMA Standard ICS 2, "Industrial Control Devices, Controllers and Assemblies," and Pub No. 250, "Enclosures for Electrical Equipment (1000 Volts Maximum)," pertaining to motor controllers and enclosures.
1.3 MAINTENANCE DATA
A. Submit maintenance data and parts list for each motor controller and component; includ- ing troubleshooting maintenance guide. Also, provide product data and shop drawings in a maintenance manual, in accordance with requirements of the Contract Documents.
WRCRWA ENCLOSED CONTROLLERS PLANT EXPANSION PROJECT 262913-1
1.4 SUBMITTALS
A. Product Data: Submit manufacturer's data and installation instructions on motor control- lers.
B. Shop Drawings: Submit shop drawings of motor controllers showing accurately scaled equipment locations and spatial relationships to associated motors and equipment.
C. Wiring Diagrams: Submit power and control wiring diagrams for motor controllers showing connections to electrical power panels, feeders, and equipment.
D. Submittal documents shall be provided in accordance with Section 26000, and other re- quirements of the Contract Documents.
PART 2 - PRODUCTS
2.1 GENERAL
A. Except as otherwise indicated, provide motor controllers and ancillary components that comply with manufacturer's standard materials, design and construction in accordance with published product information, and as required for a complete installation.
2.2 COMBINATION CONTROLLERS
A. Provide full-voltage alternating-current combination controllers, consisting of controller and circuit breaker disconnect switch mounted in a common enclosure, of types, sizes, rating, and NEMA sizes indicated on the Plans. Equip controllers with overload relays, control relays, and auxiliary contacts as required on the plans. Provide lockable operat- ing handle for disconnect switch mechanisms, mechanically interlocked with enclosure door. Provide NEMA rated enclosure type as shown on the Plans.
B. Circuit breaker disconnect shall be molded case, motor circuit protector type (MCP), sized per NEC.
C. Provide control power transformer sized properly to accommodate device loads plus 25% spare capacity. The control power transformer shall have two (2) primary, and one (1) secondary fuse sized according to NEC.
D. Multi-speed and reversing starters shall have mechanical and electrical interlock.
E. Furnish controller with control and indicating devices as indicated on the plans. Auxiliary contacts, and field connections shall be connected to terminal strips for field connection.
F. Controllers shall be as manufactured Allen-Bradley or approved equal.
2.3 OVERLOAD PROTECTION
A. Overload Protection shall be provided with the motor starters. The unit shall detect over- current, phase current imbalance, phase loss.
WRCRWA ENCLOSED CONTROLLERS PLANT EXPANSION PROJECT 262913-2
B. The overload relay shall be Class 10, 600 Volt rated, and shall have a trip indicator. The unit shall have a manual reset feature, and a normally closed contact for control.
C. Each module shall provide individual trip indication and reset for each trip condition, vis- ible without opening the motor control center compartment door. Provide a normally open auxiliary contact for remote trip indication.
E. When part of an intelligent MCC or as shown on the plans, provide motor starters with intelligent electronic overload that is controlled and monitored through an Ethernet port utilizing the Ethernet/IP protocol.
F. Overloads shall be as manufactured by Allen-Bradley or approved equal.
2.4 MAGNETIC MOTOR STARTERS
A. Starters, Size 2 and larger, shall have arc quenchers on all load breaking contacts. All starters shall be NEMA rated for the horsepower ratings specified. The Contractor shall verify the motor ratings, and coordinate the starter and overload trip ratings with the ac- tual horsepower ratings of the motors installed. Extended overload reset buttons shall be mounted so as to be accessible for operation without opening the door of the enclosure.
B. Magnetic contactors shall be factory adjusted and shall be chatter free.
C. Starters shall be furnished complete with a 120-volt control power transformer. Control circuit fuses shall be furnished both on the primary and secondary of the control circuit transformer. Control power shall be disconnected with the motor circuit protector.
D. Starters shall be designed to operate in ambient temperatures up to 40¼ C.
E. The minimum size starter shall be NEMA Size 1.
F. Magnetic Motor Starters shall be manufactured by Allen-Bradley or approved equal.
2.5 MANUAL STARTERS
A. Manual starters shall be rated for the motor load, and shall be equipped with built-in overloads.
B. Manual starters shall be provided with enclosures as indicated on the Plans, lockable handles that clearly indicate ON, OFF, and TRIPPED positions, pilot light, and positive, quick-make, quick-break mechanisms.
C. Manual Starters shall be manufactured by Allen-Bradley or approved equal.
2.6 MOTOR PHASE FAILURE RELAY
A. The relay shall detect voltage values below an adjustable value, loss of phase, and phase reversal. The unit shall automatically de-energize the control circuits of the motors to be protected, when one or all three phase voltages drop below the set point. The unit shall have a nominal trip delay time of two seconds and a reset time of two seconds. The relay shall automatically reset upon restoration of the line voltage. Relays shall be MotorSav-
WRCRWA ENCLOSED CONTROLLERS PLANT EXPANSION PROJECT 262913-3
er, Time Mark Corporation, or equal. Relays shall be installed if indicated on the draw- ings.
2.7 MOTOR PROTECTION RELAY
A. The motor protection relay, where shown on drawings, shall be capable of the following as a minimum:
1. Phase loss 2. Low voltage (adjustable) 3. Phase reversal 4. Phase unbalance
B. The motor protection relay shall be equipped with the following as a minimum:
1. Adjustable trip delay (2 to 20 seconds) 2. Automatic reset 3. Transient protection (2500 volts for 10 ms)
C. Motor protection relays shall be set during the project startup according to the individual motor characteristics and application parameters. The motor protection relays for the motors with variable frequency drives shall be set as to prevent low voltage tripping.
D. The motor protection relays shall be MotorSaver Model 777, Time Mark Model 264, or equal.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Install motor controllers in accordance with equipment manufacturer's written instruc- tions, and with recognized industry practices. Comply with applicable requirements of NEC, UL, and NEMA standards, to insure that products fulfill requirements.
B. Tighten connectors and terminals, including screws and bolts, in accordance with equip- ment manufacturer's published torque values for equipment connectors. Where manufac- turer's torque requirements are not indicated, tighten connectors and terminals to comply with tightening torques specified in UL Standards 486A and B, and the National Electri- cal Code.
C. Install fuses, of sizes indicated, in each fusible disconnect switch, if any. Install overload heaters sized to approximately 115% of motor full load current as shown on each, indi- vidual motor nameplate.
D. Prior to energizing motor controller equipment, check with ground resistance tester, phase-to phase and phase-to-ground insulation resistance levels to ensure requirements are fulfilled.
E. Prior to energizing, check circuitry for electrical continuity, and for short-circuits.
WRCRWA ENCLOSED CONTROLLERS PLANT EXPANSION PROJECT 262913-4
F. Check rotation of each motor for proper direction.
G. Upon completion of installation of motor controller equipment and electrical circuitry, energize controller circuitry and demonstrate functioning of equipment in accordance with requirements. Where possible, correct malfunctioning units at site, then retest to demonstrate compliance; otherwise, remove and replace with new units, and retest to demonstrate compliance.
END OF SECTION 262913
WRCRWA ENCLOSED CONTROLLERS PLANT EXPANSION PROJECT 262913-5
SECTION 262923 - VARIABLE-FREQUENCY MOTOR CONTROLLERS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes separately enclosed, pre-assembled, combination VFDs, rated 600 V and less, for speed control of three-phase, squirrel-cage induction motors.
B. See Section 262419 "Motor-Control Centers" for additional requirements for VFDs installed in motor-control centers. In order to maintain like equipment, VFD’s that are being supplied as part of motor-control centers shall be the same make and series of VFD’s that are being supplied outside of motor-control centers.
1.2 DEFINITIONS
A. CE: Conformite Europeene (European Compliance). B. CPT: Control power transformer. C. EMI: Electromagnetic interference. D. IGBT: Insulated-gate bipolar transistor. E. LAN: Local area network. F. LED: Light-emitting diode. G. MCP: Motor-circuit protector. H. NC: Normally closed. I. NO: Normally open. J. OCPD: Overcurrent protective device. K. PCC: Point of Common Coupling L. PID: Control action, proportional plus integral plus derivative. M. PWM: Pulse-width modulated. N. P&ID: Process & Instrumentation Diagram O. RFI: Radio-frequency interference. P. SCADA: Supervisory control and data acquisition. Q. TDD: Total Demand Distortion R. THD: Total Harmonic Distortion S. VFD: Variable-frequency drive.
1.3 PERFORMANCE REQUIREMENTS
A. Seismic Performance: VFDs shall withstand the effects of earthquake motions determined according to ASCE/SEI 7.
1. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event."
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-1
1.4 ACTION SUBMITTALS
A. Product Data: For each type and rating of VFD indicated.
B. System Harmonics Analysis: For each VFD and for the distribution system as a whole.
C. Shop Drawings: For each VFD indicated. Include dimensioned plans, elevations, and sections; and conduit entry locations and sizes, mounting arrangements, and details, including required clearances and service space around equipment.
1. Show tabulations of installed devices, equipment features, and ratings. 2. Schematic and Connection Wiring Diagrams: For power, signal, communications, and control wiring.
1.5 INFORMATIONAL SUBMITTALS
A. Coordination Drawings: Floor plans, drawn to scale, showing dimensioned layout, required working clearances, and required area above and around VFDs. Show VFD layout and relationships between electrical components and adjacent structural and mechanical elements. Show support locations, type of support, and weight on each support. Indicate field measurements.
B. Seismic Qualification Certificates: For VFDs, accessories, and components, from manufacturer.
1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation. 2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions. 3. Detailed description of equipment anchorage devices on which the certification is based, and their installation requirements.
C. Product certificates.
D. Source quality-control reports.
E. Field quality-control reports.
1.6 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
1.7 QUALITY ASSURANCE
A. Testing Agency Qualifications: Member company of NETA or an NRTL.
B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-2
C. Comply with NFPA 70.
D. IEEE Compliance: Fabricate and test VFD according to IEEE 344 to withstand seismic forces defined in Section 260548 "Vibration and Seismic Controls for Electrical Systems."
1.8 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace VFDs that fail in materials or workmanship within specified warranty period.
1. Warranty Period: Five years from date of Substantial Completion.
PART 2 - PRODUCTS
2.1 MANUFACTURED UNITS
A. Manufacturers: Subject to compliance with requirements, provide products by the following:
1. Rockwell Automation, Inc.; Allen-Bradley Brand or Approved Equal.
B. General Requirements for VFDs: Comply with NEMA ICS 7, NEMA ICS 61800-2, and UL 508C.
C. Application: Constant torque and variable torque.
D. VFD Description: Variable-frequency power converter (rectifier, dc bus, and IGBT, PWM inverter) factory packaged in an enclosure, with integral disconnecting means and overcurrent and overload protection; listed and labeled by an NRTL as a complete unit; arranged to provide self-protection, protection, and variable-speed control of one or more three-phase induction motors by adjusting output voltage and frequency.
1. Units suitable for operation of NEMA MG 1, Design A and Design B motors as defined by NEMA MG 1, Section IV, Part 30, "Application Considerations for Constant Speed Motors Used on a Sinusoidal Bus with Harmonic Content and General Purpose Motors Used with Adjustable-Voltage or Adjustable-Frequency Controls or Both." 2. Units suitable for operation of inverter-duty motors as defined by NEMA MG 1, Section IV, Part 31, "Definite-Purpose Inverter-Fed Polyphase Motors." 3. Listed and labeled for integrated short-circuit current (withstand) rating by an NRTL acceptable to authorities having jurisdiction.
E. Design and Rating: Match load type, such as fans, blowers, and pumps; and type of connection used between motor and load such as direct or through a power-transmission connection.
F. Output Rating: Three-phase; 10 to 200 (60 as programmed default) Hz, programmable as voltage proportional to frequency throughout voltage range or with sensorless vector control; maximum voltage equals input voltage.
G. Unit Operating Requirements:
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-3
1. Input AC Voltage Tolerance: Plus 10 and minus 15 percent of VFD input voltage rating. 2. Input AC Voltage Unbalance: Not exceeding 5 percent. 3. Input Frequency Tolerance: Plus or minus 3 percent of VFD frequency rating. 4. Minimum Efficiency: 97 percent at 60 Hz, full load. 5. Minimum Displacement Primary-Side Power Factor: 98 percent under any load or speed condition. 6. Minimum Short-Circuit Current (Withstand) Rating: Equal to the rating of the gear feeding the drive. If not listed, 65 kA. 7. Ambient Temperature Rating: Not less than 14 deg F (minus 10 deg C) and not exceeding 122 deg F (50 deg C). 8. Ambient Storage Temperature Rating: Not less than minus 4 deg F (minus 20 deg C) and not exceeding 158 deg F (70 deg C) 9. Humidity Rating: Less than 95 percent (noncondensing). 10. Altitude Rating: Not exceeding 3300 feet without de-rating. Up to 9850 feet with de- rating. 11. Vibration Withstand: Comply with IEC 60068-2-6. 12. Overload Capability: VFD system shall be rated for continuous operation at a minimum of 110% of motor load full load amps (FLA) times the motor service factor. Variable torque inverters shall be capable of delivering 110% of continuous rating for a minimum of 60 seconds. Constant torque inverters shall be capable of delivering 150% of continuous rating for a minimum of 120 seconds. 13. Starting Torque: Minimum 100 percent of rated torque from 3 to 60 Hz. 14. Speed Regulation: Plus or minus 0.6 Hz. 15. Output Carrier Frequency: Selectable; 0.5 to 15 kHz. 16. Stop Modes: Programmable; includes fast, free-wheel, and dc injection braking.
H. Inverter Logic: Microprocessor based, VFD isolated from all power circuits.
I. Isolated Control Interface: Allows VFDs to follow remote-control electrical signal over a minimum 100:1 speed range.
J. Internal Adjustability Capabilities:
1. Minimum Speed: 5 to 25 percent of maximum rpm. 2. Maximum Speed: 80 to 100 percent of maximum rpm. 3. Acceleration: 0.1 to 999.9 seconds. 4. Deceleration: 0.1 to 999.9 seconds. 5. Current Limit: 30 to minimum of 150 percent of maximum rating.
K. Self-Protection and Reliability Features:
1. Input transient protection by means of surge suppressors to provide three-phase protection against damage from supply voltage surges 10 percent or more above nominal line voltage. 2. Loss of Input Signal Protection: Selectable response strategy, including speed default to a percent of the most recent speed, a preset speed, or stop; with alarm. 3. Under- and overvoltage trips. 4. Inverter overcurrent trips. 5. VFD and Motor Overload/Overtemperature Protection: Microprocessor-based thermal protection system for monitoring VFDs and motor thermal characteristics, and for
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-4
providing VFD overtemperature and motor overload alarm and trip; settings selectable via the keypad; NRTL approved. 6. Critical frequency rejection, with three selectable, adjustable deadbands. 7. Instantaneous line-to-line and line-to-ground overcurrent trips. 8. Loss-of-phase protection. 9. Reverse-phase protection. 10. Short-circuit protection. 11. Motor overtemperature fault.
L. Automatic Reset/Restart: Attempt three restarts after drive fault or on return of power after an interruption and before shutting down for manual reset or fault correction; adjustable delay time between restart attempts.
M. Power-Interruption Protection: To prevent motor from re-energizing after a power interruption until motor has stopped, unless "Bidirectional Autospeed Search" feature is available and engaged.
N. Bidirectional Autospeed Search: Capable of starting VFD into rotating loads spinning in either direction and returning motor to set speed in proper direction, without causing damage to drive, motor, or load.
O. Torque Boost: Automatically varies starting and continuous torque to at least 1.5 times the minimum torque to ensure high-starting torque and increased torque at slow speeds.
P. Motor Temperature Compensation at Slow Speeds: Adjustable current fall-back based on output frequency for temperature protection of self-cooled, fan-ventilated motors at slow speeds.
Q. Integral Input Disconnecting Means and OCPD: NEMA AB 1, thermal-magnetic circuit breaker with pad-lockable, door-mounted handle mechanism.
1. Disconnect Rating: Not less than 115 percent of VFD input current rating. 2. Disconnect Rating: Not less than 115 percent of NFPA 70 motor full-load current rating or VFD input current rating, whichever is larger.
2.2 CONTROLS AND INDICATION
A. Status Lights: Door-mounted LED indicators displaying the following conditions:
1. Power on. 2. Run. 3. VFD Fault. 4. All other lights as shown on the design drawings
B. Panel-Mounted Operator Station: Manufacturer's standard front-accessible, sealed keypad and plain-English language digital display; allows complete programming, program copying, operating, monitoring, and diagnostic capability.
C. Historical Logging Information and Displays:
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-5
1. Running log of total power versus time. 2. Total run time. 3. Fault log, maintaining last four faults with time and date stamp for each.
D. Indicating Devices: Digital display mounted flush in VFD door and connected to display VFD parameters including, but not limited to:
1. Output frequency (Hz). 2. Motor speed (rpm). 3. Motor status (running, stop, fault). 4. Motor current (amperes). 5. Motor torque (percent). 6. Fault or alarming status (code). 7. PID feedback signal (percent). 8. DC-link voltage (V dc). 9. Set point frequency (Hz). 10. Motor output voltage (V ac).
E. Control Signal Interfaces:
1. Electric Input Signal Interface:
a. Speed Reference: The VFD shall be capable of being controlled locally by a speed potentiometer or remotely by a 4- to 20-mA dc signal. The 4- to 20-mA signal shall be galvanically isolated and input resistance shall not exceed 250 ohms.
b. A minimum of two programmable analog inputs shall be provided and would be typically used for PID process variable and set point. These signals shall be setup to accept a 4- to 20-mA dc signal. The 4- to 20-mA signal shall be galvanically isolated and input resistance shall not exceed 250 ohms.
c. A minimum of six multifunction programmable digital inputs. The drive shall be expandable to handle additional digital inputs if required. The digital inputs shall be programmable to perform functions including, but not limited to:
1) VFD Start/Stop Control (2 or 3 wire) 2) Forward/Reverse/Stop Control 3) Local/Remote. The VFD shall be programmable so that “Local” control may either be the keypad or by hard-wired start/stop and potentiometer. The VFD shall be programmable so that “Remote” control may either be hard- wired start/stop and 4- to 20mA speed control or via the communications network. 4) VFD Interlock/Enable. This input when de-energized will not allow the VFD to run the motor under any circumstance. 5) VFD External Fault. This input will trip the VFD and require a reset before allow the motor to run again. 6) Preset Frequencies. The VFD shall be programmable to run at pre- programmed frequencies with up to 6 different steps.
2. Output Signal Interface:
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-6
a. A minimum of two programmable analog output signals 4- to 20-mA dc, which can be configured for any of the following:
1) Output frequency (Hz). 2) Output current (load). 3) DC-link voltage (V dc). 4) Motor torque (percent). 5) Motor speed (rpm). 6) Set point frequency (Hz). 7) Motor power (kW)
b. A minimum of two programmable dry-circuit relay outputs (120-V ac, 1 A) for remote indication of the following (the drive shall be expandable to handle additional digital outputs if required):
1) Motor running. 2) VFD ready. 3) Set point speed reached. 4) Fault and warning indication (overtemperature or overcurrent). 5) PID high- or low-speed limits reached.
F. PID Control Interface: Provides closed-loop set point, differential feedback control in response to dual feedback signals. Allows for closed-loop control of fans and pumps for pressure, flow, or temperature regulation.
1. Number of Loops: One.
G. SCADA Interface: Factory-installed hardware and software to enable the SCADA to monitor, control, and display VFD status and alarms and energy usage. Allows VFD to be used with an external system within a multidrop LAN configuration; settings retained within VFD's nonvolatile memory.
1. Network Communications Ports: Ethernet. 2. Embedded SCADA Protocols for Network Communications: Ethernet/IP.
2.3 LINE CONDITIONING AND FILTERING
A. Input Line Conditioning: All new power distribution systems supplied shall be required to meet the requirements of IEEE 519-1992. Specifically, the system shall adhere to the TDD requirements of Table 10-3 of IEEE 519-1992. If the power distribution system is equipped with an Active Harmonic System, each VFD shall be equipped with a line reactor whose impedance is as recommended by the Active Harmonic System manufacturer (typically 3%). If no Active Harmonic System is part of the power distribution system, the following rules as a minimum shall define the input line conditioning for each VFD (unless further conditioning is required to meet the IEEE 519-1992 limits). With the Engineer’s approval, the contractor may decide to supply an Active Harmonic System even if not shown on the drawings, with corresponding reactors and chokes (this would typically occur if it is more cost effective to meet IEEE 519 with a single system then multiple harmonic filters).
1. All VFD’s sized for motors 50HP or larger shall be equipped with DC-link chokes.
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-7
2. All VFD’s sized for motors 40HP and less shall be equipped with 5% line reactors unless specifically called out as otherwise on the drawings. 3. All VFD’s sized for 50HP to 200HP motors shall be equipped with passive harmonic filters with DC Link Chokes. 4. All VFD’s greater than 200HP shall have be setup to have less than 5% THD for both voltage and current. This would typically require that the drive is setup with an 18-pulse front end or with an active harmonic filter. The VFD assembly shall accept a single 3- phase input and shall contain all of the harmonic mitigation equipment as part of the assembly.
B. EMI/RFI Filtering: VFD’s shall be CE marked and certify compliance with IEC 61800-3 for Category C2.
2.4 LOAD CONDITIONING
A. Load Conditioning: For VFD driven loads with conductor lengths between 200 and 1,000 feet, output dV/dt filters shall be provided as part of the VFD assembly. It is strongly recommended that VFD motor leads not be longer than 500 feet and alternative VFD locations should be considered. If absolutely necessary, loads with conductor lengths greater than 1,000 feet shall have output sine wave filters shall be provided as part of the VFD assembly. Voltage drop considerations shall be taken into account when selecting the motor’s nameplate voltage.
2.5 LINE AND LOAD CONDITIONING EQUIPMENT
A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. Transcoil International (TCI). 2. Or approved equal.
B. Line Reactors: Reactors shall be part of the VFD assembly. They shall be sized based upon the VFD input power requirements. They shall be properly installed with appropriate spacing and ventilation for ambient temperatures up to 104 F. The reactor shall meet the following criteria:
1. The reactor shall be UL 508 listed. 2. Continuous current rating: 100% RMS. 3. Intermittent current ratings: 150% for 60 seconds; 200% for 10 seconds. 4. Altitude Rating: Not exceeding 3300 feet without de-rating. Up to 9850 feet with de- rating. 5. All wiring shall be copper.
C. Passive Harmonic Filters: Filters shall be part of the VFD assembly. They shall be sized based upon the VFD input power requirements. They shall be properly installed with appropriate spacing and ventilation for ambient temperatures up to 104 F. The filter shall meet the following criteria:
1. The filter shall be UL 508 listed.
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-8
2. The filter shall filter harmonics generated by the nonlinear VFD to satisfy the requirements of IEEE 519-1992 for individual and total harmonic voltage and current distortion at the input terminals of the filter. 3. The TDD of the current at the input terminals of the filter shall not exceed the limits defined in Table 10-3 of IEEE 519-1992. 4. Full load efficiency: 97% or greater 5. The filter shall not resonate with the power distribution system nor attract harmonics from other sources. 6. The harmonic filter shall be a passive series connected low pass filter consisting of an inductor capacitor network. Active electronic components shall not be used. 7. The harmonic filter shall be equipped with a contactor that will connect the capacitor(s) only when the motor is running, avoiding nuisance VFD over-voltage tripping. 8. All wiring shall be copper.
D. dV/dt Filters: Filters shall be part of the VFD assembly. They shall be sized based upon motor horsepower and required full-load current (including service factor). They shall be properly installed with appropriate spacing and ventilation for ambient temperatures up to 104 F. The filter shall meet the following criteria:
1. The filter shall be UL 508 listed. 2. Maximum peak motor terminal voltage with 500 feet of cable: 15% of bus voltage. 3. Maximum dV/dt: 200 Volts per microsecond. 4. Continuous current rating: 100% RMS. 5. Intermittent current ratings: 150% for 60 seconds; 200% for 10 seconds. 6. Allowed inverter switching frequencies: 1kHz to 8 kHz. 7. Nominal inverter operating frequency: 60Hz; Minimum – 6 Hz; Maximum with de- rating: 120Hz. 8. Altitude Rating: Not exceeding 3300 feet without de-rating. Up to 9850 feet with de- rating. 9. Insertion loss: 3% of rated voltage maximum. 10. All wiring shall be copper.
E. Sine Wave Filters: Filters shall be part of the VFD assembly. They shall be sized based upon motor horsepower and required full-load current (including service factor). They shall be properly installed with appropriate spacing and ventilation for ambient temperatures up to 104 F. The filter shall meet the following criteria:
1. The filter shall be UL 508 listed. 2. Harmonic Voltage Distortion: 10% maximum 3. Continuous current rating: 100% RMS. 4. Intermittent current rating: 150% for 60 seconds. 5. Allowed inverter switching frequencies: 2kHz to 8 kHz. 6. Nominal inverter operating frequency: 60Hz; Minimum – 0 Hz; Maximum with de- rating: 90Hz. 7. Altitude Rating: Not exceeding 3300 feet without de-rating. Up to 9850 feet with de- rating. 8. Insertion loss: 10% of rated voltage maximum. 9. All wiring shall be copper.
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-9
2.6 BYPASS SYSTEMS
A. Provide Bypass Systems only if indicated on the drawings.
B. Bypass Operation: Safely transfers motor between power converter output and bypass circuit, manually, automatically, or both. Selector switches set modes and indicator lights indicate mode selected. Unit is capable of stable operation (starting, stopping, and running) with motor completely disconnected from power converter.
C. Bypass Mode: Field-selectable automatic or manual, allows local and remote transfer between power converter and bypass contactor and retransfer, either via manual operator interface or automatic control system feedback.
D. Bypass Controller: Two-contactor-style bypass allows motor operation via the power converter or the bypass controller; with input isolating switch and barrier arranged to isolate the power converter and permit safe troubleshooting and testing, both energized and de-energized, while motor is operating in bypass mode.
1. Bypass Contactor: Load-break, NEMA-rated contactor. 2. Output Isolating Contactor: Non-load-break, NEMA-rated contactor. 3. Isolating Switch: Non-load-break switch arranged to isolate power converter and permit safe troubleshooting and testing of the power converter, both energized and de-energized, while motor is operating in bypass mode; pad-lockable, door-mounted handle mechanism.
E. Bypass Contactor Configuration: Full-voltage (across-the-line) or reduced voltage soft-starter as shown on the drawings.
1. NORMAL/BYPASS selector switch. 2. HAND/OFF/AUTO selector switch. 3. NORMAL/TEST Selector Switch: Allows testing and adjusting of VFD while the motor is running in the bypass mode. 4. Contactor Coils: Pressure-encapsulated type with coil transient suppressors.
a. Operating Voltage: Depending on contactor NEMA size and line-voltage rating, manufacturer's standard matching control power or line voltage. b. Power Contacts: Totally enclosed, double break, and silver-cadmium oxide; assembled to allow inspection and replacement without disturbing line or load wiring.
5. Control Circuits: 120-V ac; obtained from integral CPT, with primary and secondary fuses, with CPT of sufficient capacity to operate all integral devices and remotely located pilot, indicating, and control devices.
a. CPT Spare Capacity: 100 VA.
6. Overload Relays: NEMA ICS 2.
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-10
2.7 ENCLOSURES
A. VFD Enclosures: NEMA 250, to comply with environmental conditions at installed location.
1. Dry, Clean and Non-corrosive Indoor Locations: Type 1. 2. Outdoor or Corrosive Locations: Type 4X, stainless steel. 3. Wash-Down Areas: Type 4X, stainless steel. 4. Other Wet or Damp Indoor Locations: Type 4. 5. Indoor Locations Subject to Dust, Falling Dirt, and Dripping Noncorrosive Liquids: Type 12.
B. Plenum Rating: UL 1995; NRTL certification label on enclosure, clearly identifying VFD as "Plenum Rated."
2.8 ACCESSORIES
A. General Requirements for Control-Circuit and Pilot Devices: NEMA ICS 5; factory installed in VFD enclosure cover unless otherwise indicated.
1. Push Buttons, Pilot Lights, and Selector Switches: Heavy-duty, oiltight type.
a. Push Buttons: Maintained and/or momentary as required. b. Pilot Lights: LED types; colors as shown on P&ID’s; push to test. c. Selector Switches: Rotary type.
B. Bypass contactor auxiliary contact(s) as required.
C. Control Relays: Auxiliary and adjustable solid-state time-delay relays.
D. Phase-Failure, Phase-Reversal, and Undervoltage and Overvoltage Relays: Solid-state sensing circuit with isolated output contacts for hard-wired connections. Provide adjustable undervoltage, overvoltage, and time-delay settings.
1. Current Transformers: Continuous current rating, basic impulse insulating level (BIL) rating, burden, and accuracy class suitable for connected circuitry. Comply with IEEE C57.13.
E. Supplemental Analog Meters:
1. Elapsed time meter.
F. Breather and drain assemblies, to maintain interior pressure and release condensation in NEMA 250, Type 4, 4X, and 12 enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings.
G. Space heaters, with NC auxiliary contacts, to mitigate condensation in NEMA 250, Type 4, 4X, 12 enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings.
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H. Cooling Fan and Exhaust System: For NEMA 250, maintaining enclosure NEMA rating; UL 508 component recognized: Supply fan, with non-corrosive intake and exhaust grills and filters; 120-V ac; obtained from integral CPT.
I. Air Conditioning System: For NEMA 250, maintaining enclosure NEMA rating; UL 508 component recognized; sized to maintain internal temperatures at or below 100 F.
2.9 SOURCE QUALITY CONTROL
A. Testing: Test and inspect VFDs according to requirements in NEMA ICS 61800-2.
1. Test each VFD while connected to its specified motor. 2. Verification of Performance: Rate VFDs according to operation of functions and features specified.
B. VFDs will be considered defective if they do not pass tests and inspections.
C. Prepare test and inspection reports.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Wall-Mounting Controllers: Install VFDs on walls with tops at uniform height and with disconnect operating handles not higher than 79 inches above finished floor unless otherwise indicated, and by bolting units to wall or mounting on lightweight structural-steel channels bolted to wall. For controllers not on walls, provide freestanding racks complying with Section 260529 "Hangers and Supports for Electrical Systems."
B. Seismic Bracing: Comply with requirements specified in Section 260548 "Vibration and Seismic Controls for Electrical Systems."
C. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and temporary blocking of moving parts from enclosures and components.
D. Install fuses in each fusible-switch VFD.
E. Install fuses in control circuits if not factory installed. Comply with requirements in Section 262813 "Fuses."
F. Install heaters in thermal-overload relays. Select heaters based on actual nameplate full-load amperes after motors have been installed.
G. Install, connect, and fuse thermal-protector monitoring relays furnished with motor-driven equipment.
H. Comply with NECA 1.
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3.2 IDENTIFICATION
A. Identify VFDs, components, and control wiring. Comply with requirements for identification specified in Section 260553 "Identification for Electrical Systems."
1. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs. 2. Label each VFD with engraved nameplate. 3. Label each enclosure-mounted control and pilot device.
3.3 CONTROL WIRING INSTALLATION
A. Install wiring between VFDs and remote devices and facility's central-control system. Comply with requirements in Section 260523 "Control-Voltage Electrical Power Cables."
B. Bundle, train, and support wiring in enclosures.
C. Connect selector switches and other automatic control devices where applicable.
1. Connect selector switches to bypass only those manual- and automatic control devices that have no safety functions when switches are in manual-control position. 2. Connect selector switches with control circuit in both manual and automatic positions for safety-type control devices such as low- and high-pressure cutouts, high-temperature cutouts, and motor overload protectors.
3.4 FIELD QUALITY CONTROL
A. Testing Agency: Engage a qualified testing agency to perform tests and inspections.
B. Perform tests and inspections.
C. Acceptance Testing Preparation:
1. Test insulation resistance for each VFD element, bus, component, connecting supply, feeder, and control circuit. Test continuity of each circuit.
D. Tests and Inspections:
1. Inspect VFD, wiring, components, connections, and equipment installation. 2. Test insulation resistance for each VFD element, component, connecting motor supply, feeder, and control circuits. Test continuity of each circuit. 3. Verify that voltages at VFD locations are within 10 percent of motor nameplate rated voltages. If outside this range for any motor, notify Engineer before starting the motor(s). 4. Test each motor for proper phase rotation. 5. Perform each electrical test and visual and mechanical inspection stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 6. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest.
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7. Test and adjust controls, remote monitoring, and safeties. Replace damaged and malfunctioning controls and equipment. 8. Perform voltage and current harmonic test with each VFD running at minimum and maximum speed. Submit test results for each VFD. Testing shall be witnessed by the Owner and the Engineer.
E. VFDs will be considered defective if they do not pass tests and inspections.
F. Prepare test and inspection reports, including a certified report that identifies the VFD and describes scanning results. Include notation of deficiencies detected, remedial action taken, and observations made after remedial action.
3.5 ADJUSTING
A. Program microprocessors for required operational sequences, status indications, alarms, event recording, and display features. Clear events memory after final acceptance testing and prior to Substantial Completion.
B. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload-relay pickup and trip ranges.
C. Adjust the trip settings of MCPs and thermal-magnetic circuit breakers with adjustable, instantaneous trip elements. Initially adjust to six times the motor nameplate full-load amperes and attempt to start motors several times, allowing for motor cool-down between starts. If tripping occurs on motor inrush, adjust settings in increments until motors start without tripping. Do not exceed eight times the motor full-load amperes (or 11 times for NEMA Premium Efficient motors if required). Where these maximum settings do not allow starting of a motor, notify Engineer before increasing settings.
D. Set field-adjustable circuit-breaker trip ranges as specified in Section 260573 "Overcurrent Protective Device Coordination Study."
3.6 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, reprogram, and maintain VFDs. A minimum of 4 hours of training shall be provided. The training shall cover VFD theory of operation, features and functions available, normal operation, troubleshooting, and routine maintenance. The Contractor shall submit a syllabus for the training session for approval, within 3 weeks of conducting the class. Provide each attendee with a class syllabus detailing each topic to be discussed.
3.7 SPARE PARTS
A. The following spare parts shall be supplied with each type, or frame size, of VFD: 1. 3 sets of all replaceable fuses and air conditioner or fan filters
END OF SECTION 262923
WRCRWA VARIABLE-FREQUENCY MOTOR CONTROLLERS PLANT EXPANSION PROJECT 262923-14
SECTION 263213 – ENGINE GENERATORS
PART 1 - GENERAL
1.1 SUMMARY
A. General: The CONTRACTOR shall provide a factory assembled standby diesel electric generator system complete and operable with digital electronic controls, in conformance to the Contract Documents.
B. The provisions of this Section apply to standby diesel electric generators throughout the Contract Documents, except as indicated otherwise.
C. Provide factory test, startup by a supplier authorized by the manufacturer, and on-site testing of the system.
D. The generator set manufacturer shall warrant all equipment provided under this section, whether or not is manufactured by the generator set manufacturer, so that there is one source for warranty and product service. Technicians specifically trained and certified by the manufacturer to support the product and employed by the generator set supplier shall service the generator set.
E. The CONTRACTOR shall be responsible for obtaining any required air quality permits on behalf of the OWNER, posting all public notices, and shall include all associated fees in their bid, listed as separate line items in the schedule of values. The generator vendor shall provide the Contractor with the documentation required for permitting, showing published proof of EPA certification on the engine specified and furnished herein.
1.2 CODES AND STANDARDS
A. The generator set and its installation and on-site testing shall conform to the requirements of the following codes and standards:
1. CSA C22.2, No. 14 – M91 Industrial Control Equipment 2. CSA 282, 1989 Emergency Electrical Power Supply for Buildings 3. EN50082-2, Electromagnetic Compatibility – Generic Immunity Requirements, Part 2: Industrial. 4. EN55011, Limits and Methods of Measurement of Radio Interference Characteristics of Industrial, Scientific and Medical Equipment. 5. FCC Part 15, Subpart B. 6. IEC8528 part 4. Control Systems for Generator Sets. 7. IEC Std 801.2, 801.3, and 801.5 for susceptibility, conducted, and radiated electromagnetic emissions. 8. IEEE446 – Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications. 9. IEEE587 for voltage surge resistance. 10. Mil Std 461D –1993. Military Standard, Electromagnetic Interference Characteristics. 11. Mil Std 462D - 1993. Military Standard, Measurement of Electromagnetic Interference Characteristics. 12. NEMA ICS10-1993 – AC Generator sets.
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13. NFPA70 – National Electrical Code. Equipment shall be suitable for use in systems in compliance to Article 700, 701, and 702 14. NFPA99 – Essential Electrical Systems for Health Care Facilities. 15. NFPA110 – Emergency and Standby Power Systems. The generator set shall meet all requirements for Level 1 systems. Level 1prototype tests required by this standard shall have been performed on a complete and functional unit, component level type tests will not substitute for this requirement 16. UL508. The entire control system of the generator set shall be UL508 listed and labeled. 17. UL2200. The generator set shall be listed to UL2200 or submit to an independent third party certification process to verify compliance as installed.
B. The generator set manufacturer shall be certified to ISO 9001 International Quality Standard and shall have third party certification verifying quality assurance in design/development, production, installation, and service, in accordance with ISO 9001.
1.3 ACCEPTABLE MANUFACTURERS
A. Only approved bidders shall supply equipment provided under this contract. Equipment specifications for this project are based on microprocessor-based generator sets manufactured by Cummins Onan. Equipment by other suppliers that meets the requirement of this specification are acceptable, but must be approved not less than two weeks prior to the scheduled bid date.
1.4 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 01300 - Contractor Submittals.
B. Submit shop drawings containing actual dimensions, complete wiring and schematic diagrams, control diagrams, and any other details required to demonstrate that the system has been coordinated, and will properly function as a unit. Shop drawings shall show proposed layout, anchoring, support and appurtenances, including clearances for maintenance and operations. Shop drawings shall show details of piping connections for fuel.
C. Submit a complete list of equipment and material, including manufacturer's specifications, performance charts, catalog cuts and installation instructions, and recommended spare parts list. Submit data for each different item of equipment specified, including but not limited to engine, generator, switchgear, automatic transfer switch, vibration isolators, radiator, and other components. The data shall include a complete list of parts and source of supply.
D. Submit performance test reports in booklet form showing all field tests, and adjustments performed to prove compliance with specified criteria.
E. Operation and maintenance (O&M) manuals shall describe the step-by-step procedure required for system start-up, operation and routine maintenance. The O&M manuals shall include troubleshooting and repair guidelines, as well as wiring diagrams of the system as installed.
F. Miscellaneous:
1. Dimensions, dry and wet weight.
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2. Manufacturers kilowatts output curve and fuel consumption. 3. Manufacturers transient response data of the complete engine generator set upon 50%, 75%, and 100% block loads at 1.0 pf. Data shall include maximum voltage dips, maximum frequency dips, and recovery time periods. 4. Engine altitude duration curve 5. Generator motor starting curves showing the voltage dips versus starting KVA. 6. Prototype test certifications showing all components comply with specifications. G. The following spare parts for the engine generator shall be supplied to the OWNER prior to acceptance of work: Two sets of oil filters, two sets of heavy duty air filters, one dozen spare lamps, two fuses (for each control circuit).
1. Two set of oil filters. 2. Two sets of heavy duty air filters 3. One dozen spare lamps 4. Fuses (for each control circuit) PART 2 -- PRODUCTS
2.1 ENGINE GENERATOR SET
A. Requirements
1. All materials, equipment, and parts comprising the units specified herein, shall be new and unused, and of the highest grade.
2. The engine, generator and all major items of auxiliary equipment shall be manufactured in the U.S. by manufacturers currently engaged in the production of such equipment. The unit shall be factory assembled and tested by the engine SUPPLIER and shipped to the job site by his authorized dealer having a parts and service facility in the area. The performance of the electric plant shall be certified by SUPPLIER as to the plant's full power rating, stability and voltage and frequency regulation, and field load tested at site.
3. The units offered under these Contract Documents shall be covered by the SUPPLIER's standard warranty, or guarantee, on new machines, and shall be a minimum of two years after the date of substantial completion.
B. Ratings
1. The generator set shall operate at 1800 rpm and at a voltage of: 480 Volts AC, Three phase, Four-wire, 60 hertz.
2. The generator set shall be rated at 600 kW, 750 kVA at 0.8 PF, after de-rating, based on site conditions of : Altitude 700 ft. (213 meters), ambient temperatures up to 114 degrees F (46 degrees C).
3. The generator set rating shall be based on emergency/standby service.
C. Performance
1. Voltage regulation shall be plus or minus 0.5 percent for any constant load between no load and rated load for both parallel and non-parallel applications. Random voltage variation with any steady load from no load to full load shall not exceed plus or minus 0.5 percent.
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2. Frequency regulation shall be isochronous from steady state no load to steady state rated load. Random frequency variation with any steady load from no load to full load shall not exceed plus or minus 0.25%.
3. The diesel engine-generator set shall be capable of single step load pick up of 100% nameplate kW and power factor, less applicable derating factors, with the engine-generator set at operating temperature.
4. The generator set shall be capable of sustaining a minimum of 90% of rated no load voltage with the specified kVA load at near zero power factor applied to the generator set.
5. The alternator shall produce a clean AC voltage waveform, with not more than 5% total harmonic distortion at full linear load, when measured from line to neutral, and with not more than 3% in any single harmonic. Telephone influence factor shall be less than 40.
D. Construction
1. The engine-generator set shall be mounted on a heavy-duty steel base to maintain alignment between components. The base shall incorporate a battery tray with hold- down clamps within the rails.
2. All switches, lamps, and meters in the control system shall be oil-tight and dust-tight, and the enclosure door shall be gasketed. There shall be no exposed points in the control (with the door open) that operate in excess of 50 volts.
E. Connections
1. The generator set load connections shall be composed of silver or tin plated copper bus bars, drilled to accept mechanical or compression terminations of the number and type as shown on the drawings. Sufficient lug space shall be provided for use with cables of the number and size as shown on the drawings.
2. Power connections to auxiliary devices shall be made at the devices, with required protection located at a wall-mounted common distribution panel.
3. Generator set control interfaces to other system components shall be made on a common, permanently labeled terminal block assembly.
2.2 ENGINE AND ENGINE EQUIPMENT
A. The engine shall be diesel, 4 cycle, radiator and fan cooled with 6 cylinders. The horsepower rating of the engine at its minimum tolerance level shall be sufficient to drive the alternator and all connected accessories. Two cycle engines are not acceptable. Engine accessories and features shall include:
B. An electronic governor system shall provide automatic isochronous frequency regulation. The governing system dynamic capabilities shall be controlled as a function of engine coolant temperature to provide fast, stable operation at varying engine operating temperature conditions. The control system shall actively control the fuel rate and excitation as appropriate to the state of the generator set. Fuel rate shall be regulated as a
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function of starting, accelerating to start disconnect speed, accelerating to rated speed, and operating in various isochronous or parallel states.
C. Skid-mounted radiator and cooling system rated for full load operation in 122 degrees F (50 degrees C) ambient as measured at the generator air inlet, based on 0.5 in H2O external static head. Radiator shall be sized based on a core temperature which is 20F higher than the rated operation temperature, or prototype tested to verify cooling performance of the engine/radiator/fan operation in a controlled environment. Radiator shall be provided with a duct adapter flange. The cooling system shall be filled with a 50/50-ethylene glycol/water mixture by the equipment SUPPLIER. Rotating parts shall be guarded against accidental contact.
D. Electric starter(s) capable of three complete cranking cycles without overheating.
E. Positive displacement, mechanical, full pressure, lubrication oil pump.
F. Full flow lubrication oil filters with replaceable spin-on canister elements and dipstick oil level indicator.
G. An engine driven, mechanical, positive displacement fuel pump. Fuel filter with replaceable spin-on canister element. Fuel cooler, suitable for operation of the generator se at full rated load in the ambient temperature specified shall be provided if required for operation due to the design of the engine and the installation.
H. Replaceable dry element air cleaner with restriction indicator.
I. Flexible supply and return fuel lines.
J. Engine mounted battery charging alternator, 40-ampere minimum, and solid-state voltage regulator.
K. Coolant heater.
1. Engine mounted, thermostatically controlled, coolant heater(s) for each engine. Heater voltage shall be as shown on the project drawings. The coolant heater shall be UL499 listed and labeled.
2. The coolant heater shall be installed on the engine with silicone hose connections. Steel tubing shall be used for connections into the engine coolant system wherever the length of pipe run exceeds 12 inches. The coolant heater installation shall be specifically designed to provide proper venting of the system. The coolant heaters shall be installed using quick disconnect couplers to isolate the heater for replacement of the heater element. The quick disconnect/automatic sealing couplers shall allow the heater element to be replaced without draining the engine cooling system or significant coolant loss.
3. The coolant heater shall be provided with a 24VDC thermostat, installed at the engine thermostat housing. An AC power connection box shall be provided for a single AC power connection to the coolant heater system.
4. The coolant heater(s) shall be sized as recommended by the engine SUPPLIER to warm the engine to a minimum of 100F (40C) in a 40F ambient, in compliance with
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NFPA110 requirements, or the temperature required for starting and load pickup requirements of this specification.
L. Provide vibration isolators, spring/pad type, quantity as recommended by the generator set SUPPLIER. Isolators shall include seismic restraints if required by site location.
M. Starting and Control Batteries shall be calcium/lead antimony type, 24 volt DC, sized as recommended by the engine SUPPLIER, complete with battery cables and connectors.
N. Provide an exhaust silencer for each engine of size and type as recommended by the generator set SUPPLIER and approved by the engine manufacturer. The mufflers shall be critical grade. Exhaust system shall be installed according to the engine manufacturer’s recommendations and applicable codes and standards.
O. A UL listed/CSA certified 10 amp voltage regulated battery charger shall be provided for each engine-generator set. The charger may be located in an automatic transfer switch, or may be wall mounted, at the discretion of the installer. Input AC voltage and DC output voltage shall be as required. Chargers shall be equipped with float, taper and equalize charge settings. Operational monitors shall provide visual output along with individual form C contacts rated at 4 amps, 120 VAC, 30VDC for remote indication of:
1. Loss of AC power - red light 2. Low battery voltage - red light 3. High battery voltage - red light 4. Power ON - green light (no relay contact) 5. Charger shall include an Analog DC voltmeter and ammeter, 12 hour equalize charge timer, and AC and DC fuses
P. Provide a dual wall sub-base fuel storage tank with 24 hours of capacity at full load. The tank shall be constructed of corrosion resistant steel and shall be UL listed. The equipment, as installed, shall meet all local and regional requirements for above ground tanks.
2.3 GENERATOR
A. The AC generator shall be; synchronous, four pole, 2/3 pitch, revolving field, drip-proof construction, single prelubricated sealed bearing, air cooled by a direct drive centrifugal blower fan, and directly connected to the engine with flexible drive disc. All insulation system components shall meet NEMA MG1 temperature limits for Class H insulation system. Actual temperature rise measured by resistance method at full load shall not exceed 105 degrees Centigrade.
B. The generator shall be capable of delivering rated output (kVA) at rated frequency and power factor, at any voltage not more than 5 percent above or below rated voltage.
C. A permanent magnet generator (PMG) shall be included to provide a reliable source of excitation power for optimum motor starting and short circuit performance. The PMG and controls shall be capable of sustaining and regulating current supplied to a single phase or three phase fault at approximately 300% of rated current for not more than 10 seconds.
D. The subtransient reactance of the alternator shall not exceed 12 percent, based on the standby rating of the generator set.
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2.4 GENERATOR SET CONTROL
A. The generator set shall be provided with a microprocessor-based control system that is designed to provide automatic starting, monitoring, and control functions for the generator set. The control system shall also be designed to allow local monitoring and control of the generator set, and remote monitoring and control as described in this specification.
B. The control shall be mounted on the generator set. The control shall be vibration isolated and prototype tested to verify the durability of all components in the system under the vibration conditions encountered.
C. The generator set mounted control shall include the following switches:
1. MODE SELECT switch. The mode select switch shall initiate the following control modes. When in the RUN or Manual position the generator set shall start, and accelerate to rated speed and voltage as directed by the operator. In the OFF position the generator set shall immediately stop, bypassing all time delays. In the AUTO position the generator set shall be ready to accept a signal from a remote device to start and accelerate to rated speed and voltage.
2. EMERGENCY STOP switch. Switch shall be Red "mushroom-head" push-button. Depressing the emergency stop switch shall cause the generator set to immediately shut down, and be locked out from automatic restarting.
3. RESET switch. The RESET switch shall be used to clear a fault and allow restarting the generator set after it has shut down for any fault condition.
4. PANEL LAMP switch. Depressing the panel lamp switch shall cause the entire panel to be lighted with DC control power. The panel lamps shall automatically be switched off 10 minutes after the switch is depressed, or after the switch is depressed a second time.
D. The generator set mounted control shall include the following AC Output Metering with the following features and functions:
1. Analog voltmeter, ammeter, frequency meter, and kilowatt (KW) meter. Voltmeter and ammeter shall display all three phases. Ammeter and KW meter scales shall be color coded in the following fashion: readings from 0-90% of generator set standby rating: green; readings from 90-100% of standby rating: amber; readings in excess of 100%: red.
2. Digital metering set, 0.5% accuracy, to indicate generator RMS voltage and current, frequency, output current, output KW, KW-hours, and power factor. Generator output voltage shall be available in line-to-line and line-to-neutral voltages, and shall display all three phase voltages (line to neutral or line to line) simultaneously.
3. Both analog and digital metering are required. The analog and digital metering equipment shall be driven by a single microprocessor, to provide consistent readings and performance.
E. The generator set shall be provided with alarm and status indicating lamps to indicate non-automatic generator status, and existing warning and shutdown conditions. The
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lamps shall be high-intensity LED type. The lamp condition shall be clearly apparent under bright room lighting conditions. The generator set control shall indicate the existence of the following alarm and shutdown conditions on an alphanumeric digital display panel.
1. Low Oil Pressure (alarm). 2. Low Oil Pressure (shutdown). 3. Oil Pressure Sender Failure (alarm). 4. Low Coolant Temperature (alarm). 5. High Coolant Temperature (alarm). 6. High Coolant Temperature (shutdown). 7. Engine Temperature Sender Failure (alarm). 8. Low Coolant Level (alarm or shutdown—selectable) 9. Fail to Crank (shutdown) 10. Fail to Start/Overcrank (shutdown) 11. Overspeed (shutdown) 12. Low DC Voltage (alarm) 13. High DC Voltage (alarm) 14. Weak Battery (alarm) 15. Low Fuel-Daytank (alarm) 16. High AC Voltage (shutdown) 17. Low AC Voltage (shutdown) 18. Under Frequency (shutdown) 19. Over Current (warning) 20. Over Current (shutdown) 21. Short Circuit (shutdown) 22. Over Load (alarm) 23. Emergency Stop (shutdown) 24. Provisions shall be made for indication of four customer-specified alarm or shutdown conditions. Labeling of the customer-specified alarm or shutdown conditions shall be of the same type and quality as the above specified conditions. The non-automatic indicating lamp shall be red, and shall flash to indicate that the generator set is not able to automatically respond to a command to start from a remote location.
F. The generator set mounted control shall include the following engine status monitoring:
1. Engine Oil Pressure (psi or kPA) 2. Engine Coolant Temperature (degrees F or C) 3. Engine Oil Temperature (degrees F or C) 4. Engine Speed (rpm) 5. Number of Hours of Operation (hours) 6. Number of Start Attempts 7. Battery Voltage (DC volts) 8. The control system shall also incorporate a data logging and display provision to allow logging of the last 10 warning or shutdown indications on the generator set, as well as total time of operation at various loads, as a percent of the standby rating of the generator set.
G. The generator set mounted control shall include the following engine control functions:
1. The control system provided shall include a cycle cranking system, which allows for user selected crank time, rest time, and # of cycles. Initial settings shall be for 3
WRCRWA ENGINE GENERATORS PLANT EXPANSION PROJECT SECTION 263213 - 8
cranking periods of 15 seconds each, with 15-second rest period between cranking periods.
2. The control system shall include an idle mode control, which allows the engine to run in idle mode in the RUN position only. In this mode, the alternator excitation system shall be disabled.
3. The control system shall include an engine governor control, which functions to provide steady state frequency regulation as noted elsewhere in this specification. The governor control shall include adjustments for gain, damping, and a ramping function to control engine speed and limit exhaust smoke while the unit is starting. The governor control shall be suitable for use in paralleling applications without component changes.
4. The control system shall include time delay start (adjustable 0-300 seconds) and time delay stop (adjustable 0-600 seconds) functions.
5. The control system shall include sender failure monitoring logic for speed sensing, oil pressure, and engine temperature which is capable of discriminating between failed sender or wiring components, and an actual failure conditions.
H. Alternator Control Functions:
1. The generator set shall include an automatic digital voltage regulation system that is matched and prototype tested by the engine manufacturer with the governing system provided. It shall be immune from misoperation due to load-induced voltage waveform distortion and provide a pulse width modulated output to the alternator exciter. The voltage regulation system shall be equipped with three-phase RMS sensing and shall control buildup of AC generator voltage to provide a linear rise and limit overshoot. The system shall include a torque-matching characteristic, which shall reduce output voltage in proportion to frequency below a threshold of [58-59] HZ. The voltage regulator shall include adjustments for gain, damping, and frequency roll-off. Adjustments shall be broad range, and made via digital raise- lower switches, with an alphanumeric LED readout to indicate setting level. Rotary potentiometers for system adjustments are not acceptable.
2. Controls shall be provided to monitor the output current of the generator set and initiate an alarm (over current warning) when load current exceeds 110% of the rated current of the generator set on any phase for more than 60 seconds. The controls shall shut down and lock out the generator set when output current level approaches the thermal damage point of the alternator (over current shutdown). The protective functions provided shall be in compliance to the requirements of NFPA70 article 445.
3. Controls shall be provided to individually monitor all three phases of the output current for short circuit conditions. The control/protection system shall monitor the current level and voltage. The controls shall shut down and lock out the generator set when output current level approaches the thermal damage point of the alternator (short circuit shutdown). The protective functions provided shall be in compliance to the requirements of NFPA70 article 445.
4. Controls shall be provided to monitor the KW load on the generator set, and initiate an alarm condition (over load) when total load on the generator set exceeds the generator set rating for in excess of 5 seconds. Controls shall include a load shed
WRCRWA ENGINE GENERATORS PLANT EXPANSION PROJECT SECTION 263213 - 9
control, to operate a set of dry contacts (for use in shedding customer load devices) when the generator set is overloaded.
5. An AC over/under voltage monitoring system that responds only to true RMS voltage conditions shall be provided. The system shall initiate shutdown of the generator set when alternator output voltage exceeds 110% of the operator-set voltage level for more than 10 seconds, or with no intentional delay when voltage exceeds 130%. Under voltage shutdown shall occur when the output voltage of the alternator is less than 85% for more than 10 seconds.
6. A battery monitoring system shall be provided which initiates alarms when the DC control and starting voltage is less than 25VDC or more than 32 VDC. During engine cranking (starter engaged), the low voltage limit shall be disabled, and if DC voltage drops to less than 14.4 volts for more than two seconds a "weak battery" alarm shall be initiated.
I. The generator set shall be provided with a mounted main line circuit breaker, sized to carry the rated output current of the generator set. The circuit breaker shall incorporate an electronic trip unit that operates to protect the alternator under all overcurrent conditions, or a thermal-magnetic trip with other overcurrent protection devices that positively protect the alternator under overcurrent conditions. The supplier shall submit time overcurrent characteristic curves and thermal damage curve for the alternator, demonstrating the effectiveness of the protection provided.
2.5 OUTDOOR WEATHER-PROTECTIVE HOUSING
A. The enclosure shall include hinged doors for access to both sides of the engine and alternator, and the control equipment. Key-locking and padlockable door latches shall be provided for all doors. Door hinges shall be stainless steel.
B. The CONTRACTOR shall be responsible for appropriate sizing, location, and proper functioning as per the manufacturer’s requirements.
C. All sheetmetal shall be primed for corrosion protection and finish painted with the manufacturers standard color. All surfaces of all metal parts shall be primed and painted.
D. Painting of hoses, clamps, wiring harnesses, and other non-metallic service parts shall not be acceptable. Fasteners used shall be corrosion resistant, and designed to minimize marring of the painted surface when removed for normal installation or service work.
PART 3 -- EXECUTION
3.1 SEQUENCE OF OPERATION
A. Generator set shall start on receipt of a start signal from remote equipment. The start signal shall be via hardwired connection to the generator set control.
B. The generator set shall complete a time delay start period as programmed into the control.
C. The generator set control shall initiate the starting sequence for the generator set. The starting sequence shall include the following functions:
WRCRWA ENGINE GENERATORS PLANT EXPANSION PROJECT SECTION 263213 - 10
1. The control system shall verify that the engine is rotating when the starter is signaled to operate. If the engine does not rotate after two attempts, the control system shall shut down and lock out the generator set, and indicate “fail to crank” shutdown.
2. The engine shall fire and accelerate as quickly as practical to start disconnect speed. If the engine does not start, it shall complete a cycle cranking process as described elsewhere in this specification. If the engine has not started by the completion of the cycle cranking sequence, it shall be shut down and locked out, and the control system shall indicate “fail to start”.
3. The engine shall accelerate to rated speed and the alternator to rated voltage. Excitation shall be disabled until the engine has exceeded programmed idle speed, and regulated to prevent over voltage conditions and oscillation as the engine accelerates and the alternator builds to rated voltage.
D. On reaching rated speed and voltage, the generator set shall operate as dictated by the control system in isochronous, synchronize, load share, load demand, or load govern state.
E. When all start signals have been removed from the generator set, it shall complete a time delay stop sequence. The duration of the time delay stop period shall be adjustable by the operator.
F. On completion of the time delay stop period, the generator set control shall switch off the excitation system and shall shut down.
G. Any start signal received after the time stop sequence has begun shall immediately terminate the stopping sequence and return the generator set to isochronous operation.
3.2 INSTALLATION
A. Equipment shall be installed by the CONTRACTOR in accordance with Final Submittals and Contract Documents. Installation shall comply with applicable state and local codes as required by the authority having jurisdiction. Install equipment in accordance with SUPPLIER's instructions and instructions included in the listing or labeling of UL listed products.
B. Installation of equipment shall include furnishing and installing all interconnecting wiring between all major equipment provided for the on-site power system. The CONTRACTOR shall also perform interconnecting wiring between equipment sections (when required), under the supervision of the equipment SUPPLIER.
C. Equipment shall be installed on concrete housekeeping pads. Equipment shall be permanently fastened to the pad in accordance with SUPPLIER’s instructions and seismic requirements of the site.
D. Equipment shall be initially started and operated by representatives of the SUPPLIER.
E. All equipment shall be physically inspected for damage. Scratches and other installation damage shall be repaired prior to final system testing. Equipment shall be thoroughly cleaned to remove all dirt and construction debris prior to initial operation and final testing of the system.
WRCRWA ENGINE GENERATORS PLANT EXPANSION PROJECT SECTION 263213 - 11
F. Related electrical WORK involving connections, controls, switches, and disconnects shall be performed in accordance with the applicable sections of Division 16.
3.3 FACTORY TESTING
A. The generator set SUPPLIER shall perform a complete operational test on the generator set prior to shipping from the factory. A certified test report shall be provided to the ENGINEER. Equipment supplied shall be fully tested at the factory for function and performance.
B. Factory testing may be witnessed by the OWNER and ENGINEER. Costs for travel expenses will be the responsibility of the OWNER and ENGINEER. SUPPLIER is responsible to provide two weeks notice for testing.
C. Generator set factory tests on the equipment shall be performed at rated load and rated power factor. Generator sets that have not been factory tested at rated power factor will not be acceptable. Tests shall include: run at full load, maximum power, voltage regulation, transient and steady-state governing, single step load pickup, and function of safety shutdowns.
3.4 ON-SITE ACCEPTANCE
A. The complete installation shall be tested for compliance with the specification following completion of all site work. Testing shall be conducted by representatives of the SUPPLIER, with required fuel supplied by Contractor. The ENGINEER shall be notified in advance and shall have the option to witness the tests.
B. Installation acceptance tests to be conducted on-site shall include a "cold start" test, a two hour full load test, and a one step rated load pickup test in accordance with NFPA 110. Provide a resistive load bank and make temporary connections for full load test, if necessary.
3.5 TRAINING
A. The equipment SUPPLIER shall provide training for the facility operating personnel covering operation and maintenance of the equipment provided. The training program shall be not less than 4 hours in duration and the class size shall be limited to 5 persons. Training date shall be coordinated with the facility owner.
3.6 SERVICE AND SUPPORT
A. The generator set shall be serviced by a local service organization that is trained and factory certified in generator set service. The SUPPLIER shall maintain an inventory of critical replacement parts at the local service organization, and in service vehicles. The service organization shall be on call 24 hours per day, 365 days per year.
B. The SUPPLIER shall maintain model and serial number records of each generator set provided for at least 20 years.
WRCRWA ENGINE GENERATORS PLANT EXPANSION PROJECT SECTION 263213 - 12
3.7 WARRANTY
A. The generator set and associated equipment shall be warranted for a period of not less than 2 years from the date of commissioning against defects in materials and workmanship.
B. The warranty shall be comprehensive. No deductibles shall be allowed for travel time, service hours, repair parts cost, etc.
END OF SECTION
WRCRWA ENGINE GENERATORS PLANT EXPANSION PROJECT SECTION 263213 - 13
SECTION 263600 - TRANSFER SWITCHES
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes automatic transfer switches rated 600 V and less.
B. See Section 213113 "Electric-Drive, Centrifugal Fire Pumps" for automatic transfer switches for fire pumps.
C. See Section 213213 "Electric-Drive, Vertical-Turbine Fire Pumps" for automatic transfer switches for fire pumps.
1.2 ACTION SUBMITTALS
A. Product Data: Include rated capacities, weights, operating characteristics, furnished specialties, and accessories.
B. Shop Drawings: Dimensioned plans, elevations, sections, and details showing minimum clearances, conductor entry provisions, gutter space, installed features and devices, and material lists for each switch specified.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control test reports.
1.4 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
1.5 QUALITY ASSURANCE
A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
B. Comply with NEMA ICS 1.
C. Comply with NFPA 70.
D. Comply with NFPA 99.
E. Comply with NFPA 110.
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-1
F. Comply with UL 1008 unless requirements of these Specifications are stricter.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:
B. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
a. Caterpillar; Engine Div. b. Emerson; ASCO Power Technologies, LP. c. GE Zenith Controls. d. Kohler Power Systems; Generator Division. e. Onan/Cummins Power Generation; Industrial Business Group. f. MTU Energy.
2.2 GENERAL TRANSFER-SWITCH PRODUCT REQUIREMENTS
A. Indicated Current Ratings: Apply as defined in UL 1008 for continuous loading and total system transfer, including tungsten filament lamp loads not exceeding 30 percent of switch ampere rating, unless otherwise indicated.
B. Tested Fault-Current Closing and Withstand Ratings: Adequate for duty imposed by protective devices at installation locations in Project under the fault conditions indicated, based on testing according to UL 1008.
1. Where transfer switch includes internal fault-current protection, rating of switch and trip unit combination shall exceed indicated fault-current value at installation location.
C. Solid-State Controls: Repetitive accuracy of all settings shall be plus or minus 2 percent or better over an operating temperature range of minus 20 to plus 70 deg C.
D. Resistance to Damage by Voltage Transients: Components shall meet or exceed voltage-surge withstand capability requirements when tested according to IEEE C62.41. Components shall meet or exceed voltage-impulse withstand test of NEMA ICS 1.
E. Electrical Operation: Accomplish by a nonfused, momentarily energized solenoid or electric- motor-operated mechanism, mechanically and electrically interlocked in both directions.
F. Switch Characteristics: Designed for continuous-duty repetitive transfer of full-rated current between active power sources.
1. Limitation: Switches using molded-case switches or circuit breakers or insulated-case circuit-breaker components are not acceptable. 2. Switch Action: Double throw; mechanically held in both directions.
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-2
3. Contacts: Silver composition or silver alloy for load-current switching. Conventional automatic transfer-switch units, rated 225 A and higher, shall have separate arcing contacts.
G. Neutral Switching. Where four-pole switches are indicated, provide neutral pole switched simultaneously with phase poles.
H. Neutral Terminal: Solid and fully rated, unless otherwise indicated.
I. Oversize Neutral: Ampacity and switch rating of neutral path through units indicated for oversize neutral shall be double the nominal rating of circuit in which switch is installed.
J. Battery Charger: For generator starting batteries.
1. Float type rated 10 A. 2. Ammeter to display charging current. 3. Fused ac inputs and dc outputs.
K. Enclosures: General-purpose NEMA 250, Type 1, complying with NEMA ICS 6 and UL 508, unless otherwise indicated.
2.3 AUTOMATIC TRANSFER SWITCHES
A. Comply with Level 1 equipment according to NFPA 110.
B. Switching Arrangement: Double-throw type, incapable of pauses or intermediate position stops during normal functioning, unless otherwise indicated.
C. Signal-Before-Transfer Contacts: A set of normally open/normally closed dry contacts operates in advance of retransfer to normal source. Interval is adjustable from 1 to 30 seconds.
D. Transfer Switches Based on Molded-Case-Switch Components: Comply with NEMA AB 1, UL 489, and UL 869A.
E. In-Phase Monitor: Factory-wired, internal relay controls transfer so it occurs only when the two sources are synchronized in phase.
F. Motor Disconnect and Timing Relay: Controls designate starters so they disconnect motors before transfer and reconnect them selectively at an adjustable time interval after transfer. Time delay for reconnecting individual motor loads is adjustable between 1 and 60 seconds, and settings are as indicated.
G. Programmed Neutral Switch Position: Switch operator has a programmed neutral position arranged to provide a midpoint between the two working switch positions, with an intentional, time-controlled pause at midpoint during transfer.
H. Automatic Transfer-Switch Features:
1. Undervoltage Sensing for Each Phase of Normal Source: Sense low phase-to-ground voltage on each phase. Pickup voltage shall be adjustable from 85 to 100 percent of
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-3
nominal, and dropout voltage is adjustable from 75 to 98 percent of pickup value. Factory set for pickup at 90 percent and dropout at 85 percent. 2. Adjustable Time Delay: For override of normal-source voltage sensing to delay transfer and engine start signals. Adjustable from zero to six seconds, and factory set for one second. 3. Voltage/Frequency Lockout Relay: Prevent premature transfer to generator. Pickup voltage shall be adjustable from 85 to 100 percent of nominal. Factory set for pickup at 90 percent. Pickup frequency shall be adjustable from 90 to 100 percent of nominal. Factory set for pickup at 95 percent. 4. Time Delay for Retransfer to Normal Source: Adjustable from 0 to 30 minutes, and factory set for 10 minutes to automatically defeat delay on loss of voltage or sustained undervoltage of emergency source, provided normal supply has been restored. 5. Test Switch: Simulate normal-source failure. 6. Switch-Position Pilot Lights: Indicate source to which load is connected. 7. Source-Available Indicating Lights: Supervise sources via transfer-switch normal- and emergency-source sensing circuits.
a. Normal Power Supervision: Green light with nameplate engraved "Normal Source Available." b. Emergency Power Supervision: Red light with nameplate engraved "Emergency Source Available."
8. Unassigned Auxiliary Contacts: Two normally open, single-pole, double-throw contacts for each switch position, rated 10 A at 240-V ac. 9. Transfer Override Switch: Overrides automatic retransfer control so automatic transfer switch will remain connected to emergency power source regardless of condition of normal source. Pilot light indicates override status. 10. Engine Starting Contacts: One isolated and normally closed, and one isolated and normally open; rated 10 A at 32-V dc minimum. 11. Engine Shutdown Contacts: Instantaneous; shall initiate shutdown sequence at remote engine-generator controls after retransfer of load to normal source. 12. Engine Shutdown Contacts: Time delay adjustable from zero to five minutes, and factory set for five minutes. Contacts shall initiate shutdown at remote engine-generator controls after retransfer of load to normal source. 13. Engine-Generator Exerciser: Solid-state, programmable-time switch starts engine generator and transfers load to it from normal source for a preset time, then retransfers and shuts down engine after a preset cool-down period. Initiates exercise cycle at preset intervals adjustable from 7 to 30 days. Running periods are adjustable from 10 to 30 minutes. Factory settings are for 7-day exercise cycle, 20-minute running period, and 5- minute cool-down period. Exerciser features include the following:
a. Exerciser Transfer Selector Switch: Permits selection of exercise with and without load transfer. b. Push-button programming control with digital display of settings. c. Integral battery operation of time switch when normal control power is not available.
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-4
2.4 SOURCE QUALITY CONTROL
A. Factory test and inspect components, assembled switches, and associated equipment. Ensure proper operation. Check transfer time and voltage, frequency, and time-delay settings for compliance with specified requirements. Perform dielectric strength test complying with NEMA ICS 1.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Design each fastener and support to carry load indicated by seismic requirements and according to seismic-restraint details. See Section 260548 "Vibration and Seismic Controls for Electrical Systems."
B. Floor-Mounting Switch: Anchor to floor by bolting.
1. Concrete Bases: 4 inches high, reinforced, with chamfered edges. Extend base no more than 4 inches in all directions beyond the maximum dimensions of switch, unless otherwise indicated or unless required for seismic support. Construct concrete bases according to Section 260529 "Hangers and Supports for Electrical Systems."
C. Identify components according to Section 260553 "Identification for Electrical Systems."
D. Set field-adjustable intervals and delays, relays, and engine exerciser clock.
3.2 CONNECTIONS
A. Ground equipment according to Section 260526 "Grounding and Bonding for Electrical Systems."
B. Connect wiring according to Section 260519 "Low-Voltage Electrical Power Conductors and Cables."
3.3 FIELD QUALITY CONTROL
A. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect, test, and adjust components, assemblies, and equipment installations, including connections. Report results in writing.
B. Perform tests and inspections and prepare test reports.
1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installation, including connections, and to assist in testing. 2. After installing equipment and after electrical circuitry has been energized, test for compliance with requirements.
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-5
3. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 4. Measure insulation resistance phase-to-phase and phase-to-ground with insulation- resistance tester. Use test voltages and procedure recommended by manufacturer. Comply with manufacturer's specified minimum resistance.
a. Check for electrical continuity of circuits and for short circuits. b. Inspect for physical damage, proper installation and connection, and integrity of barriers, covers, and safety features. c. Verify that manual transfer warnings are properly placed. d. Perform manual transfer operation.
5. After energizing circuits, demonstrate interlocking sequence and operational function for each switch at least three times.
a. Simulate power failures of normal source to automatic transfer switches and of emergency source with normal source available. b. Simulate loss of phase-to-ground voltage for each phase of normal source. c. Verify time-delay settings. d. Verify pickup and dropout voltages by data readout or inspection of control settings. e. Perform contact-resistance test across main contacts and correct values exceeding 500 microhms and values for 1 pole deviating by more than 50 percent from other poles. f. Verify proper sequence and correct timing of automatic engine starting, transfer time delay, retransfer time delay on restoration of normal power, and engine cool- down and shutdown.
6. Ground-Fault Tests: Coordinate with testing of ground-fault protective devices for power delivery from both sources.
a. Verify grounding connections and locations and ratings of sensors.
C. Coordinate tests with tests of generator and run them concurrently.
D. Report results of tests and inspections in writing. Record adjustable relay settings and measured insulation and contact resistances and time delays. Attach a label or tag to each tested component indicating satisfactory completion of tests.
E. Remove and replace malfunctioning units and retest as specified above.
F. Infrared Scanning: After Substantial Completion, but not more than 60 days after Final Acceptance, perform an infrared scan of each switch. Remove all access panels so joints and connections are accessible to portable scanner.
1. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of each switch 11 months after date of Substantial Completion. 2. Instrument: Use an infrared scanning device designed to measure temperature or to detect significant deviations from normal values. Provide calibration record for device.
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-6
3. Record of Infrared Scanning: Prepare a certified report that identifies switches checked and that describes scanning results. Include notation of deficiencies detected, remedial action taken, and observations after remedial action.
3.4 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain transfer switches and related equipment as specified below. Refer to Section 017900 "Demonstration and Training."
B. Coordinate this training with that for generator equipment.
END OF SECTION 263600
WRCRWA TRANSFER SWITCHES PLANT EXPANSION PROJECT 263600-7
SECTION 264313 - TRANSIENT-VOLTAGE SUPPRESSION FOR LOW-VOLTAGE ELECTRICAL POWER CIRCUITS
PART 1 - Class C Main Entrance Panel Surge Suppression Device
1.1 DESCRIPTION
A. These specifications describe the electrical and mechanical requirements for a high ener- gy surge protective device. The specified surge protective device shall provide effective high energy surge diversion for application in ANSI/IEEE C62.41-1991 Location Cate- gory C3 environments. Testing per ANSI/IEEE C62.45-1992 using ANSI/IEEE C62.41 Category C3 waveforms and amplitudes. UL 1449 third edition listed. The specified surge protective device shall provide:
1. 200,000 transient amps, per phase, of surge protection. 2. Protection modes: L-N, L-G, L-L, N-G. 3. Green, power present LED on front panel. 4. Remote alarms relay contact. 5. Ten year warranty on entire unit.
1.2 STANDARDS
A. The specified device shall be designed, manufactured, tested and installed in compliance with:
1. American National Standards Institute and Institute of Electrical and Electronic En- gineers (ANSI/IEEE C62.11, C62.41, and C62.45) 2. Federal Information Processing Standards Publication 94 (FIP PUB 94) 3. National Electrical Manufacturer Association (NEMA LS-1) 4. National Fire Protection Association (NFPA 20, 70, 75 and 78) 5. Underwriters Laboratories (UL 1449 third edition) listed 6. CAN/C22.2 No. 8-M1986; CSA Electrical Certification Notice No. 516
B. The system individual units shall be UL listed under UL 1449 Third Edition Standard for Surge Protective Devices (SPD’s) and the surge ratings shall be permanently affixed to the SPD.
1.3 ENTRANCE PANEL EQUIPMENT ELECTRICAL REQUIREMENTS
A. Environmental Requirements:
1. Operating Temperature: Operating temperature range shall be -40 to +60 degrees C (- 40 to +160 degrees F) 2. Storage Temperature: Storage temperature range shall be -40 to +85 degrees C 3. Relative Humidity: Operation shall be reliable in an environment with 0% to 95% non-condensing relative humidity. 4. Operating Altitude: The system shall be capable of operation up to an altitude of 11,000 feet above sea level. TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-1
5. Operating Voltage: Maximum continuous operating voltage shall be 115% of the nominal rated line voltage. 6. Power Frequency: The operating frequency shall be 50/60 Hz.
B. Electrical Requirements:
1. Unit Operating Voltage: The nominal unit operating voltage shall be indicated Table 1.0
Table 1.0
Voltage Description Surge Current Vpeak Vpeak Vpeak Vpea In MCO Per Phase L-N L-G L-L k N-G V 120T 120/240 VAC 1ph, 200kA 700V 700V 1200V 700V 20kA 150V 3W + gnd 120Y 120/208 VAC 3ph, 200kA 700V 700V 1200V 700V 20kA 150V 4W + gnd, wye 220Y 220/380 VAC 3ph, 200kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 240D 240 VAC 3ph, 200kA N/A 1000V 1000V N/A 20kA 320V 3W + gnd, delta 240DCT* 240/120/120 200kA 700V 700V 1200V 700V 20kA 150V 3ph, 4W + gnd, hi-leg 1200V* 1000V* 1500V* * * * 240Y 240/415 VAC 3ph, 200kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 277Y 277/480 VAC 3ph, 200kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 480D 480 VAC 3ph, 200kA N/A 2500V 2500V N/A 20kA 640V 3W + gnd,delta *High-leg delta center tapped **Hi-leg
2. Unit shall be installed in parallel with the protected equipment. 3. Contractor is responsible for determining the correct voltage configuration and se- lecting the SPD for that configuration. 4. Protection per mode shall be: L-N 100kA, L-G 100kA, L-L 200kA, N-G 100kA. 5. The maximum surge current capacity per phase of the specified system, based on the standard IEEE 8/20 microsecond waveform, shall be at least: 1 Event at 150 kA. The surge life (8/20) shall be at least 10,000 occurrences @ 6 kA. The surge protective capability shall be bi-directional and suppress both positive and negative impulses. 6. The device shall be designed so as to minimize the internal surge path impedance. Direct point-to-point internal wiring is inherently inductive and not acceptable. Con- nection to the power service shall be constructed as shown in the installation notes for best performance. 7. Equipment shall be as manufactured by MCG Electronics, Ditek, Square D, Eaton or approved equal with supporting test data TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-2
1.4 ENTRANCE PANEL PROTECTION SYSTEM COMPONENTS
A. Diagnostics: Green solid state LED indicators, per phase, shall be provided on the front cover to indicate protection status. Illuminated green LED’s indicate full protection is present at the protector, and an extinguished LED shall indicate a reduction in protection on that phase. B. NEMA 1, 12, 3R, 4, or 4X Enclosure as indicated on the drawings: Minimum 18 gauge steel. If no NEMA rating indicated on the Contract Drawings, the NEMA rating shall match or be better than the NEMA rating of the equipment the is protected by the SPD.
1.5 INSTALLATION AND MAINTENANCE
A. The unit shall be installed in accordance with the manufacturer's printed instruction to maintain warranty. All local and national codes must be observed. B. Units shall be installed as close as possible to the panel board to which it is connected. Lead length shall be less than 18”. C. Detailed maintenance instructions shall be printed on the front panel to insure safety of maintenance personnel.
1.6 WARRANTY
A. Manufacturer to provide 10 year warranty to cover repair or replacement with a new de- vice.
PART 2 - Class B Branch Panel Surge Protective Device
2.1 DESCRIPTION
A. These specifications describe the electrical and mechanical requirements for a high ener- gy surge protective device. The specified surge protective device shall provide effective high energy surge diversion for application in ANSI/IEEE C62.41-1991 Location Cate- gory B3 environments. Testing per ANSI/IEEE C62.45-1992 using ANSI/IEEE C62.41 Category B3 waveforms and amplitudes. UL 1449 third edition listed. The specified surge protective device shall provide:
1. 150,000 transient amps, per phase, of surge protection. 2. Protection modes: L-N, L-G, L-L, N-G. 3. Green, power present LED, one per phase, on front panel. 4. Remote alarm relay contacts, Form C. 5. Ten year warranty on entire unit.
2.2 STANDARDS
A. The specified device shall be designed, manufactured, tested and installed in compliance with:
1. American National Standards Institute and Institute of Electrical and Electronic En- gineers (ANSI/IEEE C62.11, C62.41, and C62.45) TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-3
2. Federal Information Processing Standards Publication 94 (FIP PUB 94) 3. National Electrical Manufacturer Association (NEMA LS-1) 4. National Fire Protection Association (NFPA 20, 70, 75 and 78) 5. Underwriters Laboratories (UL 1449 third edition) listed 6. CAN/C22.2 No. 8-M1986; CSA Electrical Certification Notice No. 516
B. The system individual units shall be UL listed under UL 1449 Third Edition Standard for Surge Protective Devices (SPD’s) and the surge ratings shall be permanently affixed to the SPD.
2.3 BRANCH PANEL EQUIPMENT ELECTRICAL REQUIREMENTS
A. Environmental Requirements:
1. Operating Temperature: Operating temperature range shall be -40 to +60 degrees C (- 40 to +160 degrees F) 2. Storage Temperature: Storage temperature range shall be -40 to +85 degrees C 3. Relative Humidity: Operation shall be reliable in an environment with 0% to 95% non-condensing relative humidity. 4. Operating Altitude: The system shall be capable of operation up to an altitude of 11,000 feet above sea level. 5. Operating Voltage: Maximum continuous operating voltage shall be 115% of the nominal rated line voltage. 6. Power Frequency: The operating frequency shall be 50/60 Hz.
B. Electrical Requirements:
1. Unit Operating Voltage: The nominal unit operating voltage shall be indicated Table 2.0
Table 2.0
Voltage Description Surge Current Vpeak Vpeak Vpeak Vpea In MCO Per Phase L-N L-G L-L k N-G V 120T 120/240 VAC 1ph, 150kA 700V 700V 1200V 700V 20kA 150V 3W + gnd 120Y 120/208 VAC 3ph, 150kA 700V 700V 1200V 700V 20kA 150V 4W + gnd, wye 220Y 220/380 VAC 3ph, 150kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 240D 240 VAC 3ph, 150kA N/A 1000V 1000V N/A 20kA 320V 3W + gnd, delta 240DCT* 240/120/120 150kA 700V 700V 1200V 700V 20kA 150V 3ph, 4W + gnd, hi-leg 1200V* 1000V* 1500V* * * * 240Y 240/415 VAC 3ph, 150kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 277Y 277/480 VAC 3ph, 150kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 480D 480 VAC 3ph, 150kA N/A 2500V 2500V N/A 20kA 640V 3W + gnd,delta TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-4
*High-leg delta center tapped **High-Leg
2. Unit shall be installed in parallel with the protected equipment. No series connected protective elements shall be used. 3. Contractor is responsible for determining the correct voltage configuration and se- lecting the SPD for that configuration. 4. Protection per mode shall be: L-N 75kA, L-G 75kA, L-L 150 kA, N-G 75 kA. 5. The maximum surge current capacity per phase of the specified system, based on the standard IEEE 8/20 microsecond waveform, shall be at least: 1 Event at 100 kA. The surge life (8/20) shall be at least 10,000 occurrences @4 kA. The surge protection capability shall be bi-directional and suppress both positive and negative impulses. 6. The device shall be designed so as to minimize the internal surge path impedance. Direct point-to-point internal wiring is inherently inductive and not acceptable. Con- nection to the power service shall be constructed as shown in the installation notes for best performance. 7. Equipment shall be as manufactured by MCG Electronics, Ditek, Square D, Eaton or approved equal with supporting test data.
2.4 BRANCH PANEL PROTECTION SYSTEM COMPONENTS
A. Diagnostics: One green solid state LED indicators, per phase, shall be provided on the front cover to indicate protection status. Illuminated green LED’s indicate full protection is present at the protector, and an extinguished LED shall indicate a reduction in protec- tion on that phase. B. NEMA 1, 12, 3R, 4, or 4X Enclosure as indicated on drawings: Minimum 18gauge steel. If no NEMA rating indicated on the Contract Drawings, the NEMA rating shall match or be better than the NEMA rating of the equipment the is protected by the SPD.
2.5 INSTALLATION AND MAINTENANCE
A. The unit shall be installed in accordance with the manufacturer's printed instruction to maintain warranty. All local and national codes must be observed. B. Units shall be installed as close as possible to the panel board to which it is connected. Lead length shall be less than 18”. C. Detailed maintenance instructions shall be printed on the front panel to insure safety of maintenance personnel.
2.6 WARRANTY
A. Manufacturer to provide 10 year warranty to cover repair or replacement with a new de- vice.
PART 3 - Class A Local Panel / Control Panel Surge Device
3.1 DESCRIPTION
A. These specifications describe the electrical and mechanical requirements for a shunt in- stalled AC power line surge device. The specified surge protective device shall provide TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-5
effective energy surge diversion for application in ANSI/IEEE C62.41-1991 Location Category B3 environments. Testing per ANSI/IEEE C62.45-1992 using ANSI/IEEE C62.41 Category B3 waveforms and amplitudes. UL 1449 third edition listed. The speci- fied surge protective device shall provide:
1. 50,000 transient amps, per phase, of surge protection. 2. Protection modes: L-N, L-G, L-L, N-G 3. Green, power present LED, red, protection reduced LED on front panel. 4. Ten year warranty on entire system.
3.2 STANDARDS
A. The specified device shall be designed, manufactured, tested and installed in compliance with:
1. American National Standards Institute and Institute of Electrical and Electronic En- gineers (ANSI/IEEE C62.11, C62.41, and C62.45) 2. Federal Information Processing Standards Publication 94 (FIP PUB 94) 3. National Electrical Manufacturer Association (NEMA LS-1) 4. National Fire Protection Association (NFPA 20, 70, 75 and 78) 5. Underwriters Laboratories (UL 1449 third edition) listed 6. CAN/C22.2 No. 8-M1986; CSA Electrical Certification Notice No. 516
The system individual units shall be UL listed under UL 1449 third Edition Standard for Surge Protective Devices (SPD’s) and the surge ratings shall be permanently affixed to the SPD.
3.3 LOCAL PANEL EQUIPMENT ELECTRICAL REQUIREMENTS
A. Environmental Requirements:
1. Operating Temperature: Operating temperature range shall be -40 to +60 degrees C (- 40 to +160 degrees F) 2. Storage Temperature: Storage temperature range shall be -40 to +85 degrees C 3. Relative Humidity: Operation shall be reliable in an environment with 0% to 95% non-condensing relative humidity. 4. Operating Altitude: The system shall be capable of operation up to an altitude of 10,000 feet above sea level. 5. Operating Voltage: Maximum continuous operating voltage shall be 115% of the nominal rated line voltage. 6. Power Frequency: The operating frequency shall be 50/60 Hz.
B. Electrical Requirements:
1. Unit Operating Voltage: The nominal unit operating voltage shall be indicated in Ta- ble 3.0
TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-6
Table 3.0
Voltage Description Surge Current Vpeak Vpeak Vpeak Vpea In MCO Per Phase L-N L-G L-L k N-G V 120T 120/240 VAC 1ph, 50kA 700V 700V 1200V 700V 20kA 150V 3W + gnd 120Y 120/208 VAC 3ph, 50kA 700V 700V 1200V 700V 20kA 150V 4W + gnd, wye 220Y 220/380 VAC 3ph, 50kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 240D 240 VAC 3ph, 50kA N/A 1000V 1000V N/A 20kA 320V 3W + gnd, delta 240DCT* 240/120/120 50kA 700V 700V 1200V 700V 20kA 150V 3ph, 4W + gnd, hi-leg 1200V* 1000V* 1500V* * * * 240Y 240/415 VAC 3ph, 50kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 277Y 277/480 VAC 3ph, 50kA 1200V 1200V 2000V 1200 20kA 320V 4W + gnd, wye V 480D 480 VAC 3ph, 50kA N/A 2500V 2500V N/A 20kA 640V 3W + gnd,delta *High-leg delta center tapped **High-Leg
2. Unit shall be installed in parallel with the protected equipment. 3. Contractor is responsible for determining the correct voltage configuration and se- lecting the SPD for that configuration. 4. Protection per mode shall be: L-N 25 kA, L-G 25 kA, L-L 50 kA, N-G 25 kA. 5. The maximum surge current capacity per phase of the specified system, based on the standard IEEE 8/20 microsecond waveform, shall be at least: 1 Event at 50 kA, the surge life shall be at least 200 events @ 6kA and 20,000 events @2kA. The surge protection capability shall be bi-directional and suppress both positive and negative impulses. 6. The device shall be designed so as to minimize the internal surge path impedance. Direct point-to-point internal wiring is inherently inductive and not acceptable. Con- nection to the power service shall be constructed as shown in the installation notes for best performance. 7. Equipment shall be as manufactured by MCG Electronics, Ditek, Square D, Eaton or approved equal with supporting test data.
3.4 LOCAL PANEL PROTECTION SYSTEM COMPONENTS
A. MOVS: The device shall be constructed of multiple 32 mm metal oxide varistors. B. Self-Diagnostics: Solid state red and green LED indicators shall be provided on the front cover to indicate AC power present at the device and protection status C. NEMA 1, 12, 3R, 4, or 4X enclosure as indicated on the drawings: Minimum 18 gauge steel provided with mounting flanges. If no NEMA rating indicated on the Contract Drawings, the NEMA rating shall match or be better than the NEMA rating of the equipment the is protected by the SPD. TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-7
3.5 INSTALLATION AND MAINTENANCE
A. The unit shall be installed in accordance with the manufacturer's printed instruction to maintain warranty. All local and national codes must be observed. B. Units shall be installed as close as possible to the panelboard to which it is connected. Lead length shall be less than 18”. C. Detailed maintenance instructions shall be printed on the front panel to insure safety of maintenance personnel.
3.6 WARRANTY
A. Manufacturer to provide 10 year warranty to cover repair or the providing of a new de- vice.
PART 4 - Class A Surge Suppression Device installed within Protected Equipment
4.1 DESCRIPTION
A. These specifications describe the electrical and mechanical requirements for a series in- stalled AC power line surge protective device. The specified surge protective device shall proved effective energy surge diversion for application in ANSI/IEEE C62.41-1991 Location Category A3 environments. Testing per ANSI/IEEE C62.45-1992 using ANSI/IEEE C62.41 Category A3 waveforms and amplitudes. UL 1449 recognized. The specified surge protective device shall provide:
1. 10,000 transient amps of surge protection. 2. L-N, L-G, H-G protected modes. 3. Green protection present LED. 4. EMI-RFI Filter. 5. Low profile construction. 6. Ten year warranty.
4.2 STANDARDS
A. The specified device shall be designed, manufactured, tested and installed in compliance with:
1. American National Standards Institute and Institute of Electrical and Electronic En- gineers (ANSI/IEEE C62.11, C62.41, and C62.45) 2. Federal Information Processing Standards Publication 94 (FIP PUB 94) 3. National Fire Protection Association (NFPA 20, 70, 75 and 78) 4. Underwriters Laboratories (UL Second Edition 1449 Recognized) 5. National Electrical Manufacturer Association (NEMA LS-1) 6. CAN/C22.2 No. 8-M1986; CSA Electrical Certification Notice No. 516
TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-8
B. The system individual units shall be UL recognized under UL 1449 third Edition Stand- ard for Surge Protective Device (SPD).
4.3 LOCAL EQUIPMENT ELECTRICAL REQUIREMENTS
A. Environmental Requirements:
1. Operating Temperature: Operating temperature range shall be –40 to +60 degrees C (-40 to +140 degrees F). 2. Storage Temperature: Storage temperature range shall be –40 to +85 degrees C. 3. Relative Humidity: Operating shall be reliable in an environment with 0% to 95% non-condensing relative humidity. 4. Operating Altitude: The system shall be capable of operation up to an altitude of 13,000 feet above sea level. 5. Operating Voltage: Maximum continuous operating voltage shall be 115% of the nominal rated line voltage. 6. Power Frequency: The power frequency range shall be 50-400 Hertz.
4.4 Electrical Requirements:
A. Unit Operating Voltage: The nominal unit operating voltage shall be indicated in Table 4.0.
Table 4.0
Joules Clamp V Peak Voltage / Description 8/20us @1mA L - N 120 VAC 1phase, 2W + G 500 220V 392V 240 VAC 1phase, 2W + G 900 425V 760V
B. Unit shall be installed in series or in parallel with the protected equipment. C. The maximum surge current capacity per phase of the specified system, based on the standard IEEE 8/20 microsecond waveform, shall be at least: 1 Event at 10 kA. The surge life (8/20us) shall be at least 10,000 occurrences @ 500A. The surge protection capability shall be by-directional and suppress both positive and negative impulses. D. The device shall be designed so as to minimize the internal surge path impedance. Direct point-to-point internal wiring is inherently inductive and not acceptable. Connection to the power service shall be constructed as shown in the installation notes for best perfor- mance. E. Equipment shall be as manufactured by MCG Electronics, Ditek, Transector or approved equal with supporting test data. F. The device shall contain a common mode noise filter with specifications as in Table 4.1:
Table 4.1
Filter Attenuation Frequency (50 ohm) -20db 45 kHz -30db 75 kHz
TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-9
-40db 150 kHz -50db 250 kHz -60db 450 kHz
4.5 EQUIPMENT LEVEL PROTECTION SYSTEM COMPONENTS
A. MOVS: The device shall be constructed of multiple metal oxide varistors. B. Self-Diagnostics: An illuminated green solid state LED indicator shall be provided on the front cover to indicate protection is present at the device. C. Connection: Solderless Screw Terminals or hard wired leads less than 12 inches. D. Enclosure: High-impact plastic.
4.6 INSTALLATION AND MAINTENANCE
A. The unit shall be installed in accordance with the manufacturer’s printed instruction to maintain warranty. All local and national codes must be observed. B. Units shall be installed within the equipment to which it is connected.
4.7 WARRANTY
A. Manufacturer to provide 2 year warranty to cover repair or replacement with a new device.
END OF SECTION 264313
TRANSIENT-VOLTAGE SUPPRESSION FOR LOW- WRCRWA VOLTAGE ELECTRICAL POWER CIRCUITS PLANT EXPANSION PROJECT 264313-10
SECTION 265000 – LIGHTING
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. The Contractor shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install lighting fixtures.
1.2 QUALITY ASSURANCE
A. Reference Standards:
1. National Electrical Code (NEC) 2. UL Standard #57, Electric Lighting Fixtures 3. UL Standard #844, Electric Lighting Fixtures for Use in Hazardous Location 4. UL Standard #1570, Fluorescent Lighting Fixtures 5. UL Standard #1571, Incandescent Lighting Fixtures 6. UL Standard #1572, High Intensity Discharge Lighting Fixtures 7. Illuminating Engineering Society (IES) 8. All applicable local lighting ordinances
B. Miscellaneous:
1. Lamps are identified for each luminaire in the Lighting Fixture Schedule on the Plans. 2. Lighting fixtures and electrical components: a. UL labeled, complete with lamps. b. Rated for area classification as indicated. 3. On the Plans, the location of lighting fixtures is intended to be used as a guide. a. Field conditions may affect actual locations. b. Coordinate with other trades to avoid conflicts in mounting of fixtures and other equipment. 4. The quality standard is established by the fixture listed in the Lighting Fixture Schedule. a. This quality standard includes, but is not necessarily limited to construction fea- tures, materials of construction, finish, and photometrics.
1.3 SUBMITTALS
A. The following shall be submitted to the Engineer for review:
1. Acknowledgment that products submitted meet requirements of standards referenced. 2. Manufacturer’s technical information on products to be used including photometric performance curves for the fixture and ballast data. 3. Acknowledgment that products submitted are UL listed. 4. When general data sheets constitute part of the submittal, identify the products to be used on this project. 5. Manufacturer’s installation instructions.
WRCRWA LIGHTING PLANT EXPANSION PROJECT 265000-1
6. Identification of fixtures by Lighting Fixture Schedule. 7. UL nameplate data (Voltage, wattage, etc.). 8. Finishes, colors, and mounting type. 9. Pole, fixture, and accessories. 10. Pole wind loading.
B. Contractor shall submit shop drawings, manufacturer's data sheets, and a complete wiring diagram detailing all connections to the electrical system in accordance with Section 26000, and other requirements of the Contract Documents.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Lamps shall be manufactured by General Electric, North American/Phillips, Sylvania, or equal.
B. Lighting fixtures shall be provided as indicated on the Lighting Fixture Schedule on the Plans.
C. Lighting ballasts shall be manufactured by General Electric, Advance, Jefferson, Univer- sal, Bodine, Lithonia, or equal.
D. Light poles shall be as indicated on the Plans. Include base template, anchor bolts, cad- mium-plated hardware and pole grounding lug, hand-hole, anchor base and bolt covers. Pole foundations shall be as indicated on the Plans.
2.2 MATERIALS
A. General:
1. Lamps: a. See lighting fixture schedule on Plans for wattage, voltage and number required. 2. All Fixtures: a. There shall be no live parts normally exposed to contact. b. When intended for use in wet area: 1) Mark fixtures “suitable for wet locations.” c. When intended for use in damp areas: 1) Mark fixtures “suitable for damp locations” or “suitable for wet loca- tions.” d. In wet or damp area, install fixtures so that water cannot enter or accumulate in the wiring compartment, lamp-holder, or other electrical parts. e. Gasket seals: Urethane foam f. Diffusers: UV stabilized acrylic plastic 3. Underground wiring: a. Provide all wiring runs with separate green grounding conductor. b. Ground all pole bases. 4. Pole wiring from base to ballast: a. No. 12 type XHHW.
WRCRWA LIGHTING PLANT EXPANSION PROJECT 265000-2
b. Each phase shall be protected by a 30A, 600V, type Tron waterproof fuse-holder, Bussman “Limitron” type fuse, size rating 3-times load current.
B. Incandescent Lamps:
1. Types: a. 30-135 watts: Energy efficient b. 200-500 watts: Standard 2. Inside frost 3. Base: Aluminum or brass 4. PAR/Halogen
C. Fluorescent Lamps:
1. Rapid start 2. Cool white (F32T8/41K-85CRI and F96T12/41K-70CRI/HO/ES) 3. Energy efficient or standard as noted on the lighting fixture schedule.
D. High-Pressure Sodium Lamps:
1. Bulb finish: Clear 2. Any burning position
E. Metal Halide Lamps:
1. Bulb finish: Clear 2. Any burning position
F. LED:
1. 50,000 hour lifetime
F. Furnish a minimum of 2 lamps, or ten percent spare lamps of each type and wattage, whichever is greater.
2.3 FIXTURES
A. Fluorescent Lighting Fixtures:
1. Ballast: a. Rapid start, high power factor type b. CBM/ETL certified c. Sound rating A d. Two internal automatic-resetting thermal switch devices for coil and capacitor 2. Internal wiring: AWM, TFN or THHN 3. Channel and end plates: 22 GA steel 4. Steel door frame and socket track: 20 GA steel 5. Channel cover: 24 GA steel 6. Emergency ballast: a. Integral rechargeable nickel-cadmium battery, battery charger, and automatic transfer circuitry.
WRCRWA LIGHTING PLANT EXPANSION PROJECT 265000-3
b. Charging indicator light. c. Test Switch. d. Provide a minimum of 900 lumen output for 90 minutes upon loss of normal power. e. Mounted integral to the fixture. f. UL 924 listed. 7. Provide fixtures with emergency ballasts with permanent caution labels warning that the fixture is fed from an unswitched source. a. Provide emergency ballast also with a similar caution label.
B. HID Lighting Fixtures:
1. Ballasts for high pressure sodium lighting fixtures: a. Type: Regulating b. Ballast design center variance: Maximum 5 percent from rated lamp wattage. c. Lamp wattage regulation spread at the lamp voltage: Maximum 10 percent for +/-10 percent line voltage variation. d. Ballast primary current during starting not to exceed normal operating current. e. Lamp current crest factor: Maximum 1.8 for +/-10 percent line voltage variation at any lamp voltage, from nominal through life. f. Power factor shall not drop below 90 percent for +/-10 percent line voltage varia- tions at any lamp voltage, from nominal through life. g. Capacitor variance: Tolerance of +/-6 percent which will not cause more than a +/-8 percent variation in regulation throughout rated lamp life for nominal line voltage. h. Capable of operation with an open circuit condition for a maximum of 6 months without significant loss of ballast or starting circuitry life. 2. Ballasts for metal halide/mercury vapor lighting fixtures: a. Type: Auto-regulator b. Voltage input range: +/-10 percent c. Lamp regulation spread: 20 percent maximum d. Power factor: 90 to 90 percent e. Input voltage dip (4sec.): 40 to 50 percent f. Crest factor of lamp current: 1.6 to 2.0 3. Ballasts for exterior HID lamps: a. UL approved b. High power factor designed for -20 Deg F temperature starting 4. Fixtures for non-hazardous locations: a. Type: Industrial low bay b. Ballast housing: Die-cast c. Filter: Activated charcoal d. Refractor: UV stabilized molded acrylic
C. LED Lighting Fixtures:
1. Heavy duty two piece, die cast aluminum housing. 2. Silicon gasketing for moisture protection 3. Polyester powder finish for impact, corrosion and UV resistance 4. Cast-in aluminum hinges for tool-less lens removal. 5. Thermal and shock resistant clear borosilicate glass refractor. 6. Field replaceable LED light engine and driver.
WRCRWA LIGHTING PLANT EXPANSION PROJECT 265000-4
2.4 MISCELLANEOUS ELECTRIC DEVICES
A. PHOTOELECTRIC CONTROL UNITS shall meet the following requirements:
1. Cadmium sulfide photocell 2. Aluminum weatherproof enclosure 3. 30 amp rated contacts 4. 120-volt AC power 5. The Photoelectric control unit shall be Tork Model 2100, or equal.
B. MOTION SENSORS shall meet the following requirements:
1. 110 degrees field of view, 60 foot range 2. Adjustable time setting from 15 seconds to 15 minutes 3. Operating temperature of -20 to + 130 degrees F. 4. Complete outdoor, weather proof sensor with complete mounting hardware 5. UL listed 6. The motion sensor(s) shall be manufactured by Leviton Model 50500-H or equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Install lamps in all luminaires.
B. Replace all failed fluorescent, incandescent, metal halide, mercury vapor and high pres- sure sodium lamps with new lamps prior to final acceptance by Owner.
C. Surface and flush mounted fixtures shall be solidly connected to a junction box. Suspend- ed fixtures shall be hung utilizing pendant mounting or stainless steel chains and hooks. Each suspended fixture, shall be electrically connected by a length of Type SO flexible cord. 3 conductor No. 14 AWG, minimum, with a twist-lock receptacle mounted in an individual junction box. Plugs and receptacles shall be as manufactured by Hubbell, General Electric Company, or equal.
D. Provide mounting brackets and/or structural mounting support for fixtures. 1. Do not support fixture from conduit system. 2. Do not support fixture from outlet boxes.
E. Install with approved mounting hardware following manufacturer’s recommendations.
F. Pole mounted fixtures shall be mounted on steel or aluminum poles as indicated on the Plans. All metal poles shall be bonded to the facility ground system. Poles shall have adequate handholes and weatherproof receptacles where indicated.
G. All anchor bolts and nuts shall be stainless steel. Contractor shall paint all steel poles with aluminum paint or other color in accordance with these Contract Documents.
WRCRWA LIGHTING PLANT EXPANSION PROJECT 265000-5
H. Fixture mounting heights and locations indicated on the Plans are approximate and are subject to revision in the field where necessary to avoid conflicts and obstructions.
3.2 ADJUSTING AND CLEANING
A. Wipe all lighting fixture reflectors, lenses, lamps, and trims clean after installation and prior to acceptance of Project by Owner.
END OF SECTION 265000
WRCRWA LIGHTING PLANT EXPANSION PROJECT 265000-6 SECTION 311000 - SITE CLEARING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: 1. Clearing and grubbing. 2. Stripping and stockpiling topsoil. 3. Temporary erosion- and sedimentation-control measures.
1.2 MATERIAL OWNERSHIP
A. Except materials indicated to be stockpiled or otherwise remain Owner's property, cleared materials shall become Contractor's property and shall be removed from Project site.
1.3 PROJECT CONDITIONS
A. Prior to clearing or excavation operation, Contractor shall meet with the Owner to discuss any issues or potential problems that may arise from such activity.
B. Traffic: Minimize interference with adjoining roads, streets, walks, and other adjacent occupied or used facilities during site-clearing operations.
1. Do not close or obstruct streets, walks, or other adjacent occupied or used facilities without permission from Owner and authorities having jurisdiction. 2. Provide alternate routes around closed or obstructed traffic ways if required by Owner or authorities having jurisdiction.
C. Utility Locator Service: Notify utility locator service for area where Project is located before site clearing.
D. Pothole for existing utilities in project areas.
E. Do not commence site clearing operations until temporary erosion- and sedimentation- control and plant-protection measures are in place.
F. The following practices are prohibited outside the limits of construction:
1. Storage of construction materials, debris, or excavated material. 2. Parking vehicles or equipment. 3. Foot traffic. 4. Erection of sheds or structures. 5. Impoundment of water. 6. Excavation or other digging unless otherwise indicated. 7. Attachment of signs to or wrapping materials around trees or plants unless otherwise indicated.
WRCRWA SITE CLEARING PLANT EXPANSION PROJECT 311000 - 1 PART 2 - PRODUCTS
2.1 MATERIALS
A. Satisfactory Soil Material: Requirements for satisfactory soil material are specified in Section 312000 "Earth Moving"
1. Obtain approved borrow soil material off-site when satisfactory soil material is not available on-site.
PART 3 - EXECUTION
3.1 PREPARATION
A. Protect and maintain benchmarks and survey control points from disturbance during construction.
B. Protect existing site improvements to remain from damage during construction.
1. Restore damaged improvements to their original condition, as acceptable to Owner.
3.2 TEMPORARY EROSION AND SEDIMENTATION CONTROL
A. Provide temporary erosion- and sedimentation-control measures to prevent soil erosion and discharge of soil-bearing water runoff or airborne dust to adjacent properties and walkways, according to requirements of authorities having jurisdiction.
B. Verify that flows of water redirected from construction areas or generated by construction activity do not enter or cross protection zones.
C. Inspect, maintain, and repair erosion- and sedimentation-control measures during construction until permanent vegetation has been established.
D. Remove erosion and sedimentation controls and restore and stabilize areas disturbed during removal.
3.3 EXISTING UTILITIES
A. Locate, identify, disconnect, and seal or cap utilities indicated to be removed or abandoned in place.
1. Arrange with Owner/utility companies to shut off indicated utilities.
B. Interrupting Existing Utilities: Do not interrupt utilities serving facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary utility services according to requirements indicated:
WRCRWA SITE CLEARING PLANT EXPANSION PROJECT 311000 - 2 1. Notify Owner/Engineer not less than two days in advance of proposed utility interruptions. 2. Do not proceed with utility interruptions without Owner’s/Engineer’s written permission.
C. Removal of underground utilities is included in earthwork sections and with applicable fire suppression, plumbing, HVAC, electrical, communications, electronic safety and security and utilities sections and Section 024116 "Structure Demolition".
3.4 CLEARING AND GRUBBING
A. Any trash, construction debris, concrete slabs, old pavement, landfill, and buried obstructions such as old foundations shall be traced to the limits and removed.
B. Remove obstructions, trees, shrubs, and other vegetation to permit installation of new construction.
1. Grind down stumps and remove roots, obstructions, and debris to a depth of 18 inches below exposed subgrade.
C. Fill depressions caused by clearing and grubbing operations with satisfactory soil material unless further excavation or earthwork is indicated.
1. Place fill material in horizontal layers not exceeding a loose depth of 8 inches, and compact each layer to a density equal to adjacent original ground.
3.5 TOPSOIL STRIPPING
A. Remove existing site gravel before stripping topsoil. Stockpile site gravel at an Owner’s designated area and re-use in project work.
B. Strip topsoil to depth indicated in section 319000 “Geotechnical Report” in a manner to prevent intermingling with underlying subsoil or other waste materials. Excess trash, debris, concrete and buried obstructions shall be disposed of as indicated in the drawings and at the Engineer’s discretion.
C. Organic stripping shall be hauled off site and shall not be used as fill.
D. Stockpile topsoil away from edge of excavations without intermixing with subsoil or other materials. Grade and shape stockpiles to drain surface water. Cover to prevent windblown dust and erosion by water.
3.6 SITE IMPROVEMENTS
A. Remove existing above- and below-grade improvements as indicated and necessary to facilitate new construction.
WRCRWA SITE CLEARING PLANT EXPANSION PROJECT 311000 - 3 3.7 DISPOSAL OF SURPLUS AND WASTE MATERIALS
A. Remove surplus soil material, unsuitable topsoil and dispose offsite. Remove obstructions, demolished materials, and waste materials including trash and debris, and legally dispose of them off Owner's property.
B. Separate recyclable materials produced during site clearing from other nonrecyclable materials. Store or stockpile without intermixing with other materials and transport them to recycling facilities. Do not interfere with other Project work.
END OF SECTION 311000
WRCRWA SITE CLEARING PLANT EXPANSION PROJECT 311000 - 4 SECTION 312000 - EARTH MOVING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Base Course for concrete walks, pavements, and roadway areas. 2. Structural fill for building pads, concrete structures and auxiliary structures. 3. Bedding course for pipe and utility trenches. 4. Drainage course. 5. Controlled Low Strength Material (CLSM) for structural fill applications. 6. Accessories. 7. Clearing and Grubbing. 8. Excavation for rough grading the site. 9. Excavation for structures. 10. Excavation for piping and utility trenches. 11. Installation and compaction requirements.
1.2 RELATED SECTIONS
A. 033000 “Cast-in-Place Concrete” for sheet vapor retarder requirements.
B. 319000 “Geotechnical Report” for additional information regarding existing soils and recommendations.
1.3 DEFINITIONS
A. Backfill: Soil material used to fill an excavation.
1. Initial Backfill: Backfill placed beside and over pipe in a trench, including haunches to support sides of pipe. 2. Final Backfill: Backfill placed over initial backfill to fill a trench. 3. Structural Backfill: Backfill placed below building pads, foundations, concrete structures and other areas where specified.
B. Base Course: Aggregate layer placed between the subbase course and hot-mix asphalt paving.
C. Bedding Course: Aggregate layer placed over the excavated subgrade in a trench before laying pipe.
D. Borrow Soil: Satisfactory soil imported from off-site for use as fill or backfill.
E. Drainage Course: Aggregate layer supporting the slab-on-grade that also minimizes upward capillary flow of pore water.
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 1 F. Excavation: Removal of material encountered above subgrade elevations and to lines and dimensions indicated.
1. Authorized Additional Excavation: Excavation below subgrade elevations or beyond indicated lines and dimensions as directed by Engineer. Authorized additional excavation and replacement material will be paid for according to Contract provisions for changes in the Work. 2. Unauthorized Excavation: Excavation below subgrade elevations or beyond indicated lines and dimensions without direction by Engineer. Unauthorized excavation, as well as remedial work directed by Engineer, shall be without additional compensation.
G. Fill: Soil materials used to raise existing grades.
H. Structures: Buildings, footings, foundations, retaining walls, slabs, tanks, curbs, mechanical and electrical appurtenances, or other man-made stationary features constructed above or below the ground surface.
I. Subgrade: Uppermost surface of an excavation or the top surface of a fill or backfill immediately below base, drainage fill, drainage course, or topsoil materials.
J. Utilities: On-site underground pipes, conduits, ducts, and cables, as well as underground services within buildings.
1.4 QUALITY ASSURANCE
A. Contractor shall notify the Engineer of excavation plans a minimum of 48 hours in advance. The plan shall include a description of the location and extents of excavation.
1.5 INFORMATIONAL SUBMITTALS
A. Material test reports.
1.6 PROJECT CONDITIONS
A. Utility Locator Service: Notify utility locator service for area where Project is located before beginning earth moving operations.
PART 2 - PRODUCTS
2.1 SOIL MATERIALS
A. General: Provide borrow soil materials when sufficient satisfactory soil materials are not available from excavations.
B. Satisfactory Soils: On-site soils (following clearing and grubbing) are suitable for use as compacted general fill, utility trench and structural backfill. Borrow materials (Imported Fill Materials) shall be similar to onsite soils or non-expansive, granular soil meeting USCS
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 2 classifications of SM, SP-SM, or SW-SM with a maximum rock size of 3 inches. All imported fill soil sources and material gradations shall be approved by the Engineer prior to the material being hauled to the site.
C. Unsatisfactory Soils: Soil Classification Groups GC, SC, CL, ML, OL, CH, MH, OH, and PT according to ASTM D 2487, or a combination of these groups.
1. Unsatisfactory soils also include satisfactory soils not maintained within 2 percent of optimum moisture content at time of compaction.
2. Review Geotechnical Report included in section 319000 for additional information regarding unsuitable soils present on site.
D. Base Course: Base Course shall conform to CALTRANS Class 2 material requirements (3/4 inch maximum size).
E. Structural Fill: On-site soils or Imported fill material meeting the satisfactory soils requirements. Imported structural fill materials shall be subject to Engineer’s approval prior to being hauled to the site.
F. Bedding Course: 1. Pipe bedding material shall be a graded granular material.
Sieve Size Percentage Passing 3/8-inch 100 No. 4 90-100 No. 50 10-40 No. 100 3-20 No. 200 0-15
2. Clean Concrete Sand (Sand Equivalent SE > 30)
G. Drainage Course: 1. Narrowly graded mixture of washed crushed stone, or crushed gravel; The gradation shall have the following gradation requirements:
Sieve Size Percentage Passing 1-1/2-inch 100 3/4-inch 90-100 3/8-inch 40-100 No. 4 5-40 No. 8 0-5
2.2 CONTROLLED LOW STRENGTH MATERIAL (CLSM)
A. Where indicated in the drawings and when approved by the Engineer, Controlled Low Strength Material (CLSM) may be used as trench backfill, structural backfill, pipe bedding, or pipe
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 3 backfill. CLSM shall consist of Portland cement, aggregates, water and fly ash. Chemical admixtures and other mineral admixtures may be used when approved by the Engineer.
B. The actual mix proportions and flow characteristics shall be determined by the producer of the CLSM to meet jobsite conditions and shall be approved by the Engineer. The mixture shall be workable and non-segregating.
C. The minimum compressive strength, unless noted otherwise shall be 1,200 psi.
2.3 ACCESSORIES
A. Detectable Warning Tape: Acid- and alkali-resistant, polyethylene film warning tape manufactured for marking and identifying underground utilities, a minimum of 6 inches wide and 4 mils thick, continuously inscribed with a description of the utility, with metallic core encased in a protective jacket for corrosion protection, detectable by metal detector when tape is buried up to 30 inches deep; colored to comply with local practice or requirements of authorities having jurisdiction.
PART 3 - EXECUTION
3.1 PREPARATION
A. Protect structures, utilities, sidewalks, pavements, and other facilities from damage caused by settlement, lateral movement, undermining, washout, and other hazards created by earth moving operations.
B. Protect and maintain erosion and sedimentation controls during earth moving operations.
C. Protect subgrades and foundation soils from freezing temperatures and frost. Remove temporary protection before placing subsequent materials.
3.2 CLEARING AND GRUBBING
A. All surface improvements, debris and/or vegetation including grass, trees, and weeds on the site should be removed from the construction area. Root balls shall be completely excavated. Organic stripping shall be hauled off from the site and shall not be used as fill. Any trash, construction debris, concrete slabs, old pavement, landfill, and buried obstructions such as old foundations and utility lines exposed should be traced to the limits of the foreign materials and removed. Any excavations resulting from site clearing and grubbing should be dish-shaped to the lowest depth of disturbance and backfilled with structural fill.
3.3 EXCAVATION, GENERAL
A. Unclassified Excavation: Excavate to subgrade elevations regardless of the character of surface and subsurface conditions encountered. Unclassified excavated materials may include rock, soil materials, and obstructions. No changes in the Contract Sum or the Contract Time will be authorized for rock excavation or removal of obstructions.
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 4 1. If excavated materials intended for fill and backfill include unsatisfactory soil materials and rock, replace with satisfactory soil materials
3.4 EXCAVATION FOR STRUCTURES
A. Excavations shall include the removal of all materials that would interfere with the proper execution of the Work. The removal of said materials shall conform to the lines and grades shown on the plans or ordered by the Engineer. The Contractor shall furnish, place and maintain all supports and shoring that may be required for safety of excavations and protection of adjacent structures and all pumping, ditching or other measures necessary for the removal or exclusion of water, including taking care of storm water, groundwater and wastewater reaching the site of the Work from any source so as to prevent damage to the Work or adjoining property. Excavations shall be sloped or otherwise supported in a safe manner in accordance with applicable State, Federal or local requirements.
1. EXCAVATION FOR BUILDINGS a. Building Pad Preparation Ð The existing surface soil within the building pad area(s) should be removed to 30 inches below the lowest foundation grade or 48 inches below the original grade (whichever) is deeper, extending five feet beyond all exterior wall/column lines (including adjacent concreted areas). The exposed sub-grade should be scarified to a depth of 8 inches, uniformly moisture controlled to +/- 2% of optimum moisture, and re-compacted to at least 90% of ASTM D1557 maximum density.
2. EXCAVATION FOR CONCRETE STRUCTURES a. Concrete Structure Preparation (for structures less than 10 feet deep below existing grade) Ð The existing surface soil within the structure pad areas should be removed to 48 inches below the lowest foundation grade. The exposed sub-grade should be scarified to a depth of 8 inches, uniformly moisture conditioned to +/-2% of optimum moisture, and re-compacted to at least 90% of ASTM D1557 maximum density. b. Concrete Structure Preparation (for structures deeper than 10 feet deep below existing grade) Ð The existing surface soil within the structure pad areas should be removed to the lowest foundation grade. The exposed sub-grade should be scarified to a depth of 8 inches, uniformly moisture conditioned to +/-2% of optimum moisture, and re-compacted to at least 90% of ASTM D1557 maximum density.
3. EXCAVATION FOR AUXILIARY STRUCTURE FOUNDATIONS: a. Auxiliary structures such as free standing or retaining walls shall have the existing soil beneath the structure foundation prepared in the manner recommended for the building pad except the preparation only needs to extend 24 inches below and beyond the footing.
B. Over-excavations ordered by the Engineer that are not shown or specified and the resulting backfill will be paid for under a separate unit price bid item if such bid item has been established, otherwise payment will be made in accordance with a negotiated price. After the required excavation or over-excavation has been completed the exposed surface shall be
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 5 scarified to a depth of 8 inches, brought to optimum moisture content and compacted in accordance with the requirements for the specific structure.
C. The Contractor shall keep separate and stockpile from required excavations all topsoil consisting of the top 8-inches of native material. The Contractor shall place and grade this topsoil material as the top 6-inches on areas requiring landscaping, if applicable, to the extent it remains available.
D. The Contractor shall notify the Engineer of the completion of any structural excavation and shall allow the Engineer at least 24-hours review period before the exposed foundation is scarified and compacted or is covered with any structural backfill materials.
E. The Contractor shall remove and dispose of all satisfactory native excess excavated material at a stockpile site identified in the drawings.
F. Excavate to indicated elevations and dimensions within a tolerance of plus or minus 1 inch. If applicable, extend excavations a sufficient distance from structures for placing and removing concrete formwork, for installing services and other construction, and for inspections.
1. Excavations for Footings and Foundations: Do not disturb bottom of excavation. Excavate by hand to final grade just before placing concrete reinforcement. Trim bottoms to required lines and grades to leave solid base to receive other work.
3.5 EXCAVATION FOR WALKS AND PAVEMENTS
A. Excavate surfaces under walks and pavements to indicated lines, cross sections, elevations, and subgrades.
3.6 EXCAVATION FOR UTILITY TRENCHES
A. All trench excavations should conform to CalOSHA requirements for Type C soil. The contractor is solely responsible for the safety of workers entering trenches. Temporary excavations with depths of 4 feet or less may be cut nearly vertical for short duration. Temporary shall be no steeper than 1.5:1 (H:V). Sandy soil slopes should be kept moist, but not saturated, to reduce the potential of raveling or sloughing.
B. Trench excavations deeper than 4 feet will require shoring or slope inclinations in conformance with CalOSHA regulations for Type C soil. Surcharge loads of stockpiled soil or construction materials should be set back from the top of the slope a minimum distance equal to the height of the slope. All permanent slopes should not be steeper the 3:1 to reduce wind and rain erosion. Protected slopes with ground cover may be as steep as 2:1. However, maintenance with motorized equipment may not be possible at his inclination.
C. Unless otherwise shown or ordered, excavation for pipelines and utilities shall be open-cut trenches. The bottom of the trench shall have a minimum width equal to the outside diameter of the pipe plus 24-inches. Trenches for pipelines smaller than 4 inches shall be excavated uniformly to the grade of the bottom of the pipe. Trenches for pipelines inches and larger, unless otherwise ordered by the Engineer, shall be excavated uniformly to the grade 6-inches below the grade of the outside bottom of the pipe. The over-excavation shall be replaced with
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 6 gravel bedding material as specified herein for the particular type of pipe being installed. The pipe bedding shall be compacted by mechanical means suitable to the Engineer to ninety percent (90%) of relative density. The trench bottom shall be uniformly graded so that each pipe section when first laid will be continually in contact with the bedding along the entire length of the pipe. Where granular backfill under footings encases an underdrain piping system or has a thickness of 18-inches or greater or where shown on the Drawings, a layer of soil stabilization fabric shall be placed under the first horizontal layer of granular backfill. Soil stabilizer fabric shall be Mirafi 500 or equal. The sloping or vertical side slopes shall receive a layer of Mirafi 140 NL or equal.
D. The maximum amount of open trench permitted in any one location shall be the length necessary to accommodate the amount of pipe installed and backfilled in a single day. The Contractor shall make every reasonable effort to backfill all trenches at the end of each day. When this is not possible, barricades with warning lights meeting OSHA requirements shall be provided, set and maintained.
E. All pipeline and utility trench excavations shall be kept reasonably free from excess water during excavation, fine grading, pipe laying, and backfilling operations. Ground water shall be lowered to the extent necessary to keep the trench free from water and the trench bottom stable when the work within the trench is in progress. The Contractor shall provide and maintain at all times during construction ample means and equipment with which to properly and promptly remove and dispose of all water entering the excavation or other parts of the Work whether the water be surface water or underground water. The Contractor shall dispose of the water from the Work site in a suitable manner without damage to adjacent property.
F. When ordered by the Engineer, whether indicated on the Drawings or not, trenches shall be over-excavated beyond the depth shown or specified. Such over-excavation shall be to the depth ordered. The trench shall then be backfilled to the grade required. When the over- excavation ordered by the Engineer is 4-inches or greater below the limits shown, additional payment will be made to the Contractor for that portion of the Work which is located below said 4-inch distance. Said additional payment will be made under separate unit price bid items for over-excavation and bedding if such bid items have been established, otherwise payment will be made in accordance with a negotiated price.
G. The Contractor shall remove and dispose of all excess excavated material off-site.
H. Excavate trenches to indicated gradients, lines, depths, and elevations.
3.7 UNAUTHORIZED EXCAVATION
A. Fill unauthorized excavation under foundations or wall footings with 1,200 psi CLSM.
1. Fill unauthorized excavations under other construction, pipe, or conduit as directed by Engineer.
3.8 STORAGE OF SOIL MATERIALS
A. Stockpile borrow soil materials and excavated satisfactory soil materials without intermixing. Place, grade, and shape stockpiles to drain surface water. Cover to prevent windblown dust.
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 7 1. Stockpile soil materials away from edge of excavations. Do not store within drip line of remaining trees.
3.9 PIPE AND UTILITY TRENCH BACKFILL
A. Place backfill on subgrades free of water, mud, frost, snow, or ice.
B. Place and compact bedding course on trench bottoms and where indicated. Shape bedding course to provide continuous support for bells, joints, and barrels of pipes and for joints, fittings, and bodies of conduits.
C. Trenches under Footings: Encase all piping that passes under footings with concrete, as detailed in the drawings. Where the depth from the bottom of the footing to the top of the encasement is less than the required depth of drainage course, the area shall be filled with concrete. Where the depth from the bottom of the footing to the top of the encasement is greater than the required depth of drainage course, the area shall be filled with structural fill and drainage course as required herein.
D. Place and compact initial backfill as required in the Specifications.
1. Backfill material shall not be dropped directly on the pipe or utility conduit.
2. Carefully compact initial backfill under pipe haunches and compact evenly up on both sides and along the full length of piping or conduit to avoid damage or displacement of piping or conduit. Coordinate backfilling with utilities testing.
E. Place and compact final backfill as required in the Specifications to final subgrade elevation.
F. Install warning tape directly above utilities, 12 inches below finished grade, except 6 inches below subgrade under pavements and slabs.
G. Pipe-zone and utility trench backfill material shall be spread and compacted in layers not to exceed 6-inches in thickness. Compaction shall be achieved using mechanical equipment. Flooding, ponding or jetting shall not be used for compaction unless otherwise approved by the Engineer. Pipe zone backfill material shall be manually spread around the pipe so that when compacted the pipe zone backfill will provide uniform bearing and side support. Piping shall be protected from lateral displacement and possible damage resulting from impact or unbalanced loading during backfill operations. Trench zone backfill material shall be uniformly spread and mechanically compacted in layers not to exceed 12-inches in thickness. Moisture content shall be uniformly adjusted by wetting or drying as necessary.
H. Pipe zone including bedding compaction requirements shall be ninety-five percent (95%) of maximum density (ASTM D 1557).
I. Trench zone backfill using required excavated material shall be not less than eighty-five (85%) of maximum density except under paved areas, sidewalks, pipelines, utilities and structures which shall not be less than ninety-five percent (95%) of maximum density.
J. Aggregate base course materials shall be placed and compacted to not less than ninety-five percent (95%) of maximum density.
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 8 3.10 SOIL FILL
A. Plow, scarify, bench, or break up sloped surfaces steeper than 1 vertical to 4 horizontal so fill material will bond with existing material.
B. Place and compact fill material in layers to required elevations using satisfactory native material or approved imported fill material.
3.11 SOIL MOISTURE CONTROL
A. Uniformly moisten or aerate subgrade and each subsequent fill or backfill soil layer before compaction to moisture content indicated in the Geotechnical report.
1. Do not place backfill or fill soil material on surfaces that are muddy, frozen, or contain frost or ice. 2. Remove and replace, or scarify and air dry, otherwise satisfactory soil material that exceeds optimum moisture content and is too wet to compact to specified dry unit weight.
3.12 COMPACTION OF SOIL BACKFILLS AND FILLS UNDER STRUCUTRES
A. Place backfill and fill soil materials in layers not more than 8 inches in loose depth for material compacted by heavy compaction equipment, and not more than 4 inches in loose depth for material compacted by hand-operated tampers.
B. Place backfill and fill soil materials evenly on all sides of structures to required elevations, and uniformly along the full length of each structure.
C. Compact soil materials to not less than the percentages of maximum dry unit weight shown in section 3.4 and according to ASTM D 1557 and in accordance with Geotechnical report requirements and recommendations.
D. Backfill shall not be dropped directly on or against any structure. Backfill shall not be placed around or upon any structure until the concrete has attained the required strength to support the loads imposed. Backfill around water retaining structures shall not be placed until the structures have been tested for leaks and the structures are full of water while the backfill is being placed.
E. Equipment weighing more than 10,000 pounds shall not be used closer to walls than a horizontal distance equal to the depth of the fill at that time. Hand operated power compaction equipment shall be used where use of heavier equipment is impractical or restricted due to weight limitations or may cause damage to the structure.
3.13 GRADING
A. General: Uniformly grade areas to a smooth surface, free of irregular surface changes. Comply with compaction requirements and grade to cross sections, lines, and elevations indicated.
B. Site Rough Grading: Slope grades to direct water away from buildings and to prevent ponding. Finish subgrades to required elevations within the following tolerances:
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 9 1. Turf or Unpaved Areas: Plus or minus 1 inch. 2. Walks: Plus or minus 1 inch. 3. Pavements: Plus or minus 1/2 inch.
C. Grading inside Building Lines: Finish subgrade to a tolerance of 1/2 inch when tested with a 10-foot straightedge.
3.14 BASE COURSES UNDER PAVEMENTS AND WALKS
A. Place subbase course and base course on subgrades free of mud, frost, snow, or ice.
B. On prepared subgrade, place base course under pavements and walks as follows:
1. Shape base course to required crown elevations and cross-slope grades. 2. Place base course that exceeds 6 inches in compacted thickness in layers of equal thickness, with no compacted layer more than 6 inches thick or less than 3 inches thick. 3. Compact base course at optimum moisture content to required grades, lines, cross sections, and thickness to not less than 95 percent of maximum dry unit weight according to ASTM D 1557.
3.15 DRAINAGE COURSE UNDER CONCRETE SLABS-ON-GRADE
A. Place drainage course on subgrades free of mud, frost, snow, or ice.
B. On prepared subgrade, place and compact drainage course under cast-in-place concrete slabs- on-grade as follows:
1. Place drainage course that exceeds 6 inches in compacted thickness in layers of equal thickness, with no compacted layer more than 6 inches thick or less than 3 inches thick. 2. Compact each layer of drainage course by rolling it multiple times with a vibratory compactor. Final compaction to be inspected by the engineer prior to commencement of work.
3.16 FIELD QUALITY CONTROL
A. Testing Agency: Owner will engage a qualified geotechnical engineering testing agency to perform tests and inspections.
B. Allow testing agency to inspect and test subgrades and each fill or backfill layer. Proceed with subsequent earth moving only after test results for previously completed work comply with requirements.
C. Footing Subgrade: At footing subgrades, at least one test of each soil stratum will be performed to verify design bearing capacities. Subsequent verification and approval of other footing subgrades may be based on a visual comparison of subgrade with tested subgrade when approved by Engineer.
WRCRWA EARTH MOVING PLANT EXPANSION PROJECT 312000 - 10 D. When testing agency reports that subgrades, fills, or backfills have not achieved degree of compaction specified, scarify and moisten or aerate, or remove and replace soil materials to depth required; recompact and retest until specified compaction is obtained.
3.17 PROTECTION
A. Protecting Graded Areas: Protect newly graded areas from traffic, freezing, and erosion. Keep free of trash and debris.
B. Repair and reestablish grades to specified tolerances where completed or partially completed surfaces become eroded, rutted, settled, or where they lose compaction due to subsequent construction operations or weather conditions.
C. Where settling occurs before Project correction period elapses, remove finished surfacing, backfill with additional soil material, compact, and reconstruct surfacing.
1. Restore appearance, quality, and condition of finished surfacing to match adjacent work, and eliminate evidence of restoration to greatest extent possible.
3.18 DISPOSAL OF SURPLUS AND WASTE MATERIALS
A. Remove surplus satisfactory soil and waste materials, including unsatisfactory soil, trash, and debris, and legally dispose of them off Owner's property at the Contractor’s expense.
3.19 DEWATERING
A. Prevent surface water and subsurface or ground water from flowing into trenches and excavations and from flooding project site and surrounding area.
1. Do not allow water to accumulate in excavations. Remove water to prevent softening of foundation bottoms, undercutting footings, and soil changes detrimental to stability of subgrades and foundations. Provide and maintain pumps, well point, sumps, suction and discharge lines, and other dewatering system components necessary to convey water away from excavations.
2. Establish and maintain temporary drainage ditches and other diversions outside excavation limits to convey rainwater and water removed from excavations to collecting or runoff areas. Do not use trench excavations as temporary drainage ditches.
END OF SECTION 312000
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SECTION 312319 - DEWATERING
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes construction dewatering.
1.2 PREINSTALLATION MEETINGS
A. Preinstallation Conference: Conduct conference at Project site.
PART 2 - PRODUCTS
2.1 PERFORMANCE REQUIREMENTS
A. Dewatering Performance: Design, furnish, install, test, operate, monitor, and maintain dewatering system of sufficient scope, size, and capacity to control hydrostatic pressures and to lower, control, remove, and dispose of ground water and permit excavation and construction to proceed on dry, stable subgrades.
PART 3 - EXECUTION
3.1 PREPARATION
A. Provide temporary grading to facilitate dewatering and control of surface water.
B. Protect and maintain temporary erosion and sedimentation controls, which are specified in Section 015000 "Temporary Facilities and Controls," Section 311000 "Site Clearing," during dewatering operations.
3.2 INSTALLATION
A. Install dewatering system utilizing wells, well points, or similar methods complete with pump equipment, standby power and pumps, filter material gradation, valves, appurtenances, water disposal, and surface-water controls.
1. Space well points or wells at intervals required to provide sufficient dewatering. 2. Use filters or other means to prevent pumping of fine sands or silts from the subsurface.
B. Place dewatering system into operation to lower water to specified levels before excavating below ground-water level.
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C. Provide standby equipment on-site, installed and available for immediate operation, to maintain dewatering on continuous basis if any part of system becomes inadequate or fails.
3.3 OPERATION
A. Operate system continuously until drains, sewers, and structures have been constructed and fill materials have been placed or until dewatering is no longer required.
B. Operate system to lower and control ground water to permit excavation, construction of structures, and placement of fill materials on dry subgrades. Drain water-bearing strata above and below bottom of foundations, drains, sewers, and other excavations.
1. Do not permit open-sump pumping that leads to loss of fines, soil piping, subgrade softening, and slope instability. 2. Reduce hydrostatic head in water-bearing strata below subgrade elevations of foundations, drains, sewers, and other excavations. 3. Maintain piezometric water level a minimum of 24 inches below bottom of excavation.
C. Remove dewatering system from Project site on completion of dewatering. Plug or fill well holes with sand or cut off and cap wells a minimum of 36 inches below overlying construction.
3.4 FIELD QUALITY CONTROL
A. Survey-Work Benchmarks: Resurvey benchmarks regularly during dewatering and maintain an accurate log of surveyed elevations for comparison with original elevations. Promptly notify Engineer if changes in elevations occur or if cracks, sags, or other damage is evident in adjacent construction.
END OF SECTION 312319
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SECTION 315000 - EXCAVATION SUPPORT AND PROTECTION
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes temporary excavation support and protection systems.
1.2 PREINSTALLATION MEETINGS
A. Preinstallation Conference: Conduct conference at Project site.
1.3 INFORMATIONAL SUBMITTALS
A. Contractor Calculations: For excavation support and protection system. Include analysis data signed and sealed by the qualified professional engineer responsible for their preparation.
B. Record Drawings: Identify locations and depths of capped utilities, abandoned-in-place support and protection systems, and other subsurface structural, electrical, or mechanical conditions.
PART 2 - PRODUCTS
2.1 PERFORMANCE REQUIREMENTS
A. Provide, design, monitor, and maintain excavation support and protection system capable of supporting excavation sidewalls and of resisting earth and hydrostatic pressures and superimposed and construction loads.
1. Design excavation support and protection system, including comprehensive engineering analysis by a qualified professional engineer.
PART 3 - EXECUTION
3.1 SOLDIER PILES AND LAGGING
A. Install steel soldier piles before starting excavation. Extend soldier piles below excavation grade level to depths adequate to prevent lateral movement. Space soldier piles at regular intervals not to exceed allowable flexural strength of wood lagging. Accurately align exposed faces of flanges to vary not more than 2 inches from a horizontal line and not more than 1:120 out of vertical alignment.
B. Install wood lagging within flanges of soldier piles as excavation proceeds. Trim excavation as required to install lagging. Fill voids behind lagging with soil, and compact.
WRCRWA EXCAVATION SUPPORT AND PROTECTION PLANT EXPANSION PROJECT 315000 - 1 3.2 SHEET PILING
A. Before starting excavation, install one-piece sheet piling lengths and tightly interlock vertical edges to form a continuous barrier.
B. Accurately place the piling, using templates and guide frames unless otherwise recommended in writing by the sheet piling manufacturer. Limit vertical offset of adjacent sheet piling to 60 inches. Accurately align exposed faces of sheet piling to vary not more than 2 inches from a horizontal line and not more than 1:120 out of vertical alignment.
C. Cut tops of sheet piling to uniform elevation at top of excavation.
3.3 TIEBACKS
A. Drill, install, grout, and tension tiebacks.
B. Test load-carrying capacity of each tieback and replace and retest deficient tiebacks.
1. Have test loading observed by a qualified professional engineer responsible for design of excavation support and protection system.
C. Maintain tiebacks in place until permanent construction is able to withstand lateral earth and hydrostatic pressures.
3.4 BRACING
A. Bracing: Locate bracing to clear columns, floor framing construction, and other permanent work. If necessary to move brace, install new bracing before removing original brace.
1. Do not place bracing where it will be cast into or included in permanent concrete work unless otherwise approved by Engineer. 2. Install internal bracing if required to prevent spreading or distortion of braced frames. 3. Maintain bracing until structural elements are supported by other bracing or until permanent construction is able to withstand lateral earth and hydrostatic pressures.
3.5 REMOVAL AND REPAIRS
A. Remove excavation support and protection systems when construction has progressed sufficiently to support excavation and earth and hydrostatic pressures. Remove in stages to avoid disturbing underlying soils and rock or damaging structures, pavements, facilities, and utilities.
1. Remove excavation support and protection systems to a minimum depth of 48 inches below overlying construction and abandon remainder.
END OF SECTION 315000
WRCRWA EXCAVATION SUPPORT AND PROTECTION PLANT EXPANSION PROJECT 315000 - 2 SECTION 319000 – GEOTECHNICAL REPORT
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes the Geotechnical Report prepared for this project.
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END OF SECTION 319000
WRCRWA GEOTECHNICAL REPORT PLANT EXPANSION PROJECT 319000 - 82 SECTION 321216 - ASPHALT PAVING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Cold milling of existing asphalt pavement. 2. Hot-mix asphalt patching. 3. Hot-mix asphalt paving. 4. Hot-mix asphalt overlay. 5. Asphalt curbs.
B. Related Requirements:
1. Section 312000 "Earth Moving" for subgrade preparation, fill material, unbound- aggregate subbase and base courses, and aggregate pavement shoulders.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product.
1.3 INFORMATIONAL SUBMITTALS
A. Material Certificates: For each paving material.
1.4 QUALITY ASSURANCE
A. Manufacturer Qualifications: A paving-mix manufacturer registered with and approved by authorities having jurisdiction or the DOT of state in which Project is located.
B. Regulatory Requirements: Comply with materials, workmanship, and other applicable requirements of the local standards where the project is located for asphalt paving work.
1. Measurement and payment provisions and safety program submittals included in standard specifications do not apply to this Section.
PART 2 - PRODUCTS
2.1 DESIGN REQUIREMENTS
A. Design of the asphalt shall meet all requirements as shown in Section 319000, “Geotechnical Report,” with a Traffic Index of 7.
WRCRWA ASPHALT PAVING PLANT EXPANSION PROJECT 321216 - 1 2.2 AGGREGATES
A. Coarse Aggregate: ASTM D 692/D 692M, sound; angular crushed stone, crushed gravel, or cured, crushed blast-furnace slag.
B. Fine Aggregate: ASTM D 1073, sharp-edged natural sand or sand prepared from stone, gravel, cured blast-furnace slag, or combinations thereof.
C. Mineral Filler: ASTM D 242/D 242M, rock or slag dust, hydraulic cement, or other inert material.
2.3 ASPHALT MATERIALS
A. Asphalt Binder: AASHTO M 320.
B. Tack Coat: ASTM D 977 or AASHTO M 140 emulsified asphalt, or ASTM D 2397 or AASHTO M 208 cationic emulsified asphalt, slow setting, diluted in water, of suitable grade and consistency for application.
2.4 MIXES
A. Hot-Mix Asphalt: Dense-graded, hot-laid, hot-mix asphalt plant mixes approved by authorities having jurisdiction and complying with the following requirements:
1. Provide mixes with a history of satisfactory performance in geographical area where Project is located. 2. Base Course: Materials for aggregate base shall be as specified in the Geotechnical Report. Aggregate base shall be provided where shown and to the thickness shown. Imported aggregate bases shall be delivered to the job site as uniform mixtures and each layer shall be spread in one operation. Segregation shall be avoided and the base shall be free of pockets of coarse or fine material. The base material shall be spread and compacted in layers of equal thickness and the maximum compacted thickness of any one layer shall not exceed 6-inches. The relative compaction of each layer of aggregate base shall not be less than ninety-five percent (95%) of maximum density when measured in accordance with ASTM D 1557. The compacted surface of the finished aggregate shall be hard, uniform, and smooth to grade.
PART 3 - EXECUTION
3.1 COLD MILLING
A. Clean existing pavement surface of loose and deleterious material immediately before cold milling. Remove existing asphalt pavement by cold milling to grades and cross sections indicated.
1. Mill to a depth of 3 inches. 2. Patch surface depressions deeper than 1 inch after milling, before wearing course is laid.
WRCRWA ASPHALT PAVING PLANT EXPANSION PROJECT 321216 - 2 3.2 PATCHING
A. Asphalt Pavement: Saw cut perimeter of patch and excavate existing pavement section to sound base. Excavate rectangular or trapezoidal patches, extending 12 inches into perimeter of adjacent sound pavement, unless otherwise indicated. Cut excavation faces vertically. Remove excavated material. Recompact existing unbound-aggregate base course to form new subgrade.
B. Portland Cement Concrete Pavement: Break cracked slabs and roll as required to reseat concrete pieces firmly.
1. Remove disintegrated or badly cracked pavement. Excavate rectangular or trapezoidal patches, extending into perimeter of adjacent sound pavement, unless otherwise indicated. Cut excavation faces vertically. Recompact existing unbound-aggregate base course to form new subgrade.
C. Tack Coat: Before placing patch material, apply tack coat uniformly to vertical asphalt surfaces abutting the patch. Apply at a rate of 0.05 to 0.15 gal./sq. yd..
1. Allow tack coat to cure undisturbed before applying hot-mix asphalt paving. 2. Avoid smearing or staining adjoining surfaces, appurtenances, and surroundings. Remove spillages and clean affected surfaces.
D. Placing Patch Material: Fill excavated pavement areas with hot-mix asphalt base mix for full thickness of patch and, while still hot, compact flush with adjacent surface.
3.3 SURFACE PREPARATION
A. General: Immediately before placing asphalt materials, remove loose and deleterious material from substrate surfaces. Ensure that prepared subgrade is ready to receive paving.
B. Proof-roll subgrade below pavements with heavy pneumatic-tired equipment to identify soft pockets and areas of excess yielding. Do not proof-roll wet or saturated subgrades. Any soft pockets shall be repaired.
C. Herbicide Treatment: Apply herbicide according to manufacturer's recommended rates and written application instructions. Apply to dry, prepared subgrade or surface of compacted- aggregate base before applying paving materials.
D. Tack Coat: Apply uniformly to surfaces of existing pavement at a rate of 0.05 to 0.15 gal./sq. yd.
1. Allow tack coat to cure undisturbed before applying hot-mix asphalt paving. 2. Avoid smearing or staining adjoining surfaces, appurtenances, and surroundings. Remove spillages and clean affected surfaces.
3.4 PLACING HOT-MIX ASPHALT
A. Machine place hot-mix asphalt on prepared surface, spread uniformly, and strike off. Place asphalt mix by hand in areas inaccessible to equipment in a manner that prevents segregation of mix. Place each course to required grade, cross section, and thickness when compacted.
WRCRWA ASPHALT PAVING PLANT EXPANSION PROJECT 321216 - 3 1. Spread mix at a minimum temperature of 250 deg F. 2. Regulate paver machine speed to obtain smooth, continuous surface free of pulls and tears in asphalt-paving mat.
B. Asphalt concrete shall not be placed when the atmospheric temperature is below 40 degrees F, or during unsuitable weather as determined by the Engineer.
C. Place paving in consecutive strips not less than 10 feet wide unless infill edge strips of a lesser width are required.
D. Promptly correct surface irregularities in paving course behind paver. Use suitable hand tools to remove excess material forming high spots. Fill depressions with hot-mix asphalt to prevent segregation of mix; use suitable hand tools to smooth surface.
3.5 JOINTS
A. Construct joints to ensure a continuous bond between adjoining paving sections. Construct joints free of depressions, with same texture and smoothness as other sections of hot-mix asphalt course.
1. Clean contact surfaces and apply tack coat to joints. 2. Offset longitudinal joints, in successive courses, a minimum of 6 inches. 3. Offset transverse joints, in successive courses, a minimum of 24 inches. 4. Construct transverse joints at each point where paver ends a day's work and resumes work at a subsequent time. Construct these joints using either "bulkhead" or "papered" method according to AI MS-22, for both "Ending a Lane" and "Resumption of Paving Operations."
3.6 COMPACTION
A. General: Begin compaction as soon as placed hot-mix paving will bear roller weight without excessive displacement. Compact hot-mix paving with hot, hand tampers or with vibratory- plate compactors in areas inaccessible to rollers.
1. Complete compaction before mix temperature cools to 185 deg F.
B. Breakdown Rolling: Complete breakdown or initial rolling immediately after rolling joints and outside edge. Examine surface immediately after breakdown rolling for indicated crown, grade, and smoothness. Correct laydown and rolling operations to comply with requirements.
C. Intermediate Rolling: Begin intermediate rolling immediately after breakdown rolling while hot-mix asphalt is still hot enough to achieve specified density. Continue rolling until hot-mix asphalt course has been uniformly compacted to the following density:
1. Average Density: 95 percent of reference maximum theoretical density according to ASTM D 2041.
D. Finish Rolling: Finish roll paved surfaces to remove roller marks while hot-mix asphalt is still warm.
WRCRWA ASPHALT PAVING PLANT EXPANSION PROJECT 321216 - 4 E. Edge Shaping: While surface is being compacted and finished, trim edges of pavement to proper alignment. Bevel edges while asphalt is still hot; compact thoroughly.
F. Protection: After final rolling, do not permit vehicular traffic on pavement until it has cooled and hardened.
G. Erect barricades to protect paving from traffic until mixture has cooled enough not to become marked.
3.7 ASPHALT CURBS
A. Construct hot-mix asphalt curbs over compacted pavement surfaces. Apply a light tack coat unless pavement surface is still tacky and free from dust. Spread mix at a minimum temperature of 250 deg F.
1. Asphalt Mix: Same as pavement surface-course mix.
B. Place hot-mix asphalt to curb cross section indicated or, if not indicated, to local standard shapes, by machine or by hand in wood or metal forms. Tamp hand-placed materials and screed to smooth finish. Remove forms after hot-mix asphalt has cooled.
3.8 INSTALLATION TOLERANCES
A. Pavement Thickness: Compact each course to produce the thickness indicated within the following tolerances:
1. Base Course: Plus or minus 1/2 inch. 2. Surface Course: Plus 1/4 inch, no minus.
B. Pavement Surface Smoothness: Compact each course to produce a surface smoothness within the following tolerances as determined by using a 10-foot straightedge applied transversely or longitudinally to paved areas:
1. Base Course: 1/4 inch. 2. Surface Course: 1/8 inch. 3. Crowned Surfaces: Test with crowned template centered and at right angle to crown. Maximum allowable variance from template is 1/4 inch.
3.9 FIELD QUALITY CONTROL
A. Testing Agency: Owner will engage a qualified testing agency to perform tests and inspections.
B. Replace and compact hot-mix asphalt where core tests were taken.
C. Remove and replace or install additional hot-mix asphalt where test results or measurements indicate that it does not comply with specified requirements.
WRCRWA ASPHALT PAVING PLANT EXPANSION PROJECT 321216 - 5 3.10 WASTE HANDLING
A. General: Handle asphalt-paving waste according to approved waste management plan required in Section 017419 "Construction Waste Management and Disposal."
END OF SECTION 321216
WRCRWA ASPHALT PAVING PLANT EXPANSION PROJECT 321216 - 6 SECTION 321313 - CONCRETE PAVING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: 1. Curbs and gutters. 2. Cross gutters. 3. Walks.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Cast-In-Place Concrete. Section 033000
B. Joints In Concrete. Section 032900
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.4 QUALITY ASSURANCE
A. Ready-Mix-Concrete Manufacturer Qualifications: A firm experienced in manufacturing ready- mixed concrete products and that complies with ASTM C 94/C 94M requirements for production facilities and equipment.
B. ACI Publications: Comply with ACI 301 unless otherwise indicated.
1.5 PRECONSTRUCTION TESTING
A. Preconstruction Testing Service: Engage a qualified independent testing agency to perform preconstruction testing on concrete paving mixtures.
PART 2 - PRODUCTS
2.1 STEEL REINFORCEMENT
A. Plain-Steel Welded Wire Reinforcement: ASTM A 185/A 185M, fabricated from as-drawn steel wire into flat sheets.
B. Deformed-Steel Welded Wire Reinforcement: ASTM A 497/A 497M, flat sheet.
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 1 C. Reinforcing Bars: ASTM A 615/A 615M, Grade 60; deformed.
D. Plain-Steel Wire: ASTM A 82/A 82M, as drawn.
E. Deformed-Steel Wire: ASTM A 496/A 496M.
F. Dowel Bars: ASTM A 615/A 615M, Grade 60 plain-steel bars. Cut bars true to length with ends square and free of burrs.
G. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars, welded wire reinforcement, and dowels in place. Manufacture bar supports according to CRSI's "Manual of Standard Practice" from steel wire, plastic, or precast concrete of greater compressive strength than concrete specified.
2.2 CONCRETE MATERIALS
A. Cementitious Material: Use the following cementitious materials, of same type, brand, and source throughout Project, see Section 033000 “Cast-in-Place Concrete”.
B. Normal-Weight Aggregates: ASTM C 33, uniformly graded. Provide aggregates from a single source.
C. Water: Potable and complying with ASTM C 94/C 94M.
D. Air-Entraining Admixture: All concrete shall contain five percent (5%), plus or minus one percent (1%) entrained air of evenly dispersed air bubbles at the time of placement. The air- entraining agent shall contain no chloride and conform to ASTM C 260, or U.S. Army Corps of Engineers Specifications CRD-C13. The air-entraining agent shall be added to the batch in a portion of the mixing water. The solution shall be batched by means of a mechanical batcher capable of accurate measurement. The Engineer, or Owner and his duly authorized representatives reserve the right, at any time, to sample and test the air-entraining agent or the air content of concrete received on the job by the Contractor. Air entrainment in the concrete shall be tested by ASTM C 138, ASTM C 231 or ASTM C 173. If any sample tested does not have the specified air content, a second test shall be performed. If the second test does not meet the specified air content, the concrete represented by the test shall be removed from the job.
E. Chemical Admixtures: Admixtures certified by manufacturer to be compatible with other admixtures and to contain not more than 0.1 percent water-soluble chloride ions by mass of cementitious material.
F. Water: Complying with ASTM C 94/C 94M.
2.3 CURING MATERIALS
A. Absorptive Cover: AASHTO M 182.
B. Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-polyethylene sheet.
C. Water: Potable.
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 2 D. Evaporation Retarder: Waterborne, monomolecular, film forming, manufactured for application to fresh concrete.
E. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1, Class B, dissipating.
F. White, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 2, Class B, dissipating.
2.4 RELATED MATERIALS
A. Joint Fillers: ASTM D 1752, cork or self-expanding cork in preformed strips.
2.5 PAVEMENT MARKINGS
A. Pavement-Marking Paint: Latex, waterborne emulsion, lead and chromate free, ready mixed, complying with FS TT-P-1952, Type II, with drying time of less than 45 minutes.
1. Color: As indicated.
B. Pavement-Marking Paint: MPI #97 Latex Traffic Marking Paint.
1. Color: As indicated.
2.6 WHEEL STOPS
A. Wheel Stops: Precast, air-entrained concrete.
1. Color: Gray. 2. Dowels: Galvanized steel, 3/4 inch in diameter, 10-inch minimum length. 3. Adhesive: As recommended by wheel stop manufacturer for application to concrete pavement.
2.7 CONCRETE MIXTURES
A. Prepare design mixtures, proportioned according to ACI 301, with the following properties:
1. Compressive Strength (28 Days): 4000 psi. 2. Maximum Water-Cementitious Materials Ratio at Point of Placement: 0.50. 3. Slump Limit: 3-inches, plus ½-inches or minus 1 inch. 4. Air Content: 5 percent plus or minus 1.0 percent.
B. Chemical Admixtures: Use admixtures according to manufacturer's written instructions.
C. Synthetic Fiber: Uniformly disperse in concrete mixture at manufacturer's recommended rate.
D. Color Pigment: Add color pigment to concrete mixture according to manufacturer's written instructions.
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 3 2.8 CONCRETE MIXING
A. Ready-Mixed Concrete: Measure, batch, and mix concrete materials and concrete according to ASTM C 94/C 94M. Furnish batch certificates for each batch discharged and used in the Work.
PART 3 - EXECUTION
3.1 EXAMINATION AND SURFACE PREPARATION
A. Proof-roll prepared subbase surface below concrete paving to identify soft pockets and areas of excess yielding.
B. Remove loose material from compacted subbase surface immediately before placing concrete.
3.2 EDGE FORMS AND SCREED CONSTRUCTION
A. Set, brace, and secure edge forms, bulkheads, and intermediate screed guides to required lines, grades, and elevations. Install forms to allow continuous progress of work and so forms can remain in place at least 24 hours after concrete placement.
B. Clean forms after each use and coat with form-release agent to ensure separation from concrete without damage.
3.3 STEEL REINFORCEMENT
A. General: Comply with CRSI's "Manual of Standard Practice" for fabricating, placing, and supporting reinforcement.
3.4 JOINTS
A. General: Form construction, isolation, and contraction joints and tool edges true to line, with faces perpendicular to surface plane of concrete. Construct transverse joints at right angles to centerline unless otherwise indicated.
B. Construction Joints: Set construction joints at side and end terminations of paving and at locations where paving operations are stopped for more than one-half hour unless paving terminates at isolation joints.
C. Isolation Joints: Form isolation joints of preformed joint-filler strips abutting concrete curbs, catch basins, manholes, inlets, structures, other fixed objects, and where indicated.
D. Contraction Joints: Form weakened-plane contraction joints, sectioning concrete into areas as indicated. Construct contraction joints for a depth equal to at least one-fourth of the concrete thickness, to match jointing of existing adjacent concrete paving:
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 4 E. Edging: After initial floating, tool edges of paving, gutters, curbs, and joints in concrete with an edging tool to a 1/4-inch radius. Repeat tooling of edges after applying surface finishes. Eliminate edging-tool marks on concrete surfaces.
3.5 CONCRETE PLACEMENT
A. Moisten subbase to provide a uniform dampened condition at time concrete is placed. Do not place concrete around manholes or other structures until they are at required finish elevation and alignment.
B. Comply with ACI 301 (ACI 301M) requirements for measuring, mixing, transporting, and placing concrete.
C. Deposit and spread concrete in a continuous operation between transverse joints. Do not push or drag concrete into place or use vibrators to move concrete into place.
D. Screed paving surface with a straightedge and strike off.
E. Commence initial floating using bull floats or darbies to impart an open-textured and uniform surface plane before excess moisture or bleedwater appears on the surface. Do not further disturb concrete surfaces before beginning finishing operations or spreading surface treatments.
3.6 FLOAT FINISHING
A. General: Do not add water to concrete surfaces during finishing operations.
B. Float Finish: Begin the second floating operation when bleed-water sheen has disappeared and concrete surface has stiffened sufficiently to permit operations. Float surface with power-driven floats or by hand floating if area is small or inaccessible to power units. Finish surfaces to true planes. Cut down high spots and fill low spots. Refloat surface immediately to uniform granular texture. 1. Medium-to-Fine-Textured Broom Finish: Draw a soft-bristle broom across float-finished concrete surface perpendicular to line of traffic to provide a uniform, fine-line texture.
3.7 CURING AND DAMP-PROOFING
A. General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures.
B. Evaporation Retarder: Apply evaporation retarder to concrete surfaces if hot, dry, or windy conditions cause moisture loss approaching 0.2 lb/sq. ft. x h before and during finishing operations. Apply according to manufacturer's written instructions after placing, screeding, and bull floating or darbying concrete but before float finishing.
C. Begin curing after finishing concrete but not before free water has disappeared from concrete surface.
D. Curing Methods: Cure concrete by moisture curing, moisture-retaining-cover curing, curing compound, or a combination of these.
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 5 3.8 CURING IN COLD WEATHER
A. Comply with ACI 306.1 for cold-weather protection.
3.9 PAVING TOLERANCES
A. Comply with tolerances in ACI 117 and as follows:
1. Elevation: 3/4 inch. 2. Thickness: Plus 3/8 inch, minus 1/4 inch. 3. Surface: Gap below 10-foot- long, unleveled straightedge not to exceed 1/2 inch. 4. Joint Spacing: 3 inches. 5. Contraction Joint Depth: Plus 1/4 inch, no minus. 6. Joint Width: Plus 1/8 inch, no minus.
3.10 PAVEMENT MARKING
A. Allow concrete paving to cure for a minimum of fourteen (14) days and be dry before starting pavement marking.
B. Sweep and clean surface to eliminate loose material and dust.
C. Apply paint with mechanical equipment to produce markings of dimensions indicated with uniform, straight edges. Apply at manufacturer's recommended rates to provide a minimum wet film thickness of 15 mils.
3.11 WHEEL STOPS
A. Install wheel stops in bed of adhesive applied as recommended by manufacturer.
B. Securely attach wheel stops to paving with not less than two steel dowels located at one-quarter to one-third points. Install dowels in drilled holes in the paving and bond dowels to wheel stop. Recess head of dowel beneath top of wheel stop.
3.12 REPAIRS AND PROTECTION
A. Remove and replace concrete paving that is broken, damaged, or defective or that does not comply with requirements in this Section. Remove work in complete sections from joint to joint unless otherwise approved by Engineer.
B. The repair of holes left by rock pockets, penetrations, tie rods or other reasons will require the use of non-shrink, non-metallic grout metal.
C. Protect concrete paving from damage. Exclude traffic from paving for at least 14 days after placement. When construction traffic is permitted, maintain paving as clean as possible by removing surface stains and spillage of materials as they occur.
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 6 D. Maintain concrete paving free of stains, discoloration, dirt, and other foreign material. Sweep paving not more than two days before date scheduled for Substantial Completion inspections.
END OF SECTION 321313
WRCRWA CONCRETE PAVING PLANT EXPANSION PROJECT 321313 - 7 SECTION 323113 - CHAIN LINK FENCES AND GATES
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes: 1. Fence, framework, fabric, and accessories. 2. Excavation for post bases and concrete foundations for posts. 3. Manual gates and related hardware.
B. Description: 1. All work on the project will take place on the perimeter of the existing site and will include replacing and connecting into existing fencing. New fencing shall match existing fencing in size, type and materials of construction.
1.2 REFERNCES
A. ASTM A36 Standard Specification for Carbon Structural Steel
B. ASTM A121 Standard Specification for Metallic-Coated Carbon Steel Barbed Wire
C. ASTM A 123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel products.
D. ASTM A 153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel products.
E. ASTM A392 Standard Specification for Zinc-Coated Steel Chain-Link Fabric
F. ASTM A780 Standard Practice for Repair of Damaged and Uncoated Areas of Hot-dip Galvanized Coatings
G. ASTM A817 Standard Specification for Metallic-Coated Steel Wire for Chain Link Fence Fabric and Marcelled Tension Wire
H. ASTM A824 Standard Specification for Metallic-Coated Steel Marcelled Tension Wire for Use With Chain Link
I. ASTM B221 Standard Specification for Aluminum and Aluminum Alloy Bars, Rods, Wire Profiles and Tubes
J. ASTM F552 Standard Terminology Relating to Chain Link Fencing
K. ASTM F567 Standard Practice for Installation of Chain Link Fence
L. ASTM F626 Standard Specification for Fence Fittings
M. ASTM F900 Standard Specification for Industrial and Commercial Swing Gates
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 1 N. ASTM F1043 Standard Specification for Strength and Protective Coatings on Steel Industrial Chain Link Fence Framework
O. ASTM F1083 Standard Specification for Pipe, Steel, Hot-Dipped Zinc-Coated (Galvanized) Welded, for Fence Structures
P. ASTM F1184 Standard Specification for Industrial and Commercial Horizontal Slide Gates
Q. ASTM F1910 Standard Specification for Long Barbed Tape Obstacles
R. ASTM F1911 Standard Practice for Installation of Barbed Tape
1.3 PERFORMANCE REQUIRMENTS
A. Delegated Design: Design chain-link fences and gates, including comprehensive engineering analysis by a qualified professional engineer.
B. Structural Performance: Chain-link fence and gate framework shall with stand the effects of gravity and wind loads in accordance with ASCE 7.
1. Minimum post size: Determine according to ASTM F1043 for framework up to 12 feet high, and post sizing not to exceed 10 feet.
1.4 ACTION SUBMITTALS
A. Product Data: For each type of product indicated
B. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work.
C. Samples: Provide for privacy slats.
D. Delegated-Design Submittal: For chain-link fences and gate framework provide wind loading analysis data in accordance with ASCE 7 signed and sealed by the qualified professional engineer responsible for their preparation.
1.5 INFORMATIONAL SUBMITTALS
A. Product Certificates: For each type of chain-link fence and gate, from manufacturer.
B. Product Test Reports: For framing strength according to ASTM F 1043.
C. Sample of special warranty.
1.6 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 2 1.7 QUALITY ASSURANCE
A. Manufacturer: Company having a minimum 5 years of experience specializing in manufacturing of chain link fence products.
B. Fence Contractor: Contractor having 5 years of experience installing similar projects in accordance with ASTM F567.
1.8 DELIVERY, STORAGE, AND HANDLING
A. Storage and handling: Unload, store, and protect materials such that they are not damaged.
1.9 PROJECT CONDITIONS
A. Field measurements: 1. Verify actual field distances so that post spacing can be made uniform. 2. Verify and coordinate gate openings and column distances for entrances.
1.10 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of chain-link fences and gates that fail in materials or workmanship within specified warranty period.
1. Failures include, but are not limited to, deterioration of metals, metal finishes, and other materials beyond normal weathering. 2. Warranty Period: Five (5) years from date of Substantial Completion.
PART 2 - PRODUCTS
2.1 MANUFACTURERS;
A. Chain link fence and gates: One of the following or equal: 1. Master-Halco
2.2 CHAIN-LINK FENCE FABRIC
A. General: Provide fabric in one-piece heights measured between top and bottom of outer edge of selvage knuckle or twist. Comply with CLFMI Product Manual and with requirements indicated below:
1. Fabric Height: As indicated on Drawings. 2. Steel Wire Fabric: 9 gauge wire.
a. Mesh Size: 2-1/8 inches.
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 3
b. Zinc-Coated Fabric: ASTM A 392, Type II, Class 1, 1.2 oz./sq. ft. with zinc coating applied before weaving.
3. Selvage: Twisted top and knuckled bottom.
4. Supports: Provide the following top and bottom supports: a. Top: 1-1/4” Schedule 40 pipe b. Bottom: Tension wire
2.3 FENCE FRAMING
A. Posts and Rails: Comply with ASTM F 1043 for framing, including rails, braces, and line; terminal; and corner posts. Provide members with minimum dimensions and wall thickness according to ASTM F 1043 or ASTM F 1083 based on the following:
1. Fence Height: As indicated on Drawings.
2. Heavy Industrial Strength (Minimum steel yield strength 80,000 psi): Material Group IA, round steel pipe, Schedule 40.
a. Line Post: 2.0 inches in diameter. b. End, Corner and Pull Post: 2.5 inches in diameter .
3. Horizontal Framework Members: Top rail complying with ASTM F 1043. 4. Brace Rails: Comply with ASTM F 1043. 5. Metallic Coating for Steel Framing:
a. Zinc coating 1.8 oz/ft2 on the inside and outside surface.
2.4 TENSION WIRE
A. Metallic-Coated Steel Wire: 7 gauge , marcelled tension wire complying with ASTM A 817 and ASTM A 824, with the following metallic coating:
1. Type II, zinc coated with minimum coating weight matching chain-link fabric coating weight.
2.5 FITTINGS
A. General: Comply with ASTM F 626.
B. Post caps: 1. Provide post caps that fit snugly over posts to exclude moisture. a. Provide dome style caps for terminal posts. b. When top rail is specified provide line post loops to secure top rail.
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 4 C. Barbed Wire Arms: Galvanized pressed steel, with clips, slots, or other means for attaching strands of barbed wire, and means for attaching to posts , integral with post cap; for each post unless otherwise indicated, and as follows:
1. Provide line posts with arms that accommodate top rail or tension wire.
D. Finish:
1. Metallic Coating for Pressed Steel or Cast Iron: Not less than 1.2 oz. /sq. ft. zinc ASTM F 626.
2.6 FABRIC ACCESSORIES
A. Wire Clips: Minimum 6 gauge hot dip galvanized
B. Tension Bars: ¼ inch by ¾ inch, galvanized
C. Truss Rod Assembly: Galvanized steel minimum 3/8” diameter with pressed steel tightener (galvanized).
D. Steel Bands: 11 gauge, 1 inch wide, hot dip galvanized.
E. Bolts and Nuts: 3/8 inch diameter, galvanized and of commercial quality
2.7 BARBED WIRE
A. Fence: 1. Number of Strands: 3 2. Wires per strand: 2 3. 12.5 gauge galvanized wires with 14 gauge, 4 point galvanized barbs (at no more than 5 inches on center spacing). 4. Coatings: Galvanize in accordance with ASTM A 121, Class 2.
2.8 CHAIN LINK GATES
A. Frames and center supports: minimum 1-7/8-inch outside diameter.
B. Gate accessories: 1. Post top fittings: a. Provide post caps that fit snugly over posts to exclude moisture. b. Provide dome style caps for terminal posts and loop style caps for line posts. c. Post top fittings: Extension arms, 45-degree angle type, capable of receiving three strands of barbed wire. 2. Corner fittings: Heavy pressed steel or malleable castings. 3. Gate tensioning: a. Cross tensioning rods: 3/8 inch, galvanized. b. Turnbuckles: Heavy duty. 4. Tension rods for 4-foot gates: 3/8 inch, easily adjustable, galvanized. 5. Gate frame corner fittings: Fittings designed for purpose, manufacturer’s standard.
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 5 6. Horizontal gate stiffeners: 1-5/8 – inch outside diameter galvanized steel pipe in accordance with ASTM F1043, group IA. 7. Gate hardware: a. Catch and locking attachment: combination steel or malleable iron catch and locking attachment of acceptable design. b. Stops: 1) Capable of holding gates open. c. Color: Match color of fabric.
2.9 GROUT AND ANCHORING CEMENT
A. Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C 1107. Provide grout, recommended in writing by manufacturer, for exterior applications.
B. Erosion-Resistant Anchoring Cement: Factory-packaged, nonshrink, nonstaining, hydraulic- controlled expansion cement formulation for mixing with potable water at Project site to create pourable anchoring, patching, and grouting compound. Provide formulation that is resistant to erosion from water exposure without needing protection by a sealer or waterproof coating and that is recommended in writing by manufacturer, for exterior applications.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Examine areas and conditions, with Installer present, for compliance with requirements for a verified survey of property lines and legal boundaries, site clearing, earthwork, pavement work, and other conditions affecting performance of the Work.
1. Do not begin installation before final grading is completed unless otherwise permitted by Architect.
B. Proceed with installation only after unsatisfactory conditions have been corrected.
C. Stake locations of fence lines, gates, and terminal posts. Do not exceed intervals of 500 feet or line of sight between stakes. Indicate locations of utilities, lawn sprinkler system, underground structures, benchmarks, and property monuments.
D. Install chain-link fencing to comply with ASTM F 567 and more stringent requirements indicated.
E. Post Excavation: Drill or hand-excavate holes for posts to diameters and spacings indicated, in firm, undisturbed soil.
F. Post Setting: Set posts in concrete at indicated spacing into firm, undisturbed soil.
1. Verify that posts are set plumb, aligned, and at correct height and spacing, and hold in position during setting with concrete or mechanical devices.
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 6 2. Concrete Fill: Place concrete around posts to dimensions indicated and vibrate or tamp for consolidation. Protect aboveground portion of posts from concrete splatter.
a. Exposed Concrete: Extend 2 inches above grade; shape and smooth to shed water. b. Concealed Concrete: Top 2 inches below grade as indicated on Drawings to allow covering with surface material.
G. Terminal Posts: Locate terminal end, corner, and gate posts per ASTM F 567 and terminal pull posts at changes in horizontal or vertical alignment and as indicated on Drawings. For runs exceeding 500 feet, space pull posts an equal distance between corner or end posts.
H. Line Posts: Space line posts uniformly at 10 feet o.c.
I. Tension Wire: Install according to ASTM F 567, maintaining plumb position and alignment of fencing. Provide horizontal tension wire at the following locations:
1. Extended along top and bottom of fence fabric. 2. As indicated.
J. Chain-Link Fabric: Apply fabric to outside of enclosing framework. Leave 1 inch between finish grade of surface and bottom selvage unless otherwise indicated.
K. Barbed Wire: Install barbed wire uniformly spaced as indicated on Drawings. Pull wire taut, install securely to extension arms, and secure to end post or terminal arms.
L. Install gates according to manufacturer's written instructions, level, plumb, and secure for full opening without interference. Attach fabric as for fencing. Attach hardware using tamper- resistant or concealed means. Install ground-set items in concrete for anchorage. Adjust hardware for smooth operation and lubricate where necessary.
M. Adjust gates to operate smoothly, easily, and quietly, free of binding, warp, excessive deflection, distortion, nonalignment, misplacement, disruption, or malfunction, throughout entire operational range. Confirm that latches and locks engage accurately and securely without forcing or binding.
N. Cantilever slide gates: Install cantilever horizontal slide gates and gate posts in accordance with ASTM F567. Cantilever sliding gates shall be plumb in the closed position with minimal ground clearance and slide with an initial force of 40 lbs.
3.2 SITE CLEAN UP
A. Clean up area adjacent to fence line from debris and unused material created by fence installation
END OF SECTION 323113
WRCRWA CHAIN LINK FENCES AND GATES PLANT EXPANSION PROJECT 323113 - 7 SECTION 331400 – HYDRAULIC STRUCTURES TESTING
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall perform all cleaning, flushing, testing and appurtenant work, including conveyance of test water from Owner-designated source to point of use, and including all disposal thereof, complete and acceptable, for hydraulic structures and appurtenant piping all in accordance with the requirements of the Contract Documents.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Pipeline Testing. Section 221066
B. Cast-In-Place Concrete. Section 033000
PART 2 - PRODUCTS
2.1 MATERIALS REQUIREMENTS
A. Temporary valves, bulkheads or other water control equipment and materials shall be as determined by the Contractor subject to the Engineer's review.
PART 3 - EXECUTION
3.1 GENERAL
A. Prior to testing, all hydraulic structures shall be thoroughly cleaned and all surfaces hosed down with a high pressure hose and nozzle. All water, dirt and foreign material accumulated in this cleaning operation shall be removed from the structure.
B. The Contractor shall conduct leakage testing of concrete structures subject to hydrostatic pressure and all appurtenant piping. All testing operations shall be done in the presence of the Engineer.
C. The Contractor shall notify the Engineer at least 48-hours in advance of any planned testing and shall review with the Engineer the testing procedures.
D. Water from the Owner’s reclaimed water system will be provided for testing. However, the Contractor shall make all necessary provisions for conveying the water from the Owner- designated source to the points of use.
WRCRWA HYDRAULIC STRUCTURES TESTING PLANT EXPANSION PROJECT 331400-1 E. If industrial paint finishes or other protective coatings are to be applied to the interior surfaces of the hydraulic structure, such coatings shall be applied after all testing operations have been completed.
F. Disposal of test water from structures, after testing has been completed, shall be acceptable to the Engineer.
3.2 TESTING OF HYDRAULIC STRUCTURES
A. General: Testing shall be performed prior to backfilling, except where otherwise acceptable to the Engineer (See drawings for additional requirements). Testing shall not be performed sooner than 14-days after all portions of structure walls and associated roof systems have been completed. The test shall consist of filling the structure with water to the maximum operating water surface. The rate of filling shall not exceed 48-inches of depth per day.
B. Evaporation Calculations: To accurately measure the amount of evaporation, the following procedure shall be observed:
1. A standard 5 gallon bucket shall be filled just below the top, and the elevation noted. The bucket shall then be placed in the water of the structure being tested once filling of the structure is complete. 2. Upon completion of the hydraulic testing of the structure, the amount of water evaporated from the bucket shall be taken as the evaporation amount in the structure.
C. Leakage Test and Repairs: After the structure has been filled, the leakage test shall be performed as follows: An initial water level reading shall be made. Seven days following the initial reading, a second reading shall be made. The structure shall be considered to have passed the test if water loss during the 7-day period, as computed from the two water level readings, does not exceed 0.2 percent of the total volume of water in the structure, after allowance is made for evaporation loss. If intermediate readings or observed leakage indicate that the allowable leakage will be exceeded, the test may be terminated before the end of the 7-day period and appropriate action taken to correct the problem before commencing a new 7-day test period. If the structure continues to fail the leakage test, the Contractor shall empty the structure and shall examine the interior for evidence of any cracking or other conditions that might be responsible for the leakage. Any cracks shall be "vee'd" and sealed with polyurethane sealant in accordance with Section 033000 entitled, "Cast-In-Place Concrete". Any evidence of leakage shall be repaired. Following these operations, the Contractor shall again test the hydraulic structure. The structure will not be accepted as completed until it has passed the leakage test.
3.3 TESTING OF APPURTENANT PIPING
A. Piping appurtenant to hydraulic structures shall be tested as specified in Section 221066 entitled, "Pipeline Testing".
END OF SECTION 331400
WRCRWA HYDRAULIC STRUCTURES TESTING PLANT EXPANSION PROJECT 331400-2 SECTION 335100 - NATURAL-GAS DISTRIBUTION
PART 1 - GENERAL
1.1 DESCRIPTION:
A. This section specifies materials and procedures for the construction of outside underground gas distribution system for natural gas, complete, ready for operation, all appurtenant structures, and connections to existing building structures and to existing gas supply. This specification does not apply to LPG distribution systems.
1.2 RELATED WORK
A. Excavation, Trench Widths, Pipe Bedding, Backfill, Shoring, Sheeting, Bracing: Document 31 20 00, Earth Moving.
B. Submittals: Document 01 33 00, Shop Drawings, Product Data And Samples.
C. Exterior Pipe Coatings: Document 09 80 00, Protective Coatings
D. Metering: Document 40 91 23, Process Measurement Devices.
1.3 DEFINITIONS
A. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions. Examples include rooftop locations.
1.4 ABBREVIATIONS
A. MDPE: Medium-density polyethylene plastic
B. HDPE: High-density polyethylene plastic
C. PE: Polyethylene plastic
D. NRTL: National recognized testing laboratory
1.5 DELIVERY, STORAGE, AND HANDLING
A. Remove and dispose of liquids from existing natural-gas piping according to requirements of authorities having jurisdiction.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-1 B. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe end damage and to prevent entrance of dirt, debris, and moisture.
C. Store and handle pipes and tubes having factory-applied protective coatings to avoid damaging coating, and protect from direct sunlight.
D. Protect stored PE pipes and valves from direct sunlight.
1.6 COORDINATION
A. Coordinate connection to natural-gas main with Utility Company and Owner. See Section 3.9 of this document.
B. Coordinate sizes and locations of concrete bases with actual equipment provided.
C. Coordinate exterior utility lines and connections to building services up to the actual extent of building wall.
1.7 QUALITY ASSURANCE:
A. Products Criteria:
1. When two or more units of the same type or class of materials or equipment are required, these units shall be products of one manufacturer. 2. A nameplate bearing manufacturer's name or trademark, including model number, shall be securely affixed in a conspicuous place on equipment. In addition, the model number shall be either cast integrally with equipment, stamped, or otherwise permanently marked on each item of equipment.
B. Comply with the rules and regulations of the Utility Company having jurisdiction over the connection to public natural-gas lines and the extension, and/or modifications to public utility systems.
1.8 APPLICABLE PUBLICATIONS
A. The publications listed below form a part of this specification to the extent referenced. The publications are referred in the text by basic designation only.
B. American National Standards Institute (ANSI): B31.8-2010 ...... Gas Transmission and Distribution Piping Systems Z21.80a-2005/CSA 6.22a ...... Line Pressure Regulators, Addenda 1 to Z21.80-2003/CSA 6.22
C. American Petroleum Institute (API): Spec 6D-2010 ...... Pipeline Valves
D. American Society of Civil Engineers (ASCE): 25-06 ...... Earthquake Actuated Automatic Gas Shutoff Devices
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-2 E. American Society of Mechanical Engineers (ASME): B1.20.1-1983 ...... Pipe Threads, General Purpose, Inch B16.5-2009 ...... Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard B16.9-2007 ...... Factory-Made Wrought Buttwelding Fittings B16.11-2009 ...... Forged Fittings, Socket-Welding and Threaded B16.33-2002 ...... Manually Operated Metallic Gas Valves for use in Gas Piping Systems up to 125 psi (Sizes NPS 1/2 through NPS 2) B16.34-2009 ...... Valves - Flanged, Threaded and Welded End B16.38-2007 ...... Large Metallic Valves for Gas Distribution Manually Operated, NPS 2-1/2 (DN 65) to NPS 12 (DN 300), 125 psig (8.6 bar) Maximum B16.40-2008 ...... Manually Operated Thermoplastic Gas Shutoffs and Valves in Gas Distribution Systems B18.2.1-2010 ...... Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series) B31.8-2010 ...... Gas Transmission and Distribution Piping Systems
F. American Society for Testing and Materials (ASTM): A53/A53M-10 ...... Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless A312/A312M-11 ...... Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes D2513-11e1 ...... Polyethylene (PE) Gas Pressure Pipe, Tubing, and Fittings D2683-10 ...... Socket-Type Polyethylene Fittings for Outside Diameter- Controlled Polyethylene Pipe and Tubing D2774-08 ...... Underground Installation of Thermoplastic Pressure Piping D3261-10a ...... Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing
G. American Welding Society (AWS): A5.8/A5.8M:2004 ...... Filler Metals for Brazing and Braze Welding D10.12/D10.12M:2000 ...... Guide for Welding Mild Steel Pipe
H. Manufacturers Standardization Society (MSS): SP-78-2005 ...... Gray Iron Plug Valves Flanged and Threaded Ends SP-110-2010 ...... Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends
I. National Fire Protection Agency (NFPA): 54-2009 ...... National Fuel Gas Code
1.9 WARRANTY
A. The Contractor shall remedy any defect due to faulty material or workmanship and pay for any damage to other work resulting there from within a period of two years from final acceptance. Further, the Contractor will furnish all manufacturer's and supplier's written guarantees and warranties covering materials and equipment furnished under this Contract.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-3 PART 2 - PRODUCTS
2.1 PIPES, TUBES, AND FITTINGS
A. Steel Pipe: Steel pipe, above ground, shall be as per ASTM A53, black steel, Schedule 40, Type E , Grade B.
1. Coatings:
B. Fittings:
1. Butt weld fittings shall be wrought steel, per ASME B16.9. 2. Wrought-Steel Welding Fittings shall meet ASTM A234 for butt welding and socket welding. 3. Forged-Steel Flanges and Flanged Fittings shall be ASME B16.5, minimum Class 150, including bolts, nuts, and gaskets of the following material group, end connections, and facings: a. End Connections shall be threaded or butt welded to match pipe. b. Lapped Face is not permitted underground. c. Gasket Materials shall be ASME B16.20, metallic, flat, asbestos free, aluminum o-rings, and spiral-wound metal gaskets. d. Bolts and Nuts shall be ASME B18.2.1, carbon steel aboveground and stainless steel underground.
4. Mechanical Couplings shall include: a. Steel flanges and tube with epoxy finish. b. Buna-nitrile seals. c. Stainless-steel bolts, washers, and nuts. d. Couplings shall be capable of joining steel pipe to steel pipe.
C. PE Pipe: Pipe shall conform to ASTM D2513. 1. Materials used for the manufacture of polyethylene pipe and fittings shall be PE 2406 SDR 11, medium density polyethylene meeting cell classification 234363E per ASTM D 3350 and shall be listed in PPI (plastics pipe institute) TR-4 with standard grade HDB ratings of 1250 psi and 73 degrees F, and 1000 psi at 140 degrees F. All pipe and fittings materials shall be opaque yellow in color. Materials shall be stabilized against ultraviolet deterioration and shall be suitable for unprotected outdoor storage for at least four (4) years. 2. The same manufacturer shall supply polyethylene pipe and heat fusing fittings. 3. Pipe and fittings shall be manufactured and tested in accordance with the latest published edition of ASTM D 2513 (for socket-fusion type) or ASTM D 3261 for butt-fusion type fittings. Fusion fittings shall be manufactured in accordance with ASTM D 2513 and D.O.T. requirements. 4. The pipe and fittings manufacturer shall have an established quality control program responsible for inspecting incoming and outgoing materials. Incoming polyethylene materials shall be inspected for density, melt flow rate, UV protection and contamination. The supplier shall certify the cell classification properties of incoming material. 5. All product shall be verified for diameter, wall thickness, roundness, concentricity, toe-in, inside and outside surface finish, markings, and end cut. Quality control shall verify production checks, and test for density, melt flow rate, hoop tensile strength and ductility.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-4 Manufacturer shall maintain records of manufacturing location, pipe production and resin lots for at least 50 years. 6. The manufacturer shall certify the inspection and testing of materials and products. 7. PE Transition Fittings shall be factory-fabricated fittings with PE pipe complying with ASTM D2513, SDR 11; and steel pipe complying with ASTM A53, black steel, Schedule 40, Type E or S, Grade B. 8. Anode-less Service-Line Risers shall be factory fabricated and leak tested. a. Underground portion shall be PE pipe complying with ASTM D2513. b. Casing shall be steel pipe complying with ASTM A53, Schedule 40, black steel, Type E, Grade B, with corrosion-protective coating covering. c. Aboveground portion shall have PE transition fittings. Outlet shall be threaded or suitable for welded connection. Include tracer wire connection and ultraviolet shield. d. Stake supports with factory finish to match steel pipe casing or carrier pipe.
9. Transition Service-Line Risers shall be factory fabricated and leak tested. a. Underground Portion shall be PE pipe complying with ASTM D2513, connected to steel pipe complying with ASTM A53, Schedule 40, Type E, Grade B, with corrosion-protective coating for aboveground outlet. b. Outlet shall be threaded or flanged or suitable for welded connection. Include factory-connected anode, tracer wire connection and ultraviolet shield. c. Stake supports with factory finish to match steel pipe casing or carrier pipe. Bridging sleeve over mechanical coupling.
10. Plastic Mechanical Couplings, NPS 1-1/2 and Smaller: Capable of joining PE pipe to PE pipe. a. PE body with molded-in, stainless steel support ring. b. Buna-nitrile seals. c. Acetal collets. d. Electro-zinc-plated steel stiffener.
11. Plastic Mechanical Couplings, NPS 2 and Larger shall be Capable of joining PE pipe to PE pipe, steel pipe to PE pipe, or steel pipe to steel pipe. a. Fiber-reinforced plastic body. b. PE body tube. c. Buna-nitrile seals. d. Acetal collets. e. Stainless-steel bolts, nuts, and washers.
2.2 JOINING MATERIALS
A. Joint Compound and Tape shall be suitable for natural-gas.
B. Welding filler metals shall comply with AWS D10.12 for appropriate wall thickness and chemical analysis of steel pipe being welded.
C. Brazing filler metals shall be alloy with a melting point greater than 1000 deg F complying with AWS A5.8. Brazing alloys containing more than 0.05 percent phosphorus are prohibited.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-5 2.3 MANUAL GAS SHUTOFF VALVES
A. General:
1. All types of valves shall be accessible, labeled and specified for use for controlling multiple systems.
2. All valves shall be manually operated and equipped with a handle or lever or operation unless buried. All buried valves shall be operated and equipped with a valve nut or flat head that shall fit a contactor furnished tee-handle.
B. Metallic Valves, NPS 2 and smaller shall comply with ASME B16.33, and have the following characteristics:
1. CWP Rating of 125 psi. 2. Threaded ends complying with ASME B1.20.1. 3. Dryseal threads on flare ends that comply with ASME B1.20.3. 4. Listed and labeled by an NRTL acceptable to authorities having jurisdiction for valves 1 inch (25 mm) and smaller.
C. Metallic Valves, NPS 2-1/2 and larger shall comply with ASME B16.38.
1. CWP Rating of 125 psi. 2. Flanged Ends shall comply with ASME B16.5 for steel flanges.
D. Steel valves shall have capacity to operate in lines with 100 psi working pressure.
1. Valves 1-1/2 inches and smaller installed underground shall conform to ASME B16.34, carbon steel, socket weld ends. 2. Valves 1-1/2 inches and smaller, installed aboveground, shall conform to ASME B16.34, carbon steel, socket weld or threaded ends. 3. Valves 2 inches and larger shall conform to API spec 6D, carbon steel, buttweld ends. 4. Aboveground valves 2 inches or larger shall conform to API Spec 6D, carbon steel, buttweld or flanged ends. 5. Cast iron valves shall conform to ASTM A126, Class B, Type 301 or 302.
E. PE Ball Valves shall comply with ASME B16.40. Valves in sizes 1/2 inch to 6 inches may be used with polyethylene distribution and service lines, in lieu of steel valves, for underground installation only.
1. CWP Rating: 80 psi with an operating temperature of Minus 20 to plus 140 deg F.
F. Valve Boxes shall be cast iron, two-section box.
1. Top section shall include a cover with "GAS" lettering. 2. Bottom section shall have a base to fit over valve and barrel a minimum of 5 inches in diameter. 3. Include tee-handle, steel operating wrench with socket end fitting valve nut or flat head, and with stem of length required to operate valve.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-6 2.4 EARTHQUAKE VALVES
A. Valves shall automatically stop gas flow when actuated by earth tremor and shall be single seated with manual reset. Do not provide manual shut-off attachments.
1. Valve shall comply with ASCE 25 and automatically shut bubble tight within five seconds when subjected to a horizontal sinusoidal oscillation having a peak acceleration of 0.3 gravity with a period of 0.4 seconds. The valve shall not shut-off when subjected for five seconds to horizontal, sinusoidal oscillations having a peak acceleration of 0.4 gravity with a period of 0.1 second; a peak acceleration of 0.08 gravity with a period of 0.4 second or 1.0 second. 2. Valve should be rated for 125 psi with flanged ends for pipe sizes above 2 inches. Valves should have threaded ends for pipe sizes 2 inches and under. 3. Approvals: UL listed, State of California Standards for Earthquake Actuated Automatic Gas Shut-Off Systems.
2.5 VALVE BOXES
A. Provide cast iron extension box with screw or slide type adjustment and flared base. Minimum thickness of metal, 3/16 inch. Box shall be of such length as can be adapted, without full extension, to depth of cover required over pipe at valve location with the word "GAS" in cover.
B. Provide "T" handle socket wrenches of 5/8 inch round stock long enough to extend 2 feet above top of deepest valve box.
2.6 PRESSURE REGULATORS
A. Pressure regulators for individual service lines shall be capable of reducing distribution line pressure to pressures required for users. Ferrous bodies. Regulators should be:
1. Single stage and suitable for natural-gas, having a steel jacket and corrosion-resistant components and elevation compensator. End Connections should be threaded for regulators NPS 2 and smaller; flanged for regulators NPS 2-1/2 and larger.
B. Service Pressure Regulators shall comply with ANSI Z21.80a/CSA 6.22a, with a maximum inlet pressure of 100 psi.
C. Line Pressure Regulators shall comply with ANSI Z21.80a/CSA 6.22a with a maximum inlet pressure of 10 psi.
2.7 SERVICE METERS
A. Meters shall comply with Document 40 91 23, Process Measurement Devices and ANSI B109.2.
B. Meters shall be pipe mounted. Meters shall be provided with pressure protection as specified in ASME B31.8 and frost protection.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-7 C. Service-Meter Bars shall be malleable- or cast iron frame for supporting service meter and include offset swivel pipes, meter nuts with o-ring seal, and factory- or field-installed dielectric unions.
1. Omit meter offset swivel pipes if service-meter bar dimensions match service-meter connections.
2.8 LABELING AND IDENTIFYING
A. Detectable warning tape shall be acid- and alkali-resistant, PE film warning tape manufactured for marking and identifying underground utilities, a minimum of 6 inches wide and 4 mils thick, continuously inscribed with a description of utility, with metallic core encased in a protective jacket for corrosion protection, detectable by metal detector when tape is buried up to 30 inches deep; colored yellow.
PART 3 - EXECUTION
3.1 PREPARATION
A. Close equipment shutoff valves before turning off natural-gas to premises or piping section.
B. Inspect natural-gas piping according to NFPA 54 and the International Fuel Gas Code to determine that natural-gas utilization devices are turned off in piping section affected.
C. Comply with NFPA 54 and the International Fuel Gas Code requirements for prevention of accidental ignition.
3.2 METALLIC PIPING INSTALLATION
A. Heating trenches, storm and sanitary sewer lines, and water mains shall have right of way.
B. Warning tape shall be continuously placed 12 inches above buried gas lines.
C. Main services and main service shut off valves shall have a 24 inch minimum cover or as recommended by local utility.
D. Service lines shall have an 18 inch minimum cover or as recommended by local utility.
E. Connections between metallic and plastic piping shall be made only outside, underground, and with approved transition fittings.
3.3 NON-METALLIC PIPE INSTALLATION
A. Install pipe in trench in accordance with recommendations of the pipe manufacturer. Provide sufficient slack to allow for expansion and contraction.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-8 B. Joints shall be fusion welds made in accordance with the recommendations of the polyethylene pipe manufacturer. Adhesive joints for fiberglass plastic pipe shall be made in accordance with manufacturer’s recommendations.
C. All offsets in piping shall be made with manufactured fittings. Bending of piping to form offsets shall not be permitted.
D. Connections between plastic pipe and metal pipe shall be made in accordance with recommendations of the pipe manufacturer.
E. Copper Tracer Wire consisting of No. 14 AWG solid, single conductor, insulated copper wire shall be installed in the trench with all piping to permit location of the pipe with electronic detectors. The wire shall not be spiraled around the pipe nor taped to the pipe. Wire connections are to be made by stripping the insulation from the wire and soldering with rosin core solder. Solder joints shall be wrapped with rubber tape and electrical tape. At least every 1000 feet, provide a 5 pound magnesium anode attached to the main tracer wire by solder joint shall be wrapped with rubber tape and with electrical tape. An anode shall be attached at the end of each line.
3.4 BUILDING SERVICE LINES
A. Install gas service lines to point of connection within approximately 5 feet outside of buildings to which such service is to be connected and make connections thereto. The point of delivery is the shutoff valve.
B. Connect service lines to top of mains by two-strap service clamp or coupling socket welded to main and into which is screwed a street tee and street elbow swing, joint assembly.
C. The service lines shall be as short and as straight as practicable between the point of delivery and the gas main and shall not be bent or curved laterally unless necessary to avoid obstructions or otherwise permitted. Service lines shall be laid with as few as joints as practicable using standard lengths of pipe. Polyethylene or fiberglass service lines shall not be installed aboveground except as permitted in ANSI B31.8.
D. Install gas service lines to point of connection within approximately 5 feet outside of buildings to which such service is to be connected and make connections thereto. The point of delivery is the shutoff valve.
3.5 OUTDOOR PIPING INSTALLATION
A. Comply with the International Fuel Gas Code for installation and purging of natural-gas piping.
B. Install underground, natural-gas piping buried at least 18 inches below finished grade. Minimum cover depth is 18 inches. Natural-gas piping installed less than 18 inches below finished grade shall be installed in vented containment conduit.
C. Install fittings for changes in direction and branch connections.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-9 3.6 PIPE SLEEVES
A. Pipe shall be continuous through sleeves. Set sleeves in place before concrete is poured. Seal between sleeve/core opening and the pipe with modular mechanical type link seal. All sleeves shall be vented.
B. Provide sleeves where gas lines pass through retaining walls, foundation walls or floors. Split sleeves may be installed where existing lines pass thru new construction.
3.7 SERVICE-METER ASSEMBLY INSTALLATION
A. Install service-meter assemblies aboveground.
B. Install metal shutoff valves upstream from service regulators. Shutoff valves are not required at second regulators if two regulators are installed in series.
C. Install strainer on inlet of flow meter set.
D. Install service regulators mounted outside with vent outlet horizontal or facing down. Install screen in vent outlet if not integral with service regulator.
E. Install metal bollards to protect meter assemblies as indicated in drawings.
3.8 VALVE INSTALLATION
A. Install underground valves as indicated in drawings.
B. Install regulators with maintenance access space adequate for servicing and testing.
C. Install earthquake valves aboveground outside buildings according to listing.
D. Do not install valves under pavement unless shown on drawings.
E. Clean valve interior before installation.
3.9 CONNECTIONS
A. Connect to utility's gas main according to utility's procedures and requirements.
B. Install natural-gas piping electrically continuous, and bonded to gas appliance equipment grounding conductor of the circuit powering the appliance according to NFPA 70.
C. Install piping adjacent to appliances to allow service and maintenance of appliances.
D. Install tee fitting with capped nipple in bottom to form drip sediment traps. Install as close as practical to inlet of each appliance.
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-10 3.10 LABELING AND IDENTIFYING
A. Install detectable warning tape directly above gas piping, 12 inches below finished grade, except 6 inches below subgrade under pavements and slabs.
3.11 CONCRETE BASES
A. Anchor equipment to concrete base as indicated in drawings.
3.12 PIPE CLEANING
A. All pipe sections shall be blown down with 100 psi air to remove all sand, soil and debris.
B. Blow down procedure shall be done after system is complete, but before valves are installed.
3.13 TESTS
A. Piping System: Inspection, testing and purging shall be in accordance with NFPA 54 and ASME B31.8.
END OF SECTION 335100
WRCRWA NATURAL GAS DISTRIBUTION PLANT EXPANSION PROJECT 335100-11 SECTION 338000 - PRECAST CONCRETE MANHOLES AND VAULTS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide precast concrete manholes, catch basins, drop inlets, potable water vaults; meter vaults, and other pre-cast concrete structures complete and in place, in accordance with the Contract Documents.
1.2 RELATED SECTIONS
A. Section 033000 – Cast-in-place Concrete
B. Section 312000 – Earth Moving
1.3 SPECIFICATIONS, CODES AND STANDARDS
A. Commercial Standards
ASTM A 48 Gray Iron Castings. ASTM C 150 Portland Cement. ASTM C 443 Joints for Circular Concrete Sewer and Culvert Pipe, Using Rubber Gaskets. ASTM C 478 Precast Reinforced Concrete Manhole Sections ASTM C 877 Standard Specification for External Sealing Bands for Concrete Pipe, Manholes, and Precast Box Sections. ASTM C 923 Resilient Connectors Between Reinforced Concrete Manhole Structures, Pipes, and Laterals. ASTM C 990 Standard Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint Sealants.
1.4 CONTRACTOR SUBMITTALS
A. General: Furnish submittals in accordance with Section 013300 - Contractor Submittals.
B. Shop Drawings:
1. Show dimensions, locations, lifting inserts, reinforcement, and joints.
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 1 2. Structural design calculations for vaults and boxes shall be stamped and signed by a structural engineer registered in the State of California.
C. Manufacturer’s Certification for Manholes and Vaults: Written certification that the structure complies with the requirements of this Section.
D. Manufacturer’s Test Results: Pull out force for manhole steps.
1.5 QUALITY ASSURANCE
A. Inspection: After installation, the Contractor shall demonstrate that manholes and vaults have been properly installed, level, with water-tight joints, at the correct elevations and orientations, and that the backfilling has been carried out in accordance with the Contract Documents.
B. Any precast concrete which arrives on site with voids, cracked, or damaged, or is cracked or damaged during installation shall be cause for rejection. Contractor shall remove precast section(s) from the project site and replace with new undamaged sections at no additional cost to OWNER.
1.6 DELIVERY, STORAGE AND HANDLING
A. Handle precast units in positions consistent with their shape and design. Lift and support only from the support points indicated on the shop drawings.
B. Embedded Lifting or Handling Devices: Capable of supporting units in positions anticipated during manufacturing, storage, transportation and installation.
C. Block and brace units during storage. Provide lateral bracing which is sufficient to prevent bowing and/or warping and will not inhibit curing of the exposed surfaces.
PART 2 – PRODUCTS
2.1 MANHOLES
A. The Contractor shall provide precast manhole sections and conical sections conforming to ASTM C 478 and the requirements of this Section. Cement used in manufacturing the manholes shall be Type II modified Portland cement in accordance with ASTM C 150
1. Adjusting rings shall be standard items from the manufacturer of the manhole sections. Minimum wall thickness of rings shall be 4-inches if steel reinforced and 6-inches if not reinforced.
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 2 B. Axial length of sections shall be selected to provide the correct total height with the fewest joints. Joints shall be minimized and shall be located as close as possible to the top of the structure to help minimize opportunity for groundwater infiltration.
C. Conical sections shall have an eccentric shape and shall be designed to support cast iron frames and covers under an H-20 loading, unless indicated otherwise.
D. Design Criteria: Manhole walls, transitions, conical sections, and base shall be designed per ASTM C 478 for the depths indicated and the following:
1. AASHTO H-20 loading applied to the cover.
2. Unit weight of soil of 120 pcf located above all portions of the manhole.
3. Lateral soil pressure based on saturated soil producing 100 pcf acting on an empty manhole.
4. Internal fluid pressure based on unit weight of 63 pcf with manhole filled from invert to cover with no balancing external soil pressure.
5. External pressures and uplift forces due to groundwater elevations 2 feet below finish grade.
6. Dead load of manhole sections fully supported by the base and transition.
7. Additional reinforcing steel in walls to transfer stresses at openings.
8. The minimum clear distance between the edges of any 2 wall penetrations shall be 12- inches or one-half of the diameter of the smaller penetration, whichever is greater.
E. Joints shall have lipped male/female ends which shall provide uniform and continuous interior wall surfaces and shall be watertight. All joints (including joints between adjusting rings and manhole structure, other adjusting rings and frame and cover) shall be sealed with a preformed flexible sealant conforming to ASTM C 990.
F. Raw Sewage, Plant Drain, drain manholes, plant effluent and all vaults shall also have each joint wrapped with an external joint sealant meeting ASTM C 877. Concrete for base and channel formation shall be 4000 psi concrete conforming to Section 033000 –Cast-In-Place Concrete.
G. Barrel section to sewer pipe (Raw sewage, plant drain, drain, and plant effluent) connections shall be sealed with flexible resilient connectors complying with ASTM C923 and appropriate for the pipe material being used. Mechanical devices shall be stainless steel.
H. Where required and specified in drawings, manhole steps shall be comprised of 1/2-inch grade 60 steel reinforcement rod encased in polypropylene copolymer plastic. Steps shall have tread width of 14-inches. Furnish test results demonstrating step capability to resist a pull out force of 2200 pounds.
I. Manhole riser sections shall be greater than 12 inches in height.
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 3
J. Manhole Manufacturers, or Equal
1. Jensen Precast
2. OLDCASTLE Precast
2.2 FRAMES AND COVERS
A. Castings: Castings for manhole frames, covers, and grates shall be non-rocking with machined flat bearing surfaces, and shall conform to the requirements of ASTM A 48, Class 30. Unless otherwise indicated, cast iron covers and frames shall be heavy traffic type, 30 inches in diameter. Covers shall have cleated surfaces with pick holes and shall be ventilated in improved areas and have a solid lid design in landscape or native areas.
B. Manhole covers shall be with embossed with lettering saying "Sewer", "Storm Sewer", or “Water”.
C. All frames and covers shall be designed for H-20 traffic loading. Grates and curb inlets in traffic areas shall be designed for H-20 traffic loading.
D. Castings Manufacturers, or Equal
1. 1. D & L Supply
2. Neenah Foundry Co.
2.3 VAULTS
A. The Contractor shall provide precast vaults designed for the indicated applications and of the sizes indicated.
B. The minimum structural member thickness for vaults shall be 5-inches. Cement shall be Type V or Type II modified Portland cement as specified in ASTM C 150. The minimum 28-day concrete compressive strength shall be 4,000 psi. All reinforcing steel shall be embedded in the concrete with a minimum clear cover as recommended by ACI 318.
C. Design Loading: Vaults in areas subject to vehicular traffic shall be designed for H-20 traffic loading. Vaults in other areas shall be designed for a vertical live load of 300 psf. Lateral loads on vaults in all areas shall be calculated from:
L = 90 h, plus surcharge of 240 psf in areas of vehicular traffic Where L = loading in psf h = depth of fill in feet.
Design loading shall also take into account the lateral and uplift pressure resulting from a groundwater elevation 2 feet below existing grade.
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 4
D. Where joints are designed in pre-cast concrete vaults, such joints shall be interlocking to secure proper alignment between members and prevent migration of soil through the joint. Structural sections at joints shall be sized sufficiently to reinforce the section against localized distress during transportation and handling and against excess contact bearing pressures through the joint. All openings through the precast structure shall be reinforced to transfer loads.
1. 1. Joints shall be sealed watertight. All joints (including joints between adjusting rings and manhole structure, other adjusting rings and frame and cover) shall be sealed with a preformed flexible sealant conforming to ASTM C 990. In addition, all joints shall be wrapped with an external joint sealant meeting ASTM C 877.
E. Where openings for access to the vault are required, the full clear space opening indicated shall be provided, without obstructions from brackets or supports. For large openings where brackets or supports are designed to protrude into the opening for support of required covers, such brackets or supports shall be designed to be easily removed and replaced with a minimum of effort and without cutting or welding.
F. Covers for access openings shall be provided. Frames for covers shall be fabricated from aluminum, and shall be integrally cast into the vault concrete sections. All covers shall be tight fitting to prevent the entrance of dirt and debris. Where edge seams are permitted, no gaps greater than 1/16-inch between edges will be accepted. All covers, except round, heavy-weight, cast iron manhole covers, shall have securing mechanisms to hold the covers firmly in place against the effects of repetitious live loads such as pedestrian or vehicle traffic.
G. Where penetrations of the pre-cast concrete vaults are required for piping, conduit, or ducts, such penetrations shall be accommodated through pre-cast openings or wall sleeves, as indicated. Storm drain structures may also use thin-wall knock-out sections. All openings for penetrations shall be smooth and free of surface irregularities and without exposed steel reinforcing. With the exception of vaults on pressurized water system, vaults need not be designed to resist thrust from piping passing through the vault.
H. Lifting holes shall be plugged with a precast concrete plug sealed with a non-shrink grout.
I. I. Vault Manufacturers, or Equal
1. Jensen Precast,
2. OLDCASTLE Precast
2.4 FABRICATION
A. Maintain plant records and quality control program during fabrication of structural precast concrete sections. Make all quality control records available to Engineer upon request.
B. Use molds that are rigid, and constructed of material that will result in uniform finished surfaces.
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 5 C. If self-consolidating concrete is not used, thoroughly vibrate concrete to ensure proper consolidation, elimination of cold joints, and to minimize trapped air on at the concrete surface.
D. Fabricate and provide the required lifting devices which are compatible with embedded components.
E. Ensure reinforcing steel, anchors, inserts, plates, angle and other cast-in items are sufficiently embedded, properly secured, and correctly located. Ensure the reinforcing steel is properly supported to prevent movement or shifting during fabrication. Inadequate concrete cover over reinforcing shall be cause for rejection.
F. Cure precast concrete sections under identical conditions to develop specified concrete quality.
PART 3 – EXECUTION
3.1 GENERAL
A. Prior to accepting manholes on site, ensure that manhole meet the requirements of these specifications, are constructed of the correct materials, and are not cracked or damaged in any other way.
B. Pre-cast concrete sections shall be transported and handled with care in accordance with the manufacturer’s written recommendations. Where lifting devices are provided in pre-cast sections, such lifting devices shall be used as intended. Where no lifting devices are provided, the Contractor shall follow the manufacturer’s recommendations for lifting procedures to provide proper support during lifting.
C. Buried pre-cast concrete vaults and manholes shall be assembled and placed in excavations on properly compacted soil foundations as indicated. Pre-cast concrete vaults and manholes shall be set to grade, plumb and level, and oriented to provide the required dimensions and clearances from pipes and other structures.
D. Prior to backfilling vaults, pipe and conduit penetrations and other, openings shall be sealed with polyurethane sealant or as indicated in the drawings. With the authorization of the Engineer, grout or a closed-cell flexible insulation may be used as filler material prior to placing a final bed of polyurethane sealant.
3.2 MANHOLES
A. Connect pipe to manhole with flexible connection (unless noted otherwise), as recommended by connection manufacturer. Provide a pipe joint or additional flexible connection 18 inches from the outside of the manhole. Grout around pipe after installation is complete, unless otherwise indicated. All connections shall be watertight.
B. Place top section, cone section or flat slab on top riser section, with the opening positioned over the steps. Top of cone section or flat slab shall be from 10 to 18 inches below finished grade.
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 6 C. Install grade rings as required to adjust top of lid and frame to match finish grade elevation. Maximum height of grade rings shall be 12 inches. Maximum number of grade rings shall be two.
D. In paved areas and as indicated in the plans, concrete collars shall be constructed around manhole covers as indicated. Collars shall be of 4000 psi concrete. Collars shall be constructed after pavement has been placed.
E. Steps shall be cast-in-place or vibrated into green concrete.
F. Steps shall be installed 12-inches on centers vertically, not more than 1/2 inch out of plumb. The top step shall be no more then 12-inches below the manhole cover.
G. After manhole base has been completed, furnish and install temporary pipe plugs to seal all interior pipe opening. Plugs shall remain in place until final review and acceptance of completed pipeline. Plugs shall then be removed and shall be property of Contractor.
H. Manhole interiors shall be coated as indicated in the protective coatings schedule.
3.3 QUALITY CONTROL
A. Manholes shall be tested and accepted per the requirements of Section 331400 – Hydraulic Structures Testing. Precast concrete testing is the responsibility of the Contractor and supplier.
B. Do not install precast concrete units until concrete has attained its design compressive strength.
END OF SECTION 338000
WRCRWA PRECAST CONCRETE MANHOLES AND VAULTS PLANT EXPANSION PROJECT 338000 - 7 SECTION 352016 – ALUMINUM SLIDE GATES
PART 1 - GENERAL
1.1 SUMMARY
A. There shall be furnished aluminum slide gates as shown on the drawings. The equipment shall include gates, frames, and gear operators.
B. Approved Manufacturers:
1. Golden Harvest 2. Rodney Hunt 3. Waterman Industries, Inc 4. Whipps Inc. 5. Or equal
1.2 QUALITY ASSURANCE:
A. Except as modified or supplemented herein, all gates and operators shall conform to the applicable requirements of AWWA-C561 standards.
B. The slide gates and operators shall be the product of a manufacturer having a minimum of five (5) years successful experience in the design and production of water control equipment of this type. The manufacturer’s shop welds, welding procedures and welders shall be qualified and certified in accordance with the requirement of the latest edition of AWS Sections D1.1, 1.2 and 1.6.
C. The fully assembled gates shall be shop inspected, tested for operation and leakage, and adjusted before shipping. There shall be no assembling or adjusting on the job sites other than for the lifting mechanism.
1.3 SUBMITTALS
A. The manufacturer shall submit for approval by the purchaser, drawings showing the principal dimensions, general construction and materials used in the gate and lift mechanism.
B. The manufacturer shall submit for approval by the purchaser, complete engineering design calculations in compliance with AWWA standards latest edition.
1.4 PERFORMANCE
A. Leakage: Slide gates shall be substantially watertight under the design head conditions. Under the design seating head, the leakage shall not exceed 0.10 US gallons per minute per foot of seating perimeter. Under the design unseating head, leakage shall not exceed 0.10 US gallons per minute per foot of perimeter.
WRCRWA ALUMINUM SLIDE GATES PLANT EXPANSION PROJECT 352016-1 PART 2 - PRODUCTS
2.1 GENERAL DESIGN
A. Gates shall be either self-contained or non-self-contained of the rising stem or non-rising stem configuration as indicated on the gate schedule.
B. All parts of the gate shall have a minimum thickness of ¼ inch.
2.2 FRAME
A. The gate frame shall be extruded aluminum weighing not less than 4-1/4 pounds per foot. The guide grooves in which the head guide angle travel shall contain ultra-high molecular weight polyethylene bearing bars in dovetail slots.
B. The frame configuration shall be of the flush-bottom type and shall allow the replacement of the top and side seals without removing the gate frame from the wall or wall thimble.
2.3 SLIDE
A. The slide shall consist of aluminum plate reinforced with U-shaped aluminum extrusion welded to the plate to limit its deflection to 1/720 of the gate’s span under the design head.
2.4 GUIDES AND SEALS
A. The guide grooves shall contain UHMW bearing bars in dovetail slots and shall be of such length as to retain and support at least two thirds (2/3) of the vertical height of the slide in the fully open position.
B. Side and top seals shall be field adjustable resilient J-bulbs seals attached to the spigot and held in place by a bolted retainer bar. Seals shall be fully adjustable.
C. The flush bottom resilient neoprene seal shall be mounted to bottom of disc and seal against the invert portion of the frame.
2.5 YOKE AND PEDESTAL
A. Self-contained gates shall be provided with a yoke made of structural members or formed plates. The maximum deflection of the yoke shall be 1/360 of the gate’s span.
B. Non-self contained gates shall be provided with pedestal mounted lifts. Pedestal shall be provided with shop coating.
C. Gates which are equipped with electric motor operators and electric actuators will be sized and furnished by the gate supplier.
WRCRWA ALUMINUM SLIDE GATES PLANT EXPANSION PROJECT 352016-2 2.6 ACTUATOR REQUIREMENT:
A. Gear housing will be made of cast aluminum with a bronze alloy worm gear and heat-treated steel spur gear.
B. Electrical compartment covers: Cast Aluminum, 0-ring sealed with nickel-plated carbon steel hardware.
C. Motor: Squirrel cage induction 460 volt 3-phase 60 Hz, 16 minute normal duty. Dynamic Torque is minimal 20% of start torque.
D. Controls: Local controls including Open, Close, Stop, Local, Remote, and Off.
E. Remote Signals:
1. Position – % OPEN (analog out) 2. Fail 3. Remote signal to open and close (analog in) 4. Hand Switch in Remote Indication
F. Operation: In the remote position, gate will receive a 4-20 mA signal to set position of gate to achieve a predetermined flow rate. Control will be by a remote PLC. In the local position, the gate controlled by the local switches.
2.7 STEMS
A. The operating stem shall be sized to safely withstand without buckling or permanent distortion the stresses induced by normal operating forces. The stem shall have a minimum diameter of 1- 1/2 and shall be designed to transmit in compression at least stall thrust x 1.3 times the rated output of the electric operator. Stem threads shall be machine-cut, acme type. Stems shall be stainless steel, ASTM A-276 type 304 and shall be one-piece. Clear plastic stem covers shall be provided, properly vented, with indicator strips for field-mounting by the installing contractor.
2.8 STEM GUIDES
A. Stem guides shall be fabricated from stainless steel. Stem guides shall be equipped with a UHMWPE bushing. Guides shall be adjustable and spaced in accordance with the manufacturer’s recommendation. The L/R ratio shall not be greater than 200.
2.9 STEM COVER
A. Rising stem gates shall be provided with a clear polycarbonate stem cover. The stem cover shall have a cap and condensation vents and a clear Mylar position indicating tape. The tape shall be field applied to the stem cover after the gate has been installed and positioned.
WRCRWA ALUMINUM SLIDE GATES PLANT EXPANSION PROJECT 352016-3 2.10 LIFTING MECHANISM
A. The operating stem shall be of stainless steel designed to transmit in compression at least 2 times the rated output of the operating manual mechanism with a 40 lb effort on the crank or handwheel.
B. Gates having a width equal to or greater than two times their height shall be provided with two geared lifting mechanisms interconnected by a tandem shaft.
C. The stem shall have a slenderness ratio (L/R) less than 200. The threaded portion of the stem shall have Acme type cold rolled threads with a maximum surface of 16 micro-inches.
D. Stem lengths requiring more than one piece shall be coupled or pinned to an extension tube.
2.11 MATERIALS OF CONSTRUCTION
A. Frame, yoke, slide, stem extension: Aluminum 6061-T-6 ASTM B-209 and 211
B. Side and Top Seals: Neoprene ASTM D-2000
C. Bearing bars, Guides, Stem guide Liner: UHMW Polyethylene ASTM D4020
D. Bottom Seal: Neoprene ASTM D-2000
E. Threaded stem, Stem guides, Hand crank: Stainless steel ASTM A-276, Type 304 or 304L
F. Fasteners: Stainless steel Type 304 or 304L
G. Pedestal/Wall bracket: Cast Iron ASTM A126, class B or mild steel
H. Stem cover: Polycarbonate ASTM A-707
I. Lift and stop nut: Manganeze bronze, ASTM B584, UNS-C86500
END OF SECTION 352016
WRCRWA ALUMINUM SLIDE GATES PLANT EXPANSION PROJECT 352016-4 SECTION 352020 – STAINLESS STEEL SLUICE GATES
PART 1 - GENERAL
1.1 SCOPE
A. This section covers Stainless Steel Flow Control Sluice Gates and operators.
1.2 GENERAL
A. The equipment provided under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions and recommendations of the equipment manufacturer unless exceptions are noted by the engineer.
B. Gates and operators shall be supplied with all the necessary parts and accessories indicated on the drawings, specified or otherwise required for a complete, properly operating installation, and shall be the latest standard product of a manufacturer regularly engaged in the production of fabricated gates.
C. Gates supplied under this section shall be Series 20 Stainless Steel Flow Control Sluice Gates as manufactured by H.Fontaine Ltd, or equal.
1.3 GOVERNING STANDARDS
A. Except as modified or supplemented herein, all gates and operators shall conform to the applicable requirements of AWWA C561, latest edition.
1.4 QUALITY ASSURANCE
A. The manufacturer shall have experience in the production of substantially similar equipment, and shall show evidence of satisfactory operation in at least 50 installations. The manufacturer's shop welds, welding procedures and welders shall be qualified and certified in accordance with the requirement of the latest edition of ASME, Section IX.
B. Gates shall be shop inspected for proper operation before shipping.
C. The manufacturer shall be ISO 9001 : 2000 certified.
1.5 SUBMITTALS
A. The manufacturer shall submit for approval by the Engineer, drawings showing the principal dimensions, general construction and materials used in the gate and lift mechanism.
B. Submittals shall be in accordance with specification section 013300.
WRCRWA STAINLESS STEEL SLUICE GATES PLANT EXPANSION PROJECT 352020-1 PART 2 - PERFORMANCE
2.1 LEAKAGE
A. Sluice gates shall be substantially watertight under the design head conditions. Under the design seating head, the leakage shall not exceed 0.05 U.S. gallon per minute per foot (0.60 l/min per meter) of seating perimeter. Under the design unseating head, the leakage for heads of 20 feet (6m) or less shall not exceed 0.1 U.S. gallon per minute per foot (1.25 l/min per meter) of perimeter. For unseating heads greater than 20 feet (6m), the allowable leakage shall not exceed the rate per foot (meter) of perimeter specified by the following equations:
Maximum allowable leakage Gallons per minute per foot of perimeter: = 0.10 + (0.0025 x (unseating head in feet - 20))
Example : If we have a gate with 35 feet head, the leakage for the unseating head will be : 0.10+(0.0025 x (35 -20)) = 0.1375 US gpm/ft of perimeter
2.2 DESIGN HEAD
A. The sluice gates shall be designed to withstand the design head.
2.3 SEAL PERFORMANCE TEST
A. The gate's sealing system should have been tested through a cycle test in an abrasive environment and should show that the leakage requirements are still obtained after 25,000 cycles with a minimum deterioration.
PART 3 - PRODUCT
3.1 SLUICE GATES
A. GENERAL DESIGN. Gates shall be either self-contained or non self-contained of the rising stem, non-rising or telescopic stem configuration as indicated on the gate schedule.
B. WALL THIMBLE. The wall thimble shall be stainless steel and supplied by the gate manufacturer. Refer to the gate schedule for type and applicable locations. Material thickness should be according to the manufacturer's recommendations and be of sufficient resistance to handle the operating forces.
C. FRAME. The gate frame shall be constructed of structural members or formed plate welded to form a rigid one-piece frame. The frame shall be of the flange back design suitable for mounting on a concrete wall (CW), concrete wall with extra-wide flange (CWX), round
WRCRWA STAINLESS STEEL SLUICE GATES PLANT EXPANSION PROJECT 352020-2 manhole (RM), round manhole with extra-wide flange (RMX), a wall thimble (WT), or a standard flange (SF). The guide slot shall be made of UHMWPE (ultra high molecular weight polyethylene). The frame configuration shall be of the flush-bottom type and shall allow the replacement of the top and side seals without removing the gate frame from the concrete or wall thimble.
D. SLIDE. The slide shall consist of a flat plate reinforced with formed plates or structural members to limit its deflection to 1/720 of the gate's span under the design head.
E. GUIDES AND SEALS. The guides shall be made of UHMWPE (ultra high molecular weight polyethylene) and shall be of such length as to retain and support at least two thirds (2/3) of the vertical height of the slide in the fully open position. Side and top seals shall be made of UHMWPE (ultra high molecular weight polyethylene) of the self-adjusting type. A continuous compression cord shall ensure contact between the UHMWPE guide and the gate in all positions. The sealing system shall maintain efficient sealing in any position of the slide and allow the water to flow only in the opened part of the gate. The bottom seal shall be made of resilient neoprene set into the bottom member of the frame and shall form a flush-bottom.
3.2 OPERATORS AND STEM
A. STEM AND COUPLINGS. The operating stem shall be of stainless steel designed to transmit in compression at least 2 times the rated output of the operating manual mechanism with a 40 lbs (178 N) effort on the crank or handwheel.
1. The stem shall have a slenderness ratio (L/r) less than 200. The threaded portion of the stem shall have machined cut threads of the Acme type.
2. Where a hydraulic, pneumatic or electric operator is used, the stem design force shall not be less than 1.25 times the output thrust of the hydraulic or pneumatic cylinder with a pressure equal to the maximum working pressure of the supply, or 1.25 times the output thrust of the electric motor in the stalled condition.
3. For stems in more than one piece and with a diameter of 1¾ inches (45 mm) and larger, the different sections shall be joined together by solid bronze couplings. Stems with a diameter smaller than 1¾ inches (45 mm) shall be pinned to an extension tube.
4. The couplings shall be grooved and keyed and shall be of greater strength than the stem.
5. Gates having a width greater than two times their height shall be provided with two lifting mechanisms connected by a tandem shaft.
B. STEM GUIDES. Stem guides shall be fabricated from type 316L stainless steel. The guide shall be equipped with an UHMWPE bushing. Guides shall be adjustable and spaced in accordance with the manufacturer's recommendation. The L/r ratio shall not be greater than 200.
1. STEM COVER. Rising stem gates shall be provided with a clear polycarbonate stem cover. The stem cover shall have a cap and condensation vents and a clear Mylar position indicating tape. The tape shall be field applied to the stem cover after the gate has been installed and positioned.
2. LIFTING MECHANISM. Manual operators of the types listed in the schedule shall be
WRCRWA STAINLESS STEEL SLUICE GATES PLANT EXPANSION PROJECT 352020-3 provided by the gate manufacturer.
a. All bearings and gears shall be totally enclosed in a weather tight housing. The pinion shaft of crank-operated mechanisms shall be constructed of stainless steel and supported by roller or needle bearings.
b. Each manual operator shall be designed to operate the gate under the maximum specified seating and unseating heads by using a maximum effort of 40 lbs (178 N) on the crank or handwheel, and shall be able to withstand, without damage, an effort of 80 lbs (356 N).
c. The crank shall be removable and fitted with a corrosion-resistant rotating handle. The maximum crank radius shall be 15 inches (381 mm) and the maximum handwheel diameter shall be 24 inches (610 mm).
C. YOKE. Self-contained gates shall be provided with a yoke made of structural members or formed plates. The maximum deflection of the yoke shall be 1/360 of the gate's span.
PART 4 - MATERIALS
PART MATERIAL Frame, yoke, stem guides, slide, stem Stainless steel ASTM A-240 type 316L extension Ultra high molecular weight polyethylene Side seals, stem guide liner (UHMWPE) ASTM D-4020 Nitrile ASTM D2000 M6BG 708, A14, B14, Compression cord E014, E034 Bottom seal Neoprene ASTM D2000 Grade 2 BC 510 Stainless steel ASTM A-276 type 303 MX or Threaded stem 316 ASTM F593 and F594 GR1 for type 304 and Fasteners GR2 for type 316 Pedestal, handwheel and crank Tenzaloy aluminum
Gasket (between frame and wall) EPDM ASTM 1056
Stem cover Polycarbonate ASTM D-3935
Lift nut, couplings Manganese bronze ASTM B584 UNS-C86500
PART 5 - EXECUTION
A. INSTALLATION. Gates and appurtenances shall be handled and installed in accordance with the manufacturer's recommendations.
B. FIELD TESTS
WRCRWA STAINLESS STEEL SLUICE GATES PLANT EXPANSION PROJECT 352020-4
1. Following the completion of each gate installation, the gates shall be operated through at least two complete open/close cycles. If an electric or hydraulic operator is used, limit switches shall be adjusted following the manufacturer's instructions.
2. Gates should be checked for leakage by the contractor (refer to the “Performance” section for approval criteria).
END OF SECTION 352020
WRCRWA STAINLESS STEEL SLUICE GATES PLANT EXPANSION PROJECT 352020-5 SECTION 352030 – STAINLESS STEEL STOP LOGS
PART 1 - GENERAL
1.1 SUMMARY
A. This section covers Stainless Steel Stop Logs.
1.2 GENERAL
A. The equipment provided under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions and recommendations of the equipment manufacturer unless exceptions are noted by the engineer.
B. Stop logs shall be supplied with all the necessary parts and accessories indicated on the drawings, specified or otherwise required for a complete, properly operating installation, and shall be the latest standard product of a manufacturer regularly engaged in the production of stop logs.
C. The stop logs supplied under this section shall be Series 95 Stainless Steel Stop Logs as manufactured by H. Fontaine Ltd, or Equal.
1.3 QUALITY ASSURANCE
A. The manufacturer shall have experience in the production of substantially similar equipment and shall show evidence of satisfactory operation in at least 5 installations. The manufacturer's shop welds, welding procedures and welders shall be qualified and certified in accordance with the requirement of the latest edition of ASME, Section IX.
B. The fully assembled stop logs shall be shop inspected before shipping.
C. The manufacturer shall be ISO 9001: 2000 certified.
1.4 SUBMITTALS
A. The manufacturer shall submit, for approval by the purchaser, drawings showing the principal dimensions, general construction and materials used in the gate and lift mechanism.
WRCRWA STAINLESS STEEL STOP LOGS PLANT EXPANSION PROJECT 352030 - 1
PART 2 - PERFORMANCE
2.1 LEAKAGE
A. Stop logs shall be substantially watertight under the design head conditions. Leakage shall not exceed 0.1 U.S. gallon per minute per foot (1.25 l/min per meter) of periphery for the rated seating head.
2.2 DESIGN HEAD
A. For the purpose of these specifications, stop logs shall be defined as meeting the leakage requirements at maximum water level (height of stop logs in channel).
PART 3 - PRODUCT
3.1 STOP LOGS
A. General Design. Stop logs shall be constructed entirely of stainless steel. All hardware shall be stainless steel.
B. Frame. The frame shall be made of stainless steel channels. The frame shall be suitable for mounting on a concrete wall.
C. The logs shall consist of a flat plate reinforced with formed plates or structural members to limit their deflection to 1/360 of the gate's span under the design head. The guide shall be of UHMWPE (ultra-high molecular weight polyethylene).
D. Seals. Seals shall be made of EPDM attached to the logs by means of a UHMWPE retainer guide. The bottom seal is attached to the log with a stainless steel retainer and seal on top of the log immediately underneath.
E. A stainless steel lifting device shall be supplied for each log width. The width of the lifting device will be the same as the log channel. The lifting device shall be equipped with a device to allow releasing of the stop log from the operating floor. This device shall grab the log automatically.
PART 4 - INSTALLATION
4.1 GENERAL
A. Gates and appurtenances shall be handled and installed in accordance with the manufacturer's recommendations.
END OF SECTION 352030
WRCRWA STAINLESS STEEL STOP LOGS PLANT EXPANSION PROJECT 352030 - 2
SECTION 352035 – FIBERGLASS POLYESTER GATES
PART 1 - GENERAL
1.1 SUMMARY
A. This section includes all fiberglass polyester (FRP) gates required including all frames, mounting hardware, operating, and all associated components to provide a complete and functioning gate system.
1.2 REFERENCES:
A. Design, fabricate, and test materials and gates in accordance with manufacturer’s recommended procedures and the following codes and standards:
1. ASTM A193 Stainless Steel Anchor Bolts 2. ASTM A276 Stainless Steel Bars 3. ASTM B584 Alloy 865 Manganese Bronze 4. ASTM D256 Izod Impact Strength 5. ASTM D570 Water Absorption Rate 6. ASTM D638 Tensile Strength 7. ASTM D695 Compressive Properties of Rigid Plastic 8. ASTM D696 Coefficient of Linear Expansion 9. ASTM D790 Flexural Properties 10. ASTM D792 Density of Specific Gravity at 23 degrees C 11. ASTM D1056 Polymer Grade 12. ASTM D2563-0 Visual Defects 13. ASTM D2583 Indentation Hardness 14. ASTM D2584 Resin, Glass & Filler Content 15. AWWA C-563 Fabricated Composite Slide Gates
B. Composition of the sluice gate laminate shall be in accordance with the recommendations shown in the Quality Assurance Report for Reinforced Thermoset Plastic (RTP) Corrosion Resistant Equipment prepared under the sponsorship of the Society of the Plastics Industry, Inc. (SPI), and the Material Technology Institute (MTI) of the Chemical Process Industry for “Hand Lay-Up Laminates,” and shall meet the specifications for Type I, Grade 10 laminates shown in Appendix M-1 of said report.
C. The fully assembled gates shall be shop inspected, tested for operation and leakage, and adjusted before shipping. There shall be no assembling or adjusting on the job sites other than for the lifting mechanism.
1.3 SUBMITTALS
A. The manufacturer shall submit for approval by the purchaser, drawings showing the principal dimensions, general construction and materials used in the gate and lift mechanism.
WRCRWA FIBERGLASS POLYESTER GATES PLANT EXPANSION PROJECT 352035-1 B. The manufacturer shall submit for approval by the purchaser, complete engineering design calculations in compliance with AWWA standards latest edition.
1.4 DELIVERY, STORAGE AND HANDLING
A. Ship all gates with suitable packaging to protect products from damage. Protect all products and unload, handle, and store in accordance with all manufacturer recommendations.
1.5 PERFORMANCE
A. Leakage: Sluice gates shall be substantially watertight under the design head conditions. Under the design seating head, the leakage shall not exceed 0.10 US gallons per minute per foot of seating perimeter. Under the design unseating head, leakage shall not exceed 0.10 US gallons per minute per foot of perimeter.
B. Manufacturer must provide warranty for 25 years against corrosion.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Gate body shall be engineered composite fiberglass reinforced plastic (FRP) completely encapsulating an internal steel reinforcing structure. Body shall be infusion molded to create a seamless corrosion barrier impervious to moisture.
B. Internal steel reinforcing shall be carbon steel as needed for deflection requirements.
C. Internal core foam shall be 2lb polyisocyanurate closed cell rigid foam.
D. The Guide Frame and Guide Frame Rails shall be vinyl ester resin FRP. The Operator support yoke shall be vinyl ester resin FRP or T-316L stainless steel.
E. Stems and Gate Hardware shall be type T-316L stainless steel.
F. Gate shall be sealed on three sides for open top installations and all four sides for submerged gate applications. Seals shall be hollow bulb J seal molded of extruded neoprene. The J-seal clamping bar and fasteners shall be type T-316L stainless steel.
G. Lifting Nuts and Thrust Nuts shall be Manganese Bronze, ASTM B-584, Alloy 865.
H. Thrust Collar shall be types T-316L stainless steel.
I. Provide hand-crank type operator suitable for outdoor exposure to the elements.
J. Gates shall be Plasti-Fab Heavy Duty Titeseal Sluice Gates (design basis) or equal.
WRCRWA FIBERGLASS POLYESTER GATES PLANT EXPANSION PROJECT 352035-2 2.2 DESIGN CRITERIA
A. Visual inspections for defects shall be made without the aid of magnification and defects shall be classified as to type and level as shown in Table 1 of ANSI/ASTM D2563-0, approved 1977. (or any subsequent revision). Allowable surface tolerances are as follows:
1. No cracks, crazing, blisters, chips, pits, dry spots, fish eyes, burned areas, surface porosity, exposed glass or entrapped air is acceptable. 2. Scratches must be no more than 0.002-inches deep and wrinkles and solid blisters shall not exceed 1/8”. 3. No foreign material shall be present.
B. Deflection across the gate width shall be limited to L/360 or 1/4”, whichever is less at the maximum operating head.
C. Head Pressure: submerged gates shall be susceptible to seating head indicated in the design drawings.
D. Gate shall seal on all four (4) sides for submerged applications.
E. Wear strips UHMW Polyethylene shall have the following minimum characteristics:
Tensile Strength 5,600 psi (0.7kg/cm2) Flexural Modulus @ 730F 130,000 – 140,000 psi (230C) (9140 – 9843kg/cm2) Coefficient of Friction 0.15 Water Absorption 0.01% in 24 hours
F. Extruded Neoprene Seals shall have the following physical characteristics:
Specific Gravity 1.25 Hardness 55 – 65 Shore A Durometer Tensile Strength 1500 psi min. (0.07ksc) Elongation 300% Low temperature brittleness -
G. Physical Properties for the glass mat laminate shall meet the following minimum requirements:
Tensile strength 15,000 psi (1034 ksc) Flexural Modulus 1,000,000 psi (70307 ksc) Flexural Strength 20,000 psi (1406 ksc) Compressive Strength 22,000 psi (1547 ksc) Impact Strength 9.0 ft-lbs/in. (1.24 kgf.m/25mm) Water absorption 0.13% (in 24 hours)
2.3 CONSTRUCTION
A. Gate body shall have UV stabilizing pigment in the resin to provide long-term protection from UV exposure.
WRCRWA FIBERGLASS POLYESTER GATES PLANT EXPANSION PROJECT 352035-3 B. The surface shall be resin rich to a depth of 0.010 inches to 0.020 and reinforced with C-glass and/or polymeric fiber surfacing material. The composition of these layers shall be approximately 95% resin by weight.
C. Core material must be 100% resistant to decay and attack by fungus and bacteria and be resistant to hydrocarbons.
D. Elastomeric J-seals shall have a hardness range of 55 to 65 shore A durometer and conforming to ASTM specification D-2000 having a maximum compression set of 25%, and low temperature brittleness to meet suffice F-17 (-40 degrees).
E. Guides shall be styled for wall mounting unless indicated otherwise in the drawings. The head rail shall be affixed so as to allow the gate to be removed from the guide without disassembly.
F. Operators shall be sized to start the gate moving under a maximum head pressure with a pull of not more than 40 lbs. Provide a manual hand crank operator mounted at the height above the gate/opening indicated in the drawings. In general, operators should be located 3’-6” above the floor elevation or working platform surface elevation to facilitate access and operation of the gate.
G. Provide transparent plastic stem covers to protect the stem, operator, and minimize condensation. The stem covers shall be marked with “Open” and “Closed” position indicators.
H. Provide wall/mounted pedestals with free-standing extensions as required to mount the operator in the position indicated in the design drawings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Thoroughly clean and remove all shipping materials prior to setting.
B. Install gates per manufacturer’s recommendations.
C. Operate all gates from fully opened to fully closed to ensure proper installation and operation.
D. Gate shall be inspected under normal operating conditions (i.e. maximum seating or un-seating head conditions) to ensure proper installation and satisfactory performance including deflection, leakage rates, and smooth actuation.
END OF SECTION 352035
WRCRWA FIBERGLASS POLYESTER GATES PLANT EXPANSION PROJECT 352035-4 SECTION 352040 –FIBERGLASS STOP LOGS
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes all Stop Log systems required for the complete installation of the work.
1.2 REFERENCES
A. Design, fabricate and test stop log systems and materials in accordance with manufacturer’s recommended procedures and the following codes and standards:
1. ASTM A193 - Stainless Steel Anchor Bolts 2. ASTM A276 - Stainless Steel Bars 3. ASTM B584 - Alloy 865 Manganese Bronze 4. ASTM D256 - Izod Impact Strength 5. ASTM D570 - Water Absorption Rate 6. ASTM D638 - Tensile Strength 7. ASTM D695 - Compressive Properties of Rigid Plastic 8. ASTM D696 - Coefficient of Linear Expansion 9. ASTM D790 - Flexural Properties 10. ASTM D792 - Density and Specific Gravity at 230 C 11. ASTM D1056 - Polymer Grade 12. ASTM D2583 - Indentation Hardness 13. ASTM D2563-0 - Visual Defects 14. ASTM D2584 - Resin, Glass & Filler Content 15. AWWA C-563 - Leakage Rate 16. NSF-61 - Potable Water
B. Composition of the stop log laminate shall be in accordance with the recommendations shown in the Quality Assurance Report for Reinforced Thermoset Plastic (RTP) Corrosion Resistant Equipment prepared under the sponsorship of the Society of the Plastics Industry, Inc. (SPI), and the Material Technology Institute (MTI) of the Chemical Process Industry for “Hand Lay-UP Laminates,” and shall meet the specifications for Type I, Grade 10 laminates shown in Appendix M-1 of said report.
C. Manufacturer must provide warranty for 25 years against corrosion.
1.3 SUBMITTALS
A. Submit the following for acceptance:
WRCRWA FIBERGLASS STOP LOGS PLANT EXPANSION PROJECT 352040-1 1. Approval Drawings a. Showing all critical dimensions. b. Showing principal parts and materials. 2. Spare parts list (when applicable).
1.4 DELIVERY, STORAGE AND HANDLING
A. Ship all stop logs with suitable packaging to protect products from damage.
B. Protect stop logs, lifting pins, guide frames and lifting devices racks from damage.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Stop log panels shall be: 1. Engineered composite fiberglass reinforced plastic (FRP) completely encapsulating an internal steel reinforcing structure. a. Infusion molded to create a seamless corrosion barrier impervious to moisture. b. FRP resin shall be polyester. c. Internal Steel Reinforcing: Carbon Steel as needed for deflection requirements. d. Sandwich design for superior strength. e. Foam core between steel reinforcing. f. Seal material to be Neoprene.
B. Guide Frames 1. Guide Frame Rails to be: TypeT-316L Stainless Steel. 2. Seal material to be Neoprene.
C. Lifting Pins/Eyes 1. Lifting Pins/Eyes to be: Type T-316L stainless steel.
D. Anchor Bolts (when applicable) 1. Anchor Bolts to be: Type T-316L stainless steel.
E. Lifting Beam/Poles 1. Lifting Beam/Poles to be: Type T-316L stainless steel.
2.2 STOP LOGS
A. Acceptable Manufacturers: 1. Plasti-Fab Inc 2. Or equal.
B. Stop Log systems shall exceed AWWA C-563: 1. Leakage: Maximum allowable leakage of stop logs with seating head shall not exceed 0.10 GPM/ft of wetted linear seal area under full design head when installed in manufacturer’s WRCRWA FIBERGLASS STOP LOGS PLANT EXPANSION PROJECT 352040-2 Guide Frames.
2.3 DESIGN CRITERIA
A. Stop logs shall be 11’-0” wide X 7’-0” High overall with 2’-0” clear below the bottom log.
B. Composition of the stop log laminate shall be in accordance with the recommendations shown in the Quality Assurance Report for Reinforced Thermostat Plastic (RTP) Corrosion Resistant Equipment prepared under the sponsorship the Society of the Plastics Industry, Inc. (SPI) and the Material Technology Institute of the Chemical Process Industries, Inc. (MTI) for “Hand Lay- up Laminates” and shall meet the specifications for Type 1, Grade 10 laminates shown in Appendix M-1 of said report. 1. Visual inspection for defects shall be made without the aid of magnification and defects shall be classified as to type and level as shown in Table 1 of ANSI/ASTM D2563-0, approved 1977, (or any subsequent revision). Allowable surface tolerances are as follows:
DEFECTS ALLOWABLE TOLERANCE Cracks None Crazing Blisters Chips Pits Dry Spots Fish Eyes Burned Areas Entrapped Air Wrinkles and solid Maximum Deviation: 10% of thickness, blisters, not to exceed 1/8” but not to exceed 1/8 inch Surface porosity (pinholes or None pores in the laminate surface) Exposed Glass None Exposure of cut edges Scratches None more than .002” deep Foreign Matter None
C. Maximum Fiber Stress 1. Ultimate or yield, whichever applies, does not exceed 2.5 times the working stress.
D. Deflection 1. Deflection across the stop log width shall be limited to: L/360 or ¼”, whichever is less, at the maximum operating head.
E. Head Pressure 1. Stop log system shall be designed for a maximum head pressure of: 84 inches plus applicable hydraulic forces from adjacent piping.
F. Stop log panel Size 1. Channel Width: 132 inches. 2. Stop Log System Height: 84 inches. WRCRWA FIBERGLASS STOP LOGS PLANT EXPANSION PROJECT 352040-3 3. Channel Invert Elevation: See Plan Sheets. 4. Top of Wall Elevation: See Plan Sheets 5. Number of Stop Log Panels 7 Each 6. Panel Height: 12 inches.
G. Surface Conditions 1. All stop log panels shall be flat and level. 2. Warpage throughout the entire stop log panel shall not produce a crown of more than 1/16” in any direction.
2.4 CONSTRUCTION
A. Stop Log Panels 1. The stop log shall be fabricated by means of vacuum infusion so as to totally encapsulate the internal structural matrix and protect it against corrosion from moisture or chemical deterioration with a minimum thickness of ¼ inch FRP on the front and back facings, and ¾ inch FRP on the remaining perimeter. Stop logs shall be designed so that the maximum fiber stress (ultimate or yield, whichever applies) does not exceed 2.5 times the working stress. Stop logs shall be suitably reinforced to withstand the maximum seating head with a deflection less than L/360 of the stop log width, or ¼ inch, whichever is less. Stop log covers that are fabricated from pressed or laminated sheet material and/or glued/bonded to a substructure shall not be acceptable. No seams or joints that may delaminate, allow seepage, or provide an avenue to collect debris will be acceptable. Each Stop Log shall be molded individually to the exact dimensions specified. 2. Stop Log shall be manufactured of reinforced thermoset plastic in the form of FRP. 3. Stop Log shall have UV Stabilizing pigment in the Resin to provide long-term protection from UV. 4. The surface shall be resin rich to a depth of .010 inches to 0.020 inches and reinforced with C-glass or polymeric fiber surfacing material. 5. The surface shall be free of exposed reinforcing fibers. 6. The composition of these layers shall be approximately 95% (by weight) resin. The remaining laminate shall be made up of copolymer composite and reinforcing fibers in a form, orientation and position to meet the mechanical requirements. 7. Structural reinforcing shall be utilized to attain the necessary stiffness to meet deflection requirements, and shall be well encapsulated with a laminate not less than ¼” thick on each side to ensure against any permeation by water to the core areas. Internal steel structure to be welded per ASME/ASTM standards, sandblasted and coated with vinyl ester resin immediately prior to vacuum infusion in order to ensure complete bonding with external corrosion barrier. 8. Type T-316L stainless steel lifting pins shall be attached to the Stop Log by passing completely through the log. Stainless steel lifting pin shall be fastened to the log with sufficient reinforcing to withstand the lifting force. Lifting pins assemblies shall pass completely through the stop log, and shall be entirely encapsulated with a minimum thickness of ¼ inch of FRP. Lifting pins attached to the surface of the log are not acceptable. The through holes shall not pass through or be in contact with the internal steel reinforcing. 9. Core material must be 100% resistant to decay and attack by fungus and bacteria and be resistant to hydrocarbons. 10. To assure maximum service life, the copolymer composite shall be ultraviolet stabilized and seamless to protect inner structural members from corrosion. WRCRWA FIBERGLASS STOP LOGS PLANT EXPANSION PROJECT 352040-4 11. Metal, concrete, or wood stop logs subject to corrosion / bacterial breakdown / rot shall not be acceptable alternatives to composite FRP material. 12. Stop Log panels shall be manufactured using advanced technology vacuum infusion resin transfer processes. The closed mold vacuum process must completely evacuate all air from the mold prior to infusing the mold with premium quality resin as specified. The vacuum infusion process must eliminate the potential of air entrapment and/or voids in the matrix of the stop log panel (which cause defects and performance-detracting irregularities) thus producing a finished product that is one-piece, seamless and uniformly impenetrable by fluids eliminating interior corrosion as is produced by techniques that employ adhesives or mechanical fasteners to attach individual panels to a pre-fabricated framework resulting in seams along vertical and horizontal axes of the stop log which create stress-potential areas, portals for fluid infiltration, subsequent de-lamination and product failure due to corrosion.
B. Seals 1. The stop logs shall be equipped with elastomeric bottom seals to seal between the logs. Vertical seals shall be mounted on the face at the ends of the stop logs positioned to contact the inside of the guide rails. Seals shall be made of molded Neoprene, per ASTM D- 2000 having a hardness of 55 – 65 Shore A Durometer, conforming to ASTM D-2000, with a maximum compression set of 25%, and low temperature brittleness to meet suffix F-17 (- 40¡F).
C. Guide Frames 1. Guide frames shall be styled for in- channel mounting as shown on the contract drawings and/or stop log schedule. 2. Guide frames shall be fabricated from T-316L / stainless steel and shall have a slot suitable for mating with the stop log panels.
2.5 PHYSICAL PROPERTIES
A. Structural characteristics for a 1/8” glass mat laminate shall meet the following minimum physical properties:
Tensile strength 15,000 psi (1034 ksc) Flexural Modulus 1,000,000 psi (70307 ksc) Flexural Strength 20,000 psi (1406 ksc) Compressive Strength 22,000 psi (1547 ksc) Impact Strength 9.0 ft-lbs/in. (1.24 kgf.m/25mm) Water absorption 0.13% (in 24 hours)
B. Seals: Extruded Neoprene / EPDM Seals shall have the following physical characteristics: Specific Gravity 1.25 Hardness 55 – 65 Shore A Durometer Tensile Strength 1,500 psi min. Elongation 300% Low Temperature Brittleness -40¡
WRCRWA FIBERGLASS STOP LOGS PLANT EXPANSION PROJECT 352040-5 PART 3 - EXECUTION
3.1 INSTALLATION
A. Thoroughly clean and remove all shipping materials prior to setting.
B. Install stop log systems per Manufacturer’s recommendations.
3.2 FIELD TESTING
A. Qualified Factory representative shall provide adequate training for facility employees.
B. Representative shall complete a Certification of Proper Installation and provide copies to the Owner, Engineer, Contractor and Manufacturing Facility. (When applicable)
END OF SECTION 352040
WRCRWA FIBERGLASS STOP LOGS PLANT EXPANSION PROJECT 352040-6 SECTION 352055 – FIBERGLASS BAFFLE WALLS
PART 1 - GENERAL
1.1 SUMMARY
A. This section includes all fiberglass polyester (FRP) baffle partitions and walls required including all frames, mounting hardware and all associated components to provide a complete and functioning baffle wall.
1.2 REFERENCES:
A. Design, fabricate, and test FRP baffle walls in accordance with manufacturer’s recommended procedures and the following codes and standards:
1. ASTM A193 Stainless Steel Anchor Bolts 2. ASTM D256 Izod Impact Strength 3. ASTM D570 Water Absorption Rate 4. ASTM D638 Tensile Strength 5. ASTM D695 Compressive Properties of Rigid Plastic 6. ASTM D696 Coefficient of Linear Expansion 7. ASTM D790 Flexural Properties 8. ASTM D792 Density of Specific Gravity at 23 degrees C 9. ASTM D2563-0 Visual Defects 10. ASTM D2583 Indentation Hardness 11. ASTM D2584 Resin, Glass & Filler Content
B. Composition of the FRP baffle wall shall be in accordance with the recommendations shown in the Quality Assurance Report for Reinforced Thermoset Plastic (RTP) Corrosion Resistant Equipment prepared under the sponsorship of the Society of the Plastics Industry, Inc. (SPI), and the Material Technology Institute (MTI) of the Chemical Process Industry for “Hand Lay- Up Laminates,” and shall meet the specifications for Type I, Grade 10 laminates shown in Appendix M-1 of said report.
C. The fully assembled gates shall be shop inspected. There shall be no assembling or adjusting on the job sites.
1.3 SUBMITTALS
A. The manufacturer shall submit for approval by the purchaser, drawings showing the principal dimensions, general construction and materials used in the baffle plate, including plate the number and size of each individual baffle plate, the mounting and support method to install the gate and support members, and the configuration, size and number of any openings in the baffle plate.
B. The manufacturer shall submit for approval by the purchaser, complete engineering design calculations in compliance with AWWA standards latest edition. Submittal shall also include
WRCRWA FIBERGLASS BAFFLE WALLS PLANT EXPANSION PROJECT 352055-1 calculations for deflection and, where applicable, headloss through the openings in the baffle wall.
1.4 DELIVERY, STORAGE AND HANDLING
A. Ship all gates with suitable packaging to protect products from damage. Protect all products and unload, handle, and store in accordance with all manufacturer recommendations. Protect corners and protruding accessories form damage.
1.5 PERFORMANCE
A. Manufacturer must provide warranty for 25 years against corrosion of the baffle wall and associated components.
PART 2 - PRODUCTS
2.1 MATERIALS AND CONSTRUCTION
A. Baffle walls and framing systems, where required, shall be designed to meet the requirements listed herein, accounting for hydraulic forces exerted on the system.
B. Baffle wall shall be engineered composite fiberglass reinforced plastic (FRP) sandwich construction completely encapsulation an internal structure. Construction shall be molded to create a seamless corrosion barrier impervious to moisture. Internal steel reinforcing shall be carbon steel as needed for deflection requirements.
C. Baffle wall shall be molded in one piece with a minimum thickness of 1-inch polyurethane foam encapsulated between 1/8-inch minimum fiberglass reinforced skins. The resin and gelcoat shall be UV inhibited.
D. The exterior surfaces shall be finished with a premium grade gelcoat for superior protection against weathering and discoloration. The surface shall be resin rich to a depth of 0.10 inches to 0.20 inches.
E. The exterior surface finish shall be smooth to allow easy access for cleaning and maintenance.
F. There shall be a bolting flange on the bottom wall panel and on each side of each panel to facilitate mounting the baffle to the structure.
G. Fiberglass baffle wall supplier shall include all mounting material and hardware, including fiberglass angles, channels, brackets, and all bolts and anchors. Anchors shall be T-316L stainless steel. The manufacturer shall provide anchorage calculations, signed and sealed by a professional engineer registered in the State of California.
H. Internal core foam shall be 2lb polyisocyanurate closed cell rigid foam. Foam core must be 100% resistant to decay and attack by fungus and bacteria and be resistant to hydrocarbons.
I. Individual baffle wall panels shall be individually removable to allow for maintenance or access. Each baffle plate shall be of the dimensions and provide the opening size, placement,
WRCRWA FIBERGLASS BAFFLE WALLS PLANT EXPANSION PROJECT 352055-2 and orientation as indicated in the design drawings. Alternate baffle plate design and opening configuration must be approved by the Engineer.
J. FRP baffle walls shall be as manufactured by Plasti-Fab (design basis) or equal.
K. Visual inspections for defects shall be made without the aid of magnification and defects shall be classified as to type and level as shown in Table 1 of ANSI/ASTM D2563-0, approved 1977. (or any subsequent revision). Allowable surface tolerances are as follows:
1. No cracks, crazing, blisters, chips, pits, dry spots, fish eyes, burned areas, surface porosity, exposed glass or entrapped air is acceptable. 2. Scratches must be no more than 0.002-inches deep and wrinkles and solid blisters shall not exceed 1/8”. 3. No foreign material shall be present.
L. Deflection across the baffle wall width shall be limited to L/360 or 1/4”, whichever is less at the maximum operating head.
M. All baffle walls shall be flat and level. Warpage throughout the entire baffle wall shall not produce a crown of more than 1/16-inch in any direction.
N. Physical Properties for the glass mat laminate shall meet the following minimum requirements:
Tensile strength 15,000 psi (1034 ksc) Flexural Modulus 1,000,000 psi (70307 ksc) Flexural Strength 20,000 psi (1406 ksc) Compressive Strength 22,000 psi (1547 ksc) Impact Strength 9.0 ft-lbs/in. (1.24 kgf.m/25mm) Water absorption 0.13% (in 24 hours)
PART 3 - EXECUTION
3.1 INSTALLATION
A. Thoroughly clean and remove all shipping materials prior to setting.
B. Install baffle walls per manufacturer’s recommendations.
C. Baffle walls shall be inspected under normal operating conditions (i.e. maximum seating or un- seating head conditions) to ensure proper installation and satisfactory performance including deflection and headloss.
END OF SECTION 352055
WRCRWA FIBERGLASS BAFFLE WALLS PLANT EXPANSION PROJECT 352055-3
SECTION 353000 STAINLESS STEEL FLAP GATES
PART 1 - GENERAL CONDITIONS
1.1 SCOPE
A. This section covers fabricated Stainless Steel Circular Flap Gates.
1.2 GENERAL
A. The equipment provided under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the drawings, specifications, engineering data, instructions and recommendations of the equipment manufacturer, unless exceptions are noted by the engineer.
B. Flap Gates shall be supplied with all the necessary parts indicated on the drawings, specified or otherwise required for a complete, properly operating installation, and shall be the latest standard product of a manufacturer regularly engaged in the production of flap Gates.
C. Flap Gates supplied under this section shall be Series 60 Stainless Steel Flap Gates as manufactured by Rodney Hunt-Fontaine.
1.3 QUALITY ASSURANCE
A. The manufacturer shall have experience in the production of substantially similar equipment, and shall show evidence of satisfactory operation in at least 5 installations. The manufacturer's shop welds, welding procedures and welders shall be qualified and certified in accordance with the requirement of the latest edition of ASME, Section IX.
B. The manufacturer shall be ISO 9001: 2000 certified.
1.4 SUBMITTALS
A. The manufacturer shall submit, for approval by the purchaser, drawings showing the principal dimensions, general construction and materials used in the gate and lift mechanism.
PART 2 - PERFORMANCE
2.1 OPERATION
A. Flap Gates shall open whenever the upstream head is over 0.2’ (61mm) higher than the downstream head.
WRCRWA STAINLESS STEEL FLAP GATES PLANT EXPANSION PROJECT 353000 - 1
2.2 DESIGN HEAD
A. The Flap Gates shall be designed to withstand the design head shown in the schedule.
PART 3 - PRODUCTS
3.1 GENERAL DESIGN
A. Flap Gates shall be constructed entirely of stainless steel. All hardware shall be stainless steel.
3.2 WALL THIMBLE
A. Where required, the wall thimble shall be stainless steel and supplied by the gate manufacturer. Refer to the gate schedule for types and applicable locations. Material thicknesses shall be according to the manufacturer's recommendations.
3.3 BODY
A. The frame shall be made of structural members or formed plate welded to form a rigid one- piece frame. The frame shall be of the flange back design suitable for mounting on a concrete wall (CW), concrete wall with extra-wide flange (CWX), round manhole (RM), round manhole with extra-wide flange (RMX), wall thimble (WT), or standard flange (SF).
B. The mechanical sleeve type (MS), or spigot back type (SB), or slip on type (SO) shall be used to adapt the flap gate to a round pipe. `
3.4 COVER
A. The gate cover shall be made of structural members or formed plate adequately reinforced to withstand the maximum specified seating head without distortion.
3.5 SEALS
A. Seals shall be made of resilient neoprene attached to the body by means of a retainer ring for flaps up to 24" (610 mm). Seals shall be made of EPDM attached to the frame with a stainless steel retainer for flaps over 24" (610 mm).
3.6 HINGES
A. Hinges shall consist of a stainless steel pin and shall have a UHMWPE bushing.
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3.7 HINGE ARMS
A. Hinge arms shall be made of structural members or formed plates. Gates 30" (762 mm) and over in diameter shall have a 2-hinge arm arrangement, with 2 pivot joints per arm, an adjustable lower pivot with limited rotation and an adjustable upper hinge lug arrangement to permit adjustment of the gate opening sensitivity to unseating head
PART 4 - MATERIALS
Part Material
Body, cover, hinges, Stainless steel ASTM A-240 Type 304L hinge arm or 316L
Hinge bushing Ultra high molecular weight polyethylene (UHMWPE) ASTM D-4020
Seal for flaps up to 24" Neoprene ASTM D-2000 Grade 2 BC-510
(610 mm)
Seal for flaps over 24" EPDM ASTM D-2000 (610 mm)
Fasteners ASTM F593 and F594 GR1 for Type 304 and GR2 for type 316
PART 5 - EXECUTION
5.1 INSTALLATION
A. Gates and appurtenances shall be handled and installed in accordance with the manufacturer's recommendations.
END OF SECTION 353000
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SECTION 409000 – INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes the following:
1. General requirements which apply to all Instrumentation and Control for Process Systems (hereafter referred to as I&C).
B. Related Sections
1. The Contract Documents are a single integrated document. As such, all Divisions and Sections are applicable. The Contractor and its Subcontractors are responsible to review all parts of the Contract Documents in order to provide a complete and coordinated project.
C. Complete I&C System
1. The requirements for the I&C System shall be the responsibility of a single company hereafter referred to as the Instrumentation Supplier (IS). The IS shall be responsible for all parts of this Section and Sub-Sections as well as all other related sections that may pertain to the I&C System. 2. The Contractor, through the IS and qualified electrical and mechanical installers, shall be responsible to the Owner for the implementation of a complete I&C System. The IS shall provide all necessary coordination, material and labor such that the entire system be complete and functional. This includes but is not limited to the proper operation and monitoring of electrical power systems, process systems, mechanical equipment, instrumentation, control panels, programmable controllers, communications/networking, and SCADA system. 3. The overall I&C system design is based upon non-certified information that has been furnished by various equipment manufacturers and vendors. It is the Contractor’s responsibility to include in the bid and installation all labor and material to provide a complete system based upon actual information from equipment being supplied for the project. Any changes or additions due to non-certified manufacturer or vendor information shall be provided at no additional cost to the Owner.
1.2 REFERENCES
A. The installation and commissioning of the I&C System shall conform to all applicable codes, regulations, standards and specifications, including, but not limited to those listed below. These publications are referenced to by designation but not by edition. The latest edition accepted by the Authority Having Jurisdiction in effect at the time of bid shall govern.
1. State and Local Codes and Authority Having Jurisdiction (AHJ) 2. American National Standards Institute (ANSI)
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3. American Petroleum Institute (API) 4. Federal Communications Commission (FCC) 5. Federal Occupational Safety and Health Act (OSHA) 6. International Society of Automation (ISA) 7. Institute of Electrical and Electronic Engineers (IEEE) 8. National Electric Code (NEC). 9. National Electrical Manufacturers Association (NEMA) 10. National Fire Protection Association (NFPA) 11. Underwriters Laboratories, Inc. (UL)
1.3 DEFINITIONS
A. The following definitions may be used throughout this section and subsections (refer to the contract drawings sheet GI-1 for instrumentation abbreviations):
1. CTC: Communications termination cabinet. 2. FAT: Factory acceptance test. 3. HMI: Human machine interface. 4. I&C: Instrumentation and control for process systems 5. IS: Instrumentation supplier. 6. LAN: Local area network. 7. LCP: Local control panel. 8. NC: Normally closed. 9. NO: Normally open. 10. OIT: Operator interface terminal. 11. OSI: Owner’s System Integrator. 12. PC: Personal computer. 13. PID: Control action, proportional plus integral plus derivative. 14. PLC: Programmable logic controller. 15. P&ID: Process and instrumentation diagram 16. RIO: Remote input/output 17. SCADA: Supervisory control and data acquisition. 18. UPS: Uninterruptible power supply. 19. VCP: Vendor control panel. 20. WAN: Wide area network
1.4 I&C SYSTEM REQUIREMENTS
A. Work provided outside of Contractor’s scope: 1. The following equipment is being supplied by the Owner and is to be installed by the Contractor: a. CTC-A – Administration Building CTC Cabinet with PLC-A and associated equipment. b. CTC-D – Digester Building CTC Cabinet with PLC-D and associated equipment. c. RIO-HW – Headworks Building RIO Enclosure – The existing enclosure shall be reused and new backpanel and side panel will be provided to replace the existing backpanel and side panel.
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d. RIO-OD – Oxidation Ditch RIO Enclosure – The existing enclosure shall be reused and new backpanel and side panel will be provided to replace the existing backpanel and side panel. e. RIO-S – RAS/WAS RIO Enclosure – The existing enclosure shall be replaced with a new enclosure. f. RIO-C – Solids Building RIO Enclosure – The existing enclosure shall be reused and new backpanel and side panel will be provided to replace the existing backpanel and side panel. g. RIO-T – Chemical Building RIO Enclosure – The existing enclosure shall be reused and new backpanel and side panel will be provided to replace the existing backpanel and side panel. h. RIO-D – Digester Building RIO Enclosure – New Enclosure i. PLC-RWD – Recycled Water Pump Station PLC Enclosure – New Enclosure j. PLC-C1 – Centrifuge No. 1 Enclosure – New Enclosure being supplied by the Centrifuge Vendor. k. PLC-C2 – Centrifuge No. 2 Enclosure – New Enclosure being supplied by the Centrifuge Vendor. l. PLC-C3 – Centrifuge No. 3 Enclosure – New Enclosure being supplied by the Centrifuge Vendor. 2. All PLC equipment being supplied by the Owner is to be programmed by the Owner’s System Integrator except for PLC equipment that is furnished by Vendors. 3. All HMI and network equipment not provded by the Owner with the equipment described above shall be provided and programmed by the Owner’s System Integrator.
B. The Work is to provide a complete and operational I&C System as described by the Contract Documents. This includes but is not limited to the following:
1. Before providing a bid as the IS, coordinate with all bidders such that all costs associated with a complete I&C System are accounted for. The Owner shall not be responsible for any additional costs for scope items that have been excluded from the bid as a result of not coordinating with all bidders.
2. The IS shall submit a statement of qualifications verifying that it meets the requirements of 409000.1.8. The IS must be approved by the Engineer before proceeding with the Work.
3. In order to provide a complete system, oversee and coordinate with all equipment and services being provided outside of Contractor’s scope. a. The Engineer is responsible to ensure that equipment being supplied by the Owner related to the I&C System complies with the requirements of the Contract Documents. b. The Contractor and IS are responsible to coordinate the installation, commissioning and scheduling of equipment related to the I&C System that are provided by the Owner.
4. Oversee and coordinate with all equipment and services being provided by the Contractor but outside of the IS’s scope. a. Inform all vendors and suppliers providing equipment related to the I&C System the requirements of Division 40. b. The Owner is not responsible for any additional costs incurred by requiring vendors and/or subcontractors to meet the requirements of Division 40.
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c. If a vendor or supplier is unable to meet the requirements of Division 40, the Contractor may submit in writing to the Engineer the reasons for non-compliance. The Engineer will then evaluate the reasons and determine whether a solution may be determined or if a different vendor or supplier is required. d. The Contractor and IS are responsible for coordinating with vendors and suppliers the FAT, installation, commissioning, calibration and scheduling for the associated I&C equipment. e. The IS is responsible to insure that panel and loop drawings be supplied for vendor and subcontractor equipment. If the vendors and/or subcontractors are preparing the panel and/or loop drawings, they shall comply with the requirements of Division 40 and shall match those provided by the IS.
5. The IS shall conduct a Pre-Submittal Conference before producing any submittals. The conference should include all parties involved with the I&C System including the Engineer and Owner. The purpose of the conference shall be to review the project as a whole, make sure all parties understand their roles and responsibilities and to go over submittal requirements.
6. Prepare I&C System Submittals which includes the following: a. Instrumentation hardware submittal (including TR20 forms). b. Control panels design and submittal. c. Recommended spare parts submittal.
7. Following submittal approvals, do the following: a. Procure all instrumentation hardware and accessories. b. Procure hardware for and fabricate all control panels being provided. c. Perform FAT’s for all control panels being provided.
8. Loop drawings design and submittal shall be supplied by the OSI. The IS shall assist the OSI in obtaining all pertinent information for the project that is to be shown on the loop drawings.
9. Programming and integration shall be supplied by the OSI. Oversee and coordinate the programming and integration with the OSI for a complete I&C System.
10. Oversee the installation of the I&C System.
11. Perform bench and field calibrations of instruments as required.
12. Oversee and document loop testing.
13. Oversee and document commissioning.
14. Maintain record drawings. a. Maintain on the construction site a set of the Instrumentation Drawings that shall be continuously marked up during construction. b. The drawings should be updated at least weekly and will be checked monthly by the Owner’s representative. c. Upon completion of startup, submit the marked up drawings to the Engineer for review and for drafting.
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15. Prepare O&M manuals. a. Provide O&M manuals in accordance with Section 017823. b. Prepare an O&M manual for each major process area or building. Each of these manuals shall be divided into the following categories: 1) Table of Contents/Index. 2) Process & Instrumentation Diagrams 3) Control Panel Record Drawings, Bill of Materials and Design Data. 4) Record Loop Drawings c. Prepare O&M manuals that cover comprehensive information for the I&C System. These manuals shall include the following: 1) Table of Contents/Index. 2) Finalized Instrument Summary 3) Finalized TR20 Instrument Forms 4) Instrumentation Installation Details 5) Instrument Operational Manuals 6) Recommended Spare Parts List
16. Provide training.
1.5 ACTION SUBMITTALS
A. General 1. Submittals for Division 40 shall meet the requirements of Section 013300 Contractor Submittals. In addition, the following requirements shall be met: a. Submittals shall include bills of materials with quantities, makes, models, exact part numbers and descriptions. b. Edit all submittals such that only pertinent information is submitted. Neatly cross out information that does not apply, options that are not being supplied, etc. c. Show product dimensions, construction and installation details, wiring diagrams, and specifications. d. If there are exceptions to the Contract Drawings and Specifications, provide a list of exceptions with detailed explanations for the exceptions. The Engineer will review the list of exceptions and determine whether a solution may be determined or if the exception(s) will not be allowed. 2. Furnish submittal required by each Section within Division 40. 3. When submitting on equipment, use the equipment and instrumentation tags depicted in the Contract Drawings.
B. Instrumentation hardware submittal 1. Provide a comprehensive submittal that includes all instrumentation being supplied by the IS. Divide the submittal into the following: a. Table of Contents/Index. b. Instrument summary. c. Instrument TR20 Forms. d. Instrument Cut Sheets. e. Instrument Installation Drawings. 2. Provide an instrument summary (sorted by tag number) that has the following information: a. Tag number. b. Make, model and description.
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c. Associated process. d. Location. e. Calibrated range. f. Referenced loop drawing number and P&ID. g. Associated PLC. 3. Furnish TR20 instrumentation forms for each instrument using the forms outlined in ISA- TR20.00.01-2007. This requirement includes all instruments that are being installed as part of the project, whether they are Contractor, Owner and/or Vendor supplied. Show on each sheet who is the responsible party for supplying the instrument. The TR20 sheets should be provided electronically in Microsoft Word or Excel as well. 4. Provide instrument cut sheets for each instrument make and model being supplied for the project. Each cut sheet should have a list of instrument tag numbers that pertain to that particular cut sheet. The cut sheets should have enough information to verify that the instrument conforms to the Contract Drawings and Specifications. 5. Instrument installation drawings a. Provide instrument installation drawings for each make and model of instrument being supplied. b. Delineate what is being supplied by the IS and what is being supplied by other installers. c. Show overall dimensions, mounting locations and elevations. d. Show all cabling, conduit and piping locations. e. Show the ambient conditions of the location where the instrument is being installed which includes ambient temperature and humidity extremes, whether or not the atmosphere is corrosive and the area classification. f. Show mounting requirements, brackets, stands and anchoring. g. Show means for sun protection where required.
C. Control panels submittal 1. Provide a comprehensive submittal that includes all control panels supplied by the IS. The submittal should show that the panels are in conformance with the requirements of Section 409513. Divide the submittal into the following: a. Table of Contents/Index. b. Panel Bill of Materials and Design Data. c. Panel Shop Drawings. d. Panel Hardware Cut Sheets. 2. The Panel Bill of Materials and Design Data shall include the following: a. Each panel will have its own Bill of Materials and Design Data information presented in association with the panel drawings. The Bill of Materials shall include all hardware inside or on the enclosure. The design data will include UPS and/or battery load calculations to show that the UPS is sized appropriately for load and for backup time. The design data will show panel weight, materials and finishes. HVAC design data shall be shown. Seismic criteria shall be shown if required by the Contract Documents. 3. Panel Shop Drawings: a. Each control panel shall be designed to perform its function(s) as shown in the Contract Drawings. The control panel designs shall take into account information shown throughout the Contract Drawings and Specifications. b. Show every internal wire and connection diagrammatically. Show all interfaces between the control panel and external equipment to be connected for power, controls, signal, communications, etc.
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c. All shop drawings shall include a title block with the name of the firm designing the control panels. The title block shall also include project information, Owner information and/or logo, drawing number and description, revision fields and date. d. All shop drawings shall be developed utilizing AutoCAD version 2008 or later. All shop drawings should be submitted in PDF and AutoCAD formats and as required by Section 013300. e. Panel layout drawing(s): 1) Each control panel shall have shop drawing(s) which depict the front, back, sides and top/bottom of the panel. This includes showing any hardware mounted on the inside or outside of the panel. 2) Layout drawings should include subpanel and swing-out panel layouts. 3) Layout drawings should show locations of panel penetrations for cutouts, conduit entry and/or access plates. 4) Layout drawings should show all of the components and provide a reference to the bill of materials. 5) Show the elevations of door devices from the finished floor. f. AC and/or DC power distribution diagrams: 1) Each panel shall show power distribution schematics that shows how the panel receives power and feeds all of its internal loads as well as associated external loads. g. Communications and/or Network diagrams: 1) For panels that utilize any means of communications both internally and externally, provide a diagram depicting each communication connection. h. Input/Output and/or Internal wiring diagrams i. Terminal block diagrams 4. Provide panel hardware cut sheets for each make and model of equipment being supplied for the project. The cut sheets should have enough information to verify that the equipment conforms to the Contract Drawings and Specifications.
D. Loop Drawings Submittal 1. Provide a comprehensive submittal that includes loop drawings for every control loop on the project. This includes but is not limited to all loops shown on the P&ID’s, all loops associated with auxiliary inputs/outputs not shown on the P&ID’s (e.g. UPS status information). 2. Loop drawings may only be finalized after all control panels, MCC’s and other electrical submittals, and instrumentation submittals have been approved. Obtain all of the required information from each of these submittals to properly show the wiring of each control loop. The loop drawings shall not be submitted with incomplete information due to the lack of obtaining the appropriate information for each loop. 3. The loop drawings shall designed for and printed to 11x17 size paper. Divide the submittal into the following: a. Laminated Cover and Back and Spiral Binding. b. Table of Contents/Index (by loop number). c. Loop Drawings.
E. Recommended Spare Parts Submittal 1. Submit a list of spare parts for all of the equipment associated with the I&C System. The list of spare parts shall include list pricing for each item. 2. Provide the name, address and phone number for each manufacturer and manufacturer’s local sales representative. 3. Indicate whether or not the spare parts are being provided under this contract or not.
WRCRWA INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS PLANT EXPANSION PROJECT 409000 - 7
1.6 INFORMATIONAL SUBMITTALS
A. Field quality-control test reports.
1.7 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
1.8 QUALITY ASSURANCE
A. All equipment supplied for this project shall meet the requirements of the National Electric Code (NEC) and shall be listed by and bearing the label of the Underwriters’ Laboritories (UL).
B. The IS shall be a company that has been actively involved in the installation and commissioning of I&C Systems for a minimum period of five years.
C. The IS shall have adequate facilities, manpower and technical expertise to perform the Work associated with the I&C System and as outlined by the Contract Documents.
D. The IS shall have similar project experience of at least four successfully completed projects for a similar wastewater system. The IS company must have performed similar work for these projects as required herein.
PART 2 - PRODUCTS
2.1 MATERIALS
A. All materials provided under this Contract shall be new and free from defects.
2.2 MANUFACTURERS
A. All equipment provided for the I&C System shall be the most recent field-proven models marketed by their manufacturers at the time of submittal of the Shop Drawings unless otherwise required to match existing equipment.
B. Instruments which utilize a common measurement principle (for example, float switches) shall be furnished by a single manufacturer. Panel mounted instruments shall have matching style and general appearance. Instruments performing similar functions shall be of the same type, model, or class, and shall be from a single manufacturer.
2.3 OPERATING CONDITIONS
A. The I&C System shall be designed and constructed for satisfactory operation and long, low maintenance service under the following conditions: 1. Environment: Type the type of facility this is for such as “Wastewater Treatment Plant”. 2. Temperature Extremes: 10 F to 120 F (Outdoors); 40 F to 104 F (Indoors).
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3. Relative Humidity: 20% to 90%, non-condensing.
B. Indoor and outdoor control panels and instrument enclosures shall be suitable for operation in the ambient conditions associated with the locations designated in the Contract Documents. Heating, cooling, and dehumidifying devices shall be provided in order to maintain instrumentation devices 20 percent within the minimums and maximums of their rated environmental operating ranges. The Contractor shall provide power wiring for these devices. Enclosures suitable for the environment shall be furnished. Instrumentation in hazardous areas shall be suitable for use in the particular hazardous or classified location in which it is to be installed.
2.4 SPECIAL TOOLS
A. The IS shall furnish a priced list of special tools required to calibrate and maintain the instrumentation provided. The Owner and Engineer will select which tools are to be purchased and the IS will supply them at the prices listed.
B. Special tools shall be delivered to the Owner before startup commences.
PART 3 - EXECUTION
3.1 DELIVERY, STORAGE AND HANDLING
A. After completion of shop assembly, factory test, and approval, equipment, cabinets, panels, and consoles shall be packed in protective crates and enclosed in heavy duty polyethylene envelopes or secured sheeting to provide complete protection from damage, dust, and moisture. Dehumidifiers shall be placed inside the polyethylene coverings. The equipment shall then be skid-mounted for final transport. Lifting rings shall be provided for moving without removing protective covering. Boxed weight shall be shown on shipping tags together with instructions for unloading, transporting, storing, and handling at the Site.
B. Special instructions for proper field handling, storage, and installation required by the manufacturer shall be securely attached to each piece of equipment prior to packaging and shipment.
C. Each component shall be tagged to identify its location, instrument tag number, and function in the system. A permanent stainless steel or other non-corrosive material tag firmly attached and permanently and indelibly marked with the instrument tag number, as given in the tabulation, shall be provided on each piece of equipment in the PCIS. Identification shall be prominently displayed on the outside of the package.
D. Equipment shall not be stored outdoors. Equipment shall be stored in dry permanent shelters, including in-line equipment, and shall be adequately protected against mechanical injury. If any apparatus has been damaged, such damage shall be repaired by the Contractor. If any apparatus has been subject to possible injury by water, it shall be thoroughly dried out and put through tests as directed by the Engineer. If such tests reveal defects, the equipment shall be replaced.
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3.2 MANUFACTURER’S SERVICES
A. Manufacturer’s services shall be furnished for the following equipment: 1. Vendor supplied equipment that contain programmable controllers, operator interfaces and/or instrumentation that requires site calibration. 2. Chlorine Analyzers 3. pH Analyzers 4. ORP Analyzers 5. Dissolved Oxygen Analyzers 6. Open Channel Flow Meters 7. Mass Flow Meters 8. Turbidity Analyzers
B. The Contractor shall furnish the following manufacturer's services for the instrumentation listed below: 1. Perform bench calibration. 2. Oversee installation. 3. Verify installation of installed instruments. 4. Certify installation and reconfirm manufacturer's accuracy statement. 5. Oversee loop testing and pre-commissioning 6. Train the Owner's personnel.
3.3 INSTALLATION
A. Instrumentation shall be installed per the Instrument Installation Drawings that have been submitted and approved and per the requirements of Division 40. This includes all instrumentation for the I&C System, regardless of who the supplier is. Instrumentation shall be mounted so that it is easily accessible and viewable and such that it does not restrict access to other equipment. Mount instrumentation to pipe stands or wall mounts if they are not directly mounted or if the Contract Drawings indicate otherwise.
B. The I&C System indicated throughout the design are diagrammatic and therefore locations of equipment are approximate. The exact locations and routing of wiring and cables shall be governed by structural conditions and physical interferences and by the location of electrical terminations on equipment. Equipment shall be located and installed so that it will be readily accessible for operation and maintenance. Where job conditions require reasonable changes in approximated locations and arrangements, or when the Owner exercises the right to require changes in location of equipment which do not impact material quantities or cause material rework, the Contractor shall make such changes without additional cost to the Owner.
C. The I&C System is integrally connected to electrical, mechanical and structural systems. Coordinate with these other disciplines the installation of these related components. All conduit, cables and field wiring shall be as required by Division 26.
D. Instruments, control panels and all other I&C System related equipment shall be anchored by methods that comply with seismic requirements applicable to the Site.
E. Each existing instrument to be removed and reinstalled shall be cleaned, reconditioned, and recalibrated by an authorized service facility of the instrument manufacturer. The Contractor shall provide certification of this Work prior to reinstallation of each instrument.
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F. The Contract Documents show necessary conduit and instruments required to make a complete instrumentation system. The Contractor shall be responsible for providing any additional or different type connections as required by the instruments and specific installation requirements. Such additions and such changes, including the proposed method of installation, shall be submitted to the Engineer for approval prior to commencing that Work. Such changes shall not be a basis of claims for extra Work or delay.
G. Instrumentation, control panels, wiring and all other I&C equipment shall be properly tagged and/or labeled per the requirements of Section 260553.
H. Installation of the I&C System shall be according to the finalized Loop Drawings
3.4 FACTORY ACCEPTANCE TESTING (FAT)
A. The IS shall arrange for the manufacturers of the equipment and fabricators of panels and cabinets supplied under this Section to allow the Engineer and Owner to inspect and witness the testing of the equipment at the site of fabrication. Equipment shall include the cabinets, special control systems, and other pertinent systems and devices. A minimum of 10 days notification shall be furnished to the Engineer prior to testing. No shipments shall be made without the Engineer's approval.
B. For each FAT, the IS shall develop and submit a FAT Plan and Procedure Document within 10 days of the FAT. The FAT Plan and Procedure shall as a minimum shall have the following: 1. Descriptions of test methods to be performed during the FAT. 2. FAT Schedule and Procedure 3. FAT Checklists that allow for sign-off and comments for each test method and procedure.
C. Control Panel Completion Test Methods: The following test methods should be performed during the FAT for each control panel: 1. Completed Shop Drawings: Demonstrate that the control panel has been built according to the shop drawings and that the shop drawings are accurate. 2. Panel Layout: Demonstrate that the control panel has been laid out as designed and as required by Division 40. 3. Power Distribution: Demonstrate all power distribution circuits, including but not limited to AC power circuits, UPS operation, signals and circuits and DC circuits. 4. Control Circuits: Demonstrate the correct installation of each control circuit. Using a signal generator or multi-meter, show the correct operation of each input, output, relay, barrier, buttons, switches, or any other control device. Demonstrate the proper functionality of any hard-wired interlocks that may be associated with each control circuit. 5. Panel Networking/Communications: If any form of communications is associated with the control panel, verify the proper operation of each communication port and link.
D. Control Loop Test Methods: In order to demonstrate that the control panel will provide its function as intended, provide the following control loop test methods. If programming for the control panel is provided by others, coordinate with the programmer to have all programming completed and tested prior to the FAT. If needed, coordinate to have the programmer present for the FAT. 1. Alarm Functions: Verify and/or simulate each alarm condition associated with each control loop.
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2. Local Manual and Auto Functions: Verify and/or simulate each Local Manual and/or Auto function associated with each control loop. 3. SCADA Manual and Auto Functions: Verify and/or simulate each SCADA Manual and/or Auto function associated with each control loop. 4. Control Loop Interlocks: Demonstrate the functionality of any software interlocks that may be associated with each control loop.
E. If the FAT does not pass and needs to be repeated, the IS shall be responsible for additional per diem costs incurred by the Engineer and Owner.
F. All changes and/or corrections made during the FAT shall be noted on the checklists.
G. Following completion and approval of all FAT, provide the finalized checklists to the Engineer and as part of the equipment shop drawings.
3.5 FIELD QUALITY CONTROL
A. Allow for inspections by the Engineer and/or Owner of the I&C System at any time during the construction. Inspections shall be conducted to verify that the installation is per the requirements of the Contract Documents.
3.6 CALIBRATION
A. Devices provided under Division 40 shall be calibrated according to the manufacturer's recommended procedures to verify operational readiness and ability to meet the indicated functional and tolerance requirements.
B. Each instrument shall be calibrated at 0, 25, 50, 75, and 100 percent of span using test instruments to simulate inputs. The test instruments shall have accuracies traceable to National Institute of Standards and Testing.
C. Instruments that have been bench-calibrated shall be examined in the field to determine whether any of the calibrations are in need of adjustment. Such adjustments, if required, shall be made only after consultation with the Engineer.
D. Instruments which were not bench-calibrated shall be calibrated in the field to insure proper operation in accordance with the instrument loop diagrams or specification data sheets.
E. Each analyzer system shall be calibrated and tested as a workable system after installation. Testing procedures shall be directed by the manufacturers' technical representatives. Samples and sample gases shall be furnished by the manufacturers.
F. For each instrument calibration, provide a calibration sheet and update the corresponding TR20 Instrument Form with the new calibration data. The Calibration sheet shall include the following as a minimum: 1. Date of calibration 2. Project Name. 3. Tag Number. 4. Manufacturer, model and serial number.
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5. Calibration data including range, input, output and measurement at each calibration point. 6. Space for comments. 7. Space for sign-off by party performing calibration.
G. A calibration and testing tag shall be attached to each piece of equipment or system at a location determined by the Engineer. The IS shall sign the tag when calibration is complete. The Engineer will sign the tag when the calibration and testing has been accepted.
3.7 LOOP TESTING
A. Each control loop shall have been installed according to the finalized loop drawing. Prior to the commencement of loop testing, the following pre-requisites should have been met: 1. All associated equipment, conduit and wire has been permanently installed, terminated and inspected. 2. All wiring has been properly pulled, terminated and labeled. 3. Each wire has been tested with a point-to-point test. 4. All control panels and electrical equipment have been checked out and tested as required by Division 26. 5. All instrumentation has been appropriately installed and calibrated. 6. Loop Test Forms for each loop to be tested have been created and will be available during the loop testing.
B. Each loop test shall have a Loop Test Form prepared and ready prior to each loop test. The loop test form shall have the following: 1. Loop Number and Description 2. Check-Off List with room for sign-off and dated by the IS, Programmer, and Owner’s Witness as well as room for comments. The list of items to be checked off for each loop should include but is not limited to the following: a. Each power distribution circuit. b. Each control circuit. c. Each alarm circuit. d. Each PLC input/output point. e. Each Local Manual, Local Auto, SCADA Manual & SCADA Auto function. f. Each hard-wired and software interlock.
C. Upon completion of the above pre-requisites for loop testing, the IS shall oversee and coordinate each loop test. The IS is responsible to be present for all loop testing, whether the equipment was supplied by the IS or not. The IS is responsible to have all responsible parties associated with each loop present. This includes but is not limited to manufacturer representatives, vendor technicians, electrical installers, mechanical installers, and programmer. The IS shall coordinate with the Owner and Engineer to allow for witnessing of loop testing as deemed necessary by the Owner and Engineer.
D. Issues that arise during loop testing should be addressed and fixed immediately. If it is not feasible to immediately fix the issues, the loop testing should be re-scheduled as soon as possible to avoid delays. Any costs associated with re-testing and requiring all parties to return to the site shall in no way be incurred to the Owner.
E. Following a successful loop test, the appropriate parties should sign and date the Loop Test Forms. All Forms shall be certified and submitted to the Engineer as part of the O&M Manuals.
WRCRWA INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS PLANT EXPANSION PROJECT 409000 - 13
F. Following loop testing, in no way should any parts of the loop be modified. In no way shall any wiring be re-routed or re-terminated. If any such work occurs, all affected loops shall be re- tested at no expense to the Owner.
3.8 COMMISSIONING
A. The IS shall oversee, coordinate and be present during all commissioning activities. The IS shall be responsible for obtaining the assistance of the Contractor and Subcontractors as may be required for commissioning activities.
B. Commissioning shall commence after acceptance of wire test, calibration tests and loop tests, and inspections have demonstrated that the instrumentation and control system complies with Contract requirements. Pre-commissioning shall demonstrate proper operation of every system with process equipment operating over full operating ranges under conditions as closely resembling actual operating conditions as possible.
C. Commissioning and test activities shall follow detailed test procedures and check lists accepted by the Engineer. Test data shall be acquired using equipment as required and shall be recorded on test forms accepted by the Engineer, which include calculated tolerance limits for each step. Completion of system commissioning and test activities shall be documented by a certified report, including test forms with test data entered, delivered to the Engineer with a clear and unequivocal statement that system commissioning and test requirements have been satisfied.
D. Where feasible, system commissioning activities shall include the use of water to establish service conditions that simulate, to the greatest extent possible, normal final control element operating conditions in terms of applied process loads, operating ranges, and environmental conditions. Final control elements, control panels, and ancillary equipment shall be tested under startup and steady state operating conditions to verify that proper and stable control is achieved using motor control center and local field mounted control circuits. Hardwired and software control circuit interlocks and alarms shall be operational. The control of final control elements and ancillary equipment shall be tested using both manual and automatic (where provided) control circuits. The stable steady state operation of final control elements running under the control of field mounted automatic analog controllers or software based controllers shall be assured by adjusting the controllers as required to eliminate oscillatory final control element operation. The transient stability of final control elements operating under the control of field mounted, and software-based automatic analog controllers shall be verified by applying control signal disturbances, monitoring the amplitude and decay rate of control parameter oscillations (if any), and making necessary controller adjustments as required to eliminate excessive oscillatory amplitudes and decay rates.
E. Electronic control stations incorporating proportional, integral or differential control circuits shall be optimally tuned, experimentally, by applying control signal disturbances and adjusting the gain, reset, or rate settings as required to achieve a proper response. Measured final control element variable position/speed setpoint settings shall be compared to measured final control element position/speed values at 0, 25, 50, 75, and 100 percent of span and the results checked against indicated accuracy tolerances.
WRCRWA INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS PLANT EXPANSION PROJECT 409000 - 14
3.9 TRAINING
A. Provide training in accordance with Section 409000.
B. Develop a Training Plan for the training requirements of Division 40 and submit it to the Engineer for approval. Coordinate with the Engineer and Owner the time and locations of each training session. Schedule the trainings for after the equipment has been pre-commissioned.
C. As part of the Training Plan, submit a résumé for each individual to be providing training. Training shall be performed by qualified representatives of the equipment manufacturers and shall be specific to each piece of equipment.
D. Each training session shall include a written agenda.
E. The Contractor shall train the Owner’s personnel on the maintenance, calibration and repair of instruments provided.
F. Within 10 days after the completion of each session, the Contractor shall submit the following: 1. A list of Owner personnel who attended the training. 2. A copy of the training materials used during the session with notes, diagrams and comments.
END OF SECTION 409000
WRCRWA INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS PLANT EXPANSION PROJECT 409000 - 15
SECTION 409113 – CHEMICAL PROPERTIES PROCESS MEASUREMENT DEVICES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Chlorine Process Measurement Devices. 2. Gas Analysis Process Measurement Devices 3. ORP Process Measurement Devices.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID’s. Each system shall be factory calibrated and certified prior to delivery.
CHEMICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409113 - 1
PART 2 - PRODUCTS
2.1 GENERAL
A. Each process measurement system shall consist of a sensor and an analyzer/transmitter. Where shown on the drawings, the analyzer/transmitter may be utilized for multiple sensors. When an analyzer/transmitter is used for multiple sensors, it shall be capable of displaying simultaneously each process measurement.
B. Each analyzer/transmitter shall be equipped with means to transmit process measurement information to the plant SCADA system.
1. For hardwired signals, unless otherwise indicated on the drawings, provide the following: a. 4-20mA output signal for each process measurement (for up to 500 Ohm loads) b. Two programmable SPDT relay outputs, rated at 5A up to 230VAC, for each process measurement
C. Each analyzer/transmitter shall be powered by 115VAC (+/- 10%) at 60Hz unless specifically shown on the drawings as being powered by 24VDC (+/- 15%). Each analyzer/transmitter shall retain its programmable settings in non-volatile memory.
D. Each sensor and corresponding analyzer/transmitter shall be supplied as a complete and operable system. This includes all cabling, mounting hardware and fasteners. When installed outdoors, the analyzer/transmitter shall be protected from the sun such that direct sunlight will not shine on the display.
E. All analyzers/transmitters shall be waterproof and made from corrosion resistant materials.
F. All sensors shall be rated for permanent submersion and shall be corrosion resistant.
2.2 CHLORINE PROCESS MEASUREMENT DEVICES
A. Each analyzer/transmitter should be installed indoors in a room that shall have temperatures not less than 40 F and not greater than 104 F.
B. The chlorine analyzer shall measure free or total chlorine and shall have an accuracy of 0.03 mg/L up to 5.00 mg/L. The analyzer shall utilize the colorimetric with the DPD method for measuring the chlorine.
C. The analyzer shall be equipped with a self-cleaning Y-strainer to prevent fouling. For wastewater effluent applications, install an external 20 mesh Y-strainer for removal of particles larger than 1000 microns. The strainer should be transparent to allow for visible indication of when it should be cleaned. Provide two spare 20 mesh screens for the strainer.
D. Provide maintenance and calibration equipment necessary to maintain and calibrate the chlorine analyzer for a period of three years. This includes the maintenance kits for replacing tubing, caps and fittings. Provide reagent sets for three years of operation.
CHEMICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409113 - 2
E. Acceptable Manufacturers: 1. Hach model CL17. 2. Siemens/Wallace & Tiernan MFC-Analyzer/Controller
2.3 GAS ANALYSIS PROCESS MEASUREMENT DEVICES
A. Each gas sensor/analyzer shall be provided with a NEMA 4X rating for unclassified areas and NEMA 7 ratings (explosion-proof) for classified areas and specifically listed for Class 1, Division 1 groups B, C and D.
B. All gas analyzers shall be 24VDC powered. Unless specifically indicated otherwise on the drawings, provide for each building with any gas analyzers a 24VDC power supply housed inside of a NEMA 4X enclosure.
C. All analyzers shall have a 4-20mA output for each gas being detected capable of driving a 500 ohm loop load. All analyzers shall have programmable relays rated at 5A up to 230VAC for wiring to a PLC, Horn and/or beacon.
D. Furnish and install a sampling pump module where required to draw an air sample into the analyzer sensor.
E. Infrared type sensors shall be supplied when available for gases being detected.
F. Provide maintenance and calibration equipment necessary to maintain and calibrate the gas analyzers for a period of three years.
G. The following gas detection configurations shall be considered as standard unless shown otherwise on the drawings:
1. Ammonia: 0-100 ppm 2. Carbon Monoxide: 0-500 ppm 3. Chlorine: 0-10 ppm 4. Carbon Dioxide (Infrared): 0-2% 5. Combustible Gas: 0-100% LEL 6. Hydrogen: 0-1000 ppm 7. Hydrogen Sulfide (H2S): 0-100 ppm 8. Oxygen: 0-25% 9. Sulfur Dioxide (SO2): 0-100 ppm
H. The gas analyzers shall be furnished with a display that indicates the measured gas level.
I. Acceptable Manufacturers: 1. MSA Ultima X Series 2. Det-tronics
CHEMICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409113 - 3
2.4 ORP PROCESS MEASUREMENT DEVICES
A. Each ORP analyzer/transmitter shall be rated for operation with ambient temperature within - 4 F to 122 F. If the analyzer/transmitter is to be installed in locations that may experience temperatures less than -4 F, it shall be housed in an enclosure which is equipped with a thermostatically controlled heater. If the analyzer/transmitter is to be installed in locations that may exceed 122 F, it shall be housed in an air conditioned enclosure. All enclosures and air conditioners shall be rated NEMA 4X.
B. The ORP Sensor assembly shall meet the following criteria:
1. Contain the sensing elements and electronics for digital communications to the analyzer/transmitter in a self-contained, corrosion-resistant and submersible housing. 2. Built-in temperature compensation. 3. Allowed to be installed in liquids whose temperatures are 32 to 200 F and whose pressure is up to 100 psi. 4. The sensor shall have a measuring range of -1500 to 1500 mV. 5. Shall not require sample conditioning or electrolyte solutions.
C. Acceptable Manufacturers: 1. Hach model pHD ORP System with SC200 or SC1000 analyzer/transmitter. 2. WTW/Xylem model SensoLyt 700 IQ pH System with 182 or 2020 analyzer/transmitter.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers’ recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
B. Install all analyzers/transmitters five feet off of floor level. Install in a location that is easily accessible while as near to the sensor(s) as possible.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 409000 and per the manufacturer’s documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble-free operation.
CHEMICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409113 - 4
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
2. Test the process measurement system for proper operation at low, mid and high process conditions.
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 409000.
END OF SECTION 409113
CHEMICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409113 - 5
SECTION 409119 – PHYSICAL PROPERTIES PROCESS MEASUREMENT DEVICES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Pressure Process Measurement Devices. 2. Temperature Process Measurement Devices. 3. Weight Process Measurement Devices.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID’s. Each system shall be factory calibrated and certified prior to delivery.
PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 1
PART 2 - PRODUCTS
2.1 GENERAL
A. Each process measurement system shall consist of a sensor and an analyzer/transmitter. Where shown on the drawings, the analyzer/transmitter may be utilized for multiple sensors. When an analyzer/transmitter is used for multiple sensors, it shall be capable of displaying simultaneously each process measurement.
B. Each analyzer/transmitter shall be equipped with means to transmit process measurement information to the plant SCADA system.
1. For hardwired signals, unless otherwise indicated on the drawings, provide the following: a. 4-20mA output signal for each process measurement (for up to 500 Ohm loads) b. Two programmable SPDT relay outputs, rated at 5A up to 230VAC, for each process measurement
C. Each analyzer/transmitter shall be powered by 115VAC (+/- 10%) at 60Hz unless specifically shown on the drawings as being powered by 24VDC (+/- 15%). Each analyzer/transmitter shall retain its programmable settings in non-volatile memory.
D. Each sensor and corresponding analyzer/transmitter shall be supplied as a complete and operable system. This includes all cabling, mounting hardware and fasteners. When installed outdoors, the analyzer/transmitter shall be protected from the sun such that direct sunlight will not shine on the display.
E. All analyzers/transmitters shall be waterproof and made from corrosion resistant materials.
F. All sensors shall be rated for permanent submersion and shall be corrosion resistant.
2.2 PRESSURE PROCESS MEASUREMENT DEVICES
A. General
1. All inline pressure instruments shall be supplied with isolation ball valve and bleed needle valve for each measurement point. Valve materials shall be selected based upon the properties of the liquid or gas and the atmosphere.
2. Unless otherwise indicated on the Contract Drawings, pressure process measurement devices shall measure process pressure relative to atmospheric pressure (gauge pressure).
3. Pressure process measurement devices which are to measure differential pressure shall have the appropriate inlet and outlet ports and isolation and bleed valves for each port.
4. All pressure instrumentation shall be properly mounted, ideally in locations that are easily accessible and viewable. Supply all appropriate mounting poles, plates and accessories such that each instrument is properly supported and mounted.
B. Inline Pressure Diaphragm Seals PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 2
1. Diaphragm seals shall consist of bottom housing, lower ring, diaphragm capsule, fill screw, flushing connection, and a top housing.
2. The diaphragm seal shall attach to the inlet connection of a pressure instrument to isolate its measuring element from the process fluid. The space between the diaphragm and the pressure element shall be completely filled with a suitable liquid. Displacement of the liquid fill in the pressure element through the movement of the diaphragm shall transmit process pressure changes directly to a gauge, transmitter, switch, or other pressure instrument. The diaphragm seal shall have a removable bottom housing to permit servicing. The diaphragm seal shall be factory assembled to the corresponding pressure instrument and be factory-filled. The assembly shall be shipped with a tag reading "Do not disassemble for installation."
3. For sewage, sludge, liquids containing solids, corrosive gases, provide seals with 316SS diaphragm and housing. Nuts, bolts, fill connection and valved flush components shall also be 316SS.
4. For chemical solutions and for liquids or gases that will corrode 316SS, provide seals with PVC body and Viton FKM (for vacuum and up to 15 PSI) or PTFE (for above 15 psi) diaphragm material.
5. Acceptable Manufacturers a. Ashcroft model 101 (for 316SS diaphragm seals). b. Plast-O-Matic Valves Inc. Series GGS (for PVC body diaphragm seals). c. Or Approved Equal.
C. Pressure Transmitters
1. Electronic gauge or differential pressure transmitters shall consist of a capsule assembly, bottom works, vent plug, drain plug, cover flange, ½” NPT process connector and connection, amplifier unit, integral indicator, terminal box with cover, block and bleed valves, and conduit connections.
2. Transmitter shall be rated NEMA 4X. For hazardous locations, it shall be installed with an appropriate intrinsically safe barrier to guarantee the circuit may not abnormally create an ignition.
3. Transmitter shall be of a two-wire, 24VDC loop powered, producing 4 to 20 mA output proportional to the calibrated range of the instrument, capable of driving a 600 ohm load.
4. Static pressure rating shall be a minimum of 500 psig. The maximum over range pressure limit shall be a minimum of 150% of the range. Span shall be adjustable over a minimum of 5:1 range.
5. The 4 to 20 mA signal shall be capable of being calibrated electronically. Output signal damping shall be provided as an internal adjustment. Equipment shall be suitable for an ambient operating range of minus 40 degree F to plus 212 degrees F. The transmitter shall be equipped with the Hart protocol.
PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 3
6. Accuracy, including linearity and repeatability, shall be a plus or minus 0.2 percent of span. Gauge pressure transmitters used for flow service shall include square root extraction to produce an output signal linearly proportional to flow. Wetted parts, including block and bleed valve parts, shall be constructed of 316 stainless steel.
7. Acceptable Manufacturers a. Rosemount 3051. b. Or Approved Equal.
D. Pressure Switches
1. For unclassified locations, pressure switches shall be housed in a NEMA 4X enclosure. For classified locations, pressure switches shall be housed in a NEMA 7 enclosure.
2. Gauge and Differential pressures switches shall be diaphragm-actuated, dual adjustable, with SPDT snap action switch. Contacts shall be rated for a minimum of 5 Amps at 120 VAC. The dead band shall be adjustable up to 60 percent of full scale. Set points shall fall between 20 and 80 percent of the adjustable range. The diaphragm shall be Buna-N, unless otherwise indicated, and the lower housing shall be brass with a 1/4-inch bottom sensing connection, unless otherwise indicated.
3. Acceptable Manufacturers a. Ashcroft Series B (Gauge) and D (Differential). b. Or Approved Equal.
E. Pressure Gauges
1. Pressure gauges shall be 4-1/2 inches in diameter with white laminated dials and black graduations. Windows shall be shatterproof glass acrylic. Gauges shall have a blowout disc and be encased in phenolic, steel, or cast iron. Measuring element shall be a stainless steel bourdon tube with welded, stress-relieved joints. Socket shall have wrench flats. Movement shall be rotary geared stainless steel material. Gauges shall perform as a liquid-filled gauge in a dry gauge and fight against vibration and pulsations. Gauges shall be calibrated to read in applicable units. Accuracy shall be plus and minus 1/2 percent range to 150 percent of the working pressure or vacuum of the pipe or vessel to which they are connected.
2. Acceptable Manufacturers a. Ashcroft 1279. b. Or Approved Equal.
2.3 TEMPERATURE PROCESS MEASUREMENT DEVICES
A. General
1. All temperature sensors or gauges to be used for monitoring temperature of liquids or gases shall be equipped with a thermowell. Thermowells shall have a minimum wall thickness between bore and outside of well of 3/16”. . Wells shall have one-inch male NPT process connections except where line classification indicates some other type. PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 4
Element connections shall be 1/2-inch female NPT. Material shall be Type 316 stainless steel unless the process requires otherwise. Flanged thermowells, where required, shall meet material and size requirements of the line classification. Insertion length shall be specific to the application, not exceeding the manufacturer's published recommendations for the allowable length and for the line velocity.
2. Temperature monitoring instrumentation for HVAC and room temperature monitoring are specified elsewhere.
B. Temperature Sensors and Transmitters
1. Temperature sensors shall be RTD’s and shall be 100 or 1000 ohm nominal at 0 C. 1000 ohm sensors shall be used wherever RTD wires to the transmitter or PLC type device exceed 50 feet. All RTD’s shall be setup as 3-wire installations.
2. Insertion type RTD’s shall be tip-sensitive, platinum 385 in ¼” 316SS sheath with watertight potting. Time constant in agitated water shall not exceed six seconds. RTD shall comply with International Practical Temperature Scale (IPTS) 68 standards. Accuracy shall be plus or minus 0.1 degree C. The RTD assembly shall be spring loaded for insertion into a thermowell.
3. RTD only assemblies (typically ran to an RTD input card on a PLC) shall have a stainless steel connection head rated NEMA 4X. It shall have a measuring range of -200 C to 1000 C.
4. Temperature transmitters shall be 2 wire devices with continuously adjustable span and zero adjustments, integral direct reading indicator, solid state circuitry, and a 4 - 20 mA DC output linearly proportional to the indicated temperature span. Transmitters shall be provided with 316 stainless steel thermowell, spring-loading device, extensions, union coupler, and explosion-proof aluminum connection head. Union shall extend out beyond the pipe lagging.
5. Acceptable Manufacturers a. Thermowells 1) b. RTD only insertion assemblies 1) Rosemount Series 78. 2) Or Approved Equal. c. Sensor and Transmitter Assemblies 1) Rosemount 3144P. 2) Or Approved Equal.
C. Temperature Gauges
1. Thermometers shall have be a 7-inch vertical column with a single direct-reading scale and scale as indicated. Each shall be rust and corrosion-resistant with a leak-proof, hermetically sealed 316 stainless steel housing. The sensing element shall be silicone dampened for vibration resistance. Stem length shall be the maximum standard size compatible with the piping or vessel but shall not exceed 9-inches. Dial shall be adjustable 360 degrees around the stem axis and tiltable to 90 degrees from vertical to
PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 5
obtain the best viewing angle. Accuracy shall be plus or minus 1 percent of range. Each thermometer shall be provided with a thermowell.
2. Acceptable Manufacturers
a. Wika Model TI.901. b. Or Approved Equal.
2.4 WEIGHT PROCESS MEASUREMENT DEVICES
A. General
1. Provide a complete and fully functional electronic truck scale system that consists of load cells, indicator and appurtenances.
2.
B. Load Cells
C. Weight Indicator/Controller
1. The weight indicator/controller shall accept inputs from four load cells to determine the weight of trucks as they are put onto the scale.
2. The indicator shall be a full electronic design with various capabilities for weighing including general weighing, in-motion weighing, accumulation, check weighing, counting, peak measurement and batching.
3. The indicator shall be setup to read in pounds.
4. The indicator shall be equipped with a 4-20mA analog output signal representing the weight on the scale.
5. The indicator shall be equipped with an Ethernet port that is equipped to communicate over the Modbus TCP protocol. Current weight and history shall be obtainable over this interface.
6. The indicator shall be powered by 120VAC, 60 Hz.
7. The indicator enclosure shall be rated NEMA 4X and shall be stainless steel. It shall be installed in a location that will not be exposed to direct sunlight. If it may be exposed to direct sunlight, an instrument shade shall be installed to block the instrument from sunlight.
D. Acceptable Manufacturers 1. Avery Weigh-tronix ZM305 Series or approved equal
PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 6
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers’ recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
B. Install all analyzers/transmitters five feet off of floor level. Install in a location that is easily accessible while as near to the sensor(s) as possible.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 409000 and per the manufacturer’s documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble-free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
2. Test the process measurement system for proper operation at low, mid and high process conditions.
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 409000.
END OF SECTION 409119
PHYSICAL PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409119 - 7
SECTION 409123 – MISCELLANEOUS PROPERTIES PROCESS MEASUREMENT DEVICES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Dissolved Oxygen Process Measurement Devices. 2. Flow Process Measurement Devices. 3. Level Process Measurement Devices. 4. Turbidity Process Measurement Devices.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID’s. Each system shall be factory calibrated and certified prior to delivery.
MISCELLANEOUS PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409123 - 1
PART 2 - PRODUCTS
2.1 GENERAL
A. Each process measurement system shall typically consist of a sensor and an analyzer/transmitter. Where shown on the drawings, the analyzer/transmitter may be utilized for multiple sensors. When an analyzer/transmitter is used for multiple sensors, it shall be capable of displaying simultaneously each process measurement.
B. Each analyzer/transmitter shall be equipped with means to transmit process measurement information to the plant SCADA system.
1. For hardwired signals, unless otherwise indicated on the drawings, provide the following: a. 4-20mA output signal for each process measurement (for up to 500 Ohm loads) b. Two programmable SPDT relay outputs, rated at 5A up to 230VAC, for each process measurement
C. Each analyzer/transmitter shall be powered by 115VAC (+/- 10%) at 60Hz unless specifically shown on the drawings as being powered by 24VDC (+/- 15%). Each analyzer/transmitter shall retain its programmable settings in non-volatile memory.
D. Each sensor and corresponding analyzer/transmitter shall be supplied as a complete and operable system. This includes all cabling, mounting hardware and fasteners. When installed outdoors, the analyzer/transmitter shall be protected from the sun such that direct sunlight will not shine on the display.
E. All analyzers/transmitters shall be waterproof and made from corrosion resistant materials.
F. All sensors to be immersed in liquids shall be rated for permanent submersion and shall be corrosion resistant.
2.2 DISSOLVED OXYGEN PROCESS MEASUREMENT DEVICES
A. Each DO analyzer/transmitter shall be rated for operation with ambient temperature within -4 F to 122 F. If the analyzer/transmitter is to be installed in locations that may experience temperatures less than -4 F, it shall be housed in an enclosure which is equipped with a thermostatically controlled heater. If the analyzer/transmitter is to be installed in locations that may exceed 122 F, it shall be housed in an air conditioned enclosure. All enclosures and air conditioners shall be rated NEMA 4X.
B. The DO Sensor assembly shall meet the following criteria:
1. Contain the sensing elements and electronics for digital communications to the analyzer/transmitter in a self-contained, corrosion-resistant and submersible housing. 2. Built-in temperature compensation. 3. Allowed to be installed in liquids whose temperatures are 32 to 200 F and whose pressure is up to 100 psi. 4. The sensor shall have a measuring range of 0 to 20 ppm.
MISCELLANEOUS PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409123 - 2
5. The sensor shall continuously measure dissolved oxygen by exciting a luminescent material and then detecting light emitted by the material that is proportional to the amount of dissolved oxygen in the liquid.
C. Shall not require sample conditioning or electrolyte solutions.
D. Acceptable Manufacturers:
1. Hach model LDO Probe 2 with SC200 or SC1000 analyzer/transmitter. 2. WTW/Xylem FDO 700 IQ with 182 or 2020 analyzer/transmitter.
2.3 FLOW PROCESS MEASUREMENT DEVICES
A. ROTAMETERS
1. Rotameters in chemical solution lines and where indicated shall have vertical bottom inlets and top outlets with ANSI 150-lb flanged ends for vertical mounting.
2. The meters shall have Hastelloy C floats, 10-inch long scales, and a range of 10:1 with an accuracy of plus or minus 2 percent. Meters shall be rated for a minimum working pressure of 150 psi. Flanged rotameters for chemical solutions and where indicated shall be calibrated in gallons per minute.
3. The bodies shall have union ends for ease of maintenance, polysulphone tubes, aluminum or brass end fittings, Type 316 stainless steel internal parts and scales suitable for the indicated capacity range.
4. The meters shall have accuracy within plus and minus 5 percent of the capacity range indicated.
5. Meters in air and pump seal flushing lines shall be of the modified rotameter design with screwed ends, spring-loaded pistons, and union bodies for mounting in any position.
6. For activated carbon solution, bodies shall be Type 316 stainless steel construction with magnetically actuated float and scale.
7. For other chemicals bodies shall have Type 316 stainless steel ends with heavy borosilicate glass tubes and packing glands or other best suitable material.
8. Rotameters with NPT screwed ends for water, air, and fuel gas service shall be calibrated in gallons per minute or cubic feet per minute. The scales shall be suitable for the capacity ranges indicated.
9. Acceptable Manufacturers: a. Krohne VA40 Series. b. Dwyer UV Series. c. Or Approved Equal.
B. FLOW SWITCHES
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1. Thermal dispersion type flow switches
a. Thermal dispersion type flow switches shall be used for pump discharge monitoring, chemical injection monitoring, gas flow monitoring and for flows in pipes with velocities greater than 0.25 fps.
b. The flow element shall be constructed of a material that is best suited for the liquid or gas that it is serving. Typically for chemicals the material will be Hastelloy C and for other liquids or gases it will be 316SS.
c. The switch shall be capable of operating in liquids or gases whose temperatures range from -40 F to 350 F and up to 2000 psi operating pressure.
d. The flow switch assembly shall be insertion type with ¾” male NPT threads. The insertion length shall be such that the thermal dispersion elements are in the center of the pipe.
e. The flow switch shall accept 115VAC or 24VDC as shown on the Contract Drawings. It shall have two SPDT relay outputs rated at 5A up to 240VAC.
f. The flow switch shall be rated to be installed in Class 1, Division I Groups B,C & D hazardous locations. The electronics shall be housed in a powder coated aluminum enclosure that is rated NEMA 4X.
g. Acceptable Manufacturers: 1) Fluid Components International (FCI) FLT93 Series. 2) Sierra Instruments Innova-Switch Series. 3) Or Approved Equal.
2. Paddle type flow switches
a. Paddle type flow switches shall be used for low flow, clean water applications such as seal water systems and eyewash stations.
b. The lower and upper housing shall be stainless steel and leak-proof. The machined tee, flow section, and other wetted parts shall be stainless steel with ½” NPT connections.
c. An adjustable bypass valve shall set the trip point of the switch.
d. The snap action switch shall be magnetically actuated and shall be SPDT and rated at 5A up to 250VAC.
e. Acceptable Manufacturers: 1) Dwyer Low Flow Model V6 2) Or Approved Equal.
C. OPEN CHANNEL FLOW METER
MISCELLANEOUS PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409123 - 4
1. Ultrasonic type open channel flow meters
a. In applications where level measurement may be used to calculate flow, including flume and weir applications, an ultrasonic transducer and remote transmitter system shall be utilized. For the ultrasonic transducer and remote transmitter system, refer to the requirements of 2.4.E Ultrasonic Level Measuring System.
b. The ultrasonic open channel flow system shall be capable of internally converting the measured level into the calculated flow value and then displaying it on the screen. The meter shall output a 4-20mA signal that represents the flow rate. It shall also have a contact output that may be used for flow totalization.
c. The ultrasonic open channel flow system shall be equipped with a separate temperature sensor to be mounted adjacent to the ultrasonic sensor for temperature compensation.
d. Acceptable Manufacturers: 1) Siemens Sitrans LUT440 (transmitter) with XPS-5 (transducer) and TS-3 (temperature sensor). 2) Or Approved Equal.
D. MAGNETIC FLOW METER
1. Materials
a. All mounting hardware shall be 316 stainless steel, the instrument enclosure and the spool mag shall be rated NEMA 4X, the flow sensor liner shall be Polyurethane lined, and the electrode material shall be 316 stainless steel.
b. Spool size shall be as specified on the drawings.
c. All applications with flow element below grade where no de-watering means or in submersible applications shall provide the flow element as NEMA 6P (IP-68).
d. Transmitter shall be integral or remote to the flow element as shown on the P&ID’s.
2. Design and fabrication
a. Utilize characterized field principle of electromagnetic induction to produce signal directly proportional to flow rate. The meter shall use a pulsed DC magnetic field excitation.
b. Provide flanged end connections per ANSI B16 rated for piping system operating and test conditions.
c. Operating pressure: 150 psi.
d. Operating temperature: 122 F.
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e. Grounding requirements: per manufacturer requirements. Typically inlet and outlet grounding rings of same material as electrode.
f. When the transmitter is remote to the flow element, provide cable between flow element and transmitter. Coordinate with the installer the length of the cable required. No splices in any way will be allowed.
g. Complete zero stability shall be inherent to the meter system. The system shall have a programmable low flow cutoff.
h. Empty pipe detection to prevent false measurement when pipe is empty or partially filled.
i. Forward and reverse flow measurement and totalization as well as net flow totalization.
j. 4-20mA DC isolated output into maximum 800 ohms. Signal shall be programmable to indicate forward and/or reverse flow. k. Provide a dry contact output for flow direction indication.
l. Provide a programmable frequency output for flow totalization.
m. +/- 0.5% accuracy for flow rates above 1 fps.
3. Acceptable Manufacturers a. Siemens SITRANS F 5100W. b. Endress+Hauser Promag 53. c. Rosemount 8700. d. ABB WaterMaster. e. Or Approved Equal.
E. MASS FLOW METER
1. Materials
a. All mounting hardware shall be 316SS. The instrument enclosure shall be rated NEMA 4X. For hazardous locations, the assembly shall be rated for Class 1 Division I Groups B,C & D locations.
b. Sensor Material: 316L Stainless Steel, all welded construction.
c. Sensor Support Material: 316L Stainless Steel all-welded construction.
d. Process Connection: 316 Stainless Steel Compression Fitting to fit 1” FNPT Fitting on pipe (by Contractor).
e. LCD display for setup, calibration and flow monitoring.
2. Design and fabrication
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a. Velocity Measurement Accuracy: +/- 2% of reading from 10 to 100% of calibrated range.
b. Output 4-20mA signal proportional to flow rate. 700 ohms maximum resistance.
c. Power Supply 18 to 30 VDC.
d. Repeatability: 0.25% or better.
e. Process Temperature Rating: -10 Deg C to +120 Deg C.
f. Process Pressure Rating: 150 PSIG.
g. Sensor Material: 316L Stainless Steel, all welded construction.
h. Sensor Support Material: 316L Stainless Steel all-welded construction.
i. Insertion Length: Per manufacturer’s recommendations.
j. Process Line Sizes: 3” pipe and larger.
k. Sensor Enclosure Temperature Rating: -20 Deg C to +50 Deg C.
l. Field Wiring: 1 pair of twisted and shielded 14-18 gauge wire having a maximum loop resistance of 4 ohms.
m. Installation location shall be in a location that maximizes the number of upstream and downstream diameters. A minimum of 15 pipe diameters and 5 pipe diameters downstream shall be required. If this is not possible, flow conditioning plates shall be installed per the manufacturer’s recommendation or a factory calibrated inline assembly.
3. Acceptable Manufacturers a. Sierra Instruments 640S Series (Insertion Type). b. Fluid Components International (FCI) ST51 Series (Insertion Type). c. Sierra Instruments 780S (Inline Type). d. Or Approved Equal.
2.4 LEVEL PROCESS MEASUREMENT DEVICES
A. FLOAT SWITCHES
1. Float switches shall consist of a mechanical switch, hermetically sealed in a plastic casing, freely suspended at the desired height from its own cable. When the liquid level reaches the float switch, the casing will tilt and the mechanical switch will change state.
2. The casing shall be constructed of polypropylene with the sheathed cable extruding from the casing. The cable shall be three conductors, made specifically for underwater use and heavy flexing service.
MISCELLANEOUS PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409123 - 7
3. The float switch shall have a 10A resistive rating up to 250VAC.
4. Weight and buoyancy shall be such that contaminants like a cake of grease will not result in the float switch changing operating level more than one inch.
5. A NEMA 4X 316SS junction box shall be supplied for termination of the float cable(s) allowing for conventional wiring and conduit to be run from the junction box to a control panel. It shall have terminal blocks for the required number of circuits and shall accept sealed fittings.
6. Float switch cables shall be suspended in a manner that provides minimum strain to the cable and will not damage it. This is typically achieved with a stainless steel cord support grip or strain relief grip as manufactured by Kellems. When support grips are used, a stainless steel hook shall be installed for hanging the support. All screws, fasteners, boxes and grips shall be 316SS. In no way are any steel or galvanized steel components allowed.
7. The float cable length shall be long enough for easily removing the float from the water for testing and long enough to reach its termination junction box.
8. If the float switch is to be installed in a classified area, an appropriate intrinsically safe barrier shall be utilized to guarantee the circuit may not abnormally create an ignition.
9. Manufacturers: a. Flygt ENM-10. b. Or Approved Equal.
B. FLOOD SWITCHES
1. High level flood switches shall be the type that is suspended on a column. A ¼” NPT connection with flying leads allows the column and float assembly to be attached to a junction box. The junction box shall be rated NEMA 4X and be nonmetallic. The flood switch shall be CPVC and shall be made for use with liquid chemicals and corrosive liquids. Switch contacts shall be SPST N.O. with 20VA rating minimum.
2. If the flood switch is to be installed in a classified area, an appropriate intrinsically safe barrier shall be utilized to guarantee the circuit may not abnormally create an ignition.
3. Manufacturers: a. GEMS LS-74780. b. Or Approved Equal.
C. SUBMERSIBLE LEVEL TRANSMITTERS
1. The submersible level transmitter shall consist of a submersible transducer, electronic transmitter, support cable, and interconnecting cable with cable shield and vent tube for atmospheric reference. The vent tube shall be provided with a replaceable moisture barrier. The submersible transducer shall be the strain gauge type suitable for sensing pressure equivalent to the liquid level range indicated.
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2. The transducer shall have 316 stainless steel process wetted parts and shall be provided with a waterproof interconnecting cable. The transducer shall be suspended by a corrosion resistant cable as recommended by the manufacturer. The installation shall allow easy removal of the transducer and cable assembly for maintenance purposes. The electronic level transmitter shall be remote mounted and shall produce a 4 - 20 mA DC signal linearly proportional to the level range indicated and be capable of driving a load of 700 ohms. 3. The interconnecting cable shall have a pull strength of 200 pounds, be factory attached to the transducer, and shall be terminated in a NEMA 4X 316SS enclosure. The enclosure shall house the vent tube moisture barrier and local indication. 4. The measurement system shall be suitable for the area classification and operation over a temperature range of 32 to 122 degrees Fahrenheit with an accuracy of plus or minus 0.5 percent of span. The transmitter shall have a non-fouling, large diaphragm (greater than 2”). The diaphragm shall be protected by a spacer assembly that also allows the transducer to sit on the floor of the wet well.
5. For lengths greater than 20 feet the transducer shall have ½” threads and shall be suspended in the wet well by ½” stainless steel conduit.
6. Acceptable Manufacturers a. KPSI model 750. b. Or Approved Equal.
D. FLANGED LEVEL TRANSMITTERS
1. Flanged level transmitters shall be a flanged, differential pressure-sensing unit. The transmitter shall be a 2 wire device with continuously adjustable span, zero and damping adjustments, integral indicator, scaled in engineering units, with a 4 digit LCD display, solid state circuitry, and 4 - 20 mA output with HART protocol. Accuracy shall be 0.075 percent of span. Process wetted parts, bolts, flanges, adapters, drains and vents shall be stainless steel. Body and mounting brackets shall be corrosion resistant and suitable for the environment. The flanged process connection shall be 316SST ANSI Class 150 4- inch with a 3” 316SST diaphragm. The diaphragm shall extend past the flange such that it is flush with walls of the pipe. The low pressure connection shall be 1/4-inch or 1/2- inch NPT.
2. Components: Diaphragm seals shall consist of a flange with flush or extended diaphragm to be flush with the walls of the pipe. It shall have a direct mount, coplanar, welded connection for connection of the transmitter to the seal.
3. Operating Principles: The diaphragm seal shall attach to the inlet connection of a pressure instrument to isolate its measuring element from the process fluid. The space between the diaphragm and the pressure element shall be completely filled with a suitable liquid that is rated for the environmental conditions. Displacement of the liquid fill in the pressure element through the movement of the diaphragm shall transmit process pressure changes directly to a gauge, transmitter, switch, or other pressure instrument.
4. Materials: Exposed surfaces, housings, and diaphragm shall be constructed of 316, stainless steel.
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5. Acceptable Manufacturers a. Rosemount model 3051L with model 1199 diaphragm seal. b. Or Approved Equal.
E. ULTRASONIC LEVEL MEASURING SYSTEM
1. As indicated on the drawings, the ultrasonic level measuring system shall be setup as a level transducer with remote mounted transmitter or as a single transducer/transmitter assembly. For hazardous locations, the single transducer/transmitter shall be utilized. It shall be loop powered and shall be installed with an appropriate intrinsically safe barrier to guarantee the circuit may not abnormally create an ignition.
2. All transducer and transducer/transmitter assemblies shall be rated IP68 for permanent submergence. Remote transmitter shall be in a non-corrosive NEMA 4X housing. Transmitters shall have an LCD display and shall be programmable by buttons on the transmitter or with a handheld programmer. When programmed with a handheld programmer, each transmitter shall be supplied with an accompanying programmer.
3. The transducer shall be encapsulated in chemical and corrosion resistant material, such as Kynar, Teflon or TEFZEL. It shall be capable of operating from -40 F to 158 F. The transducer shall be compatible with the level range as indicated on the Contract Drawings. As a minimum, the transducer shall be capable of measuring a range of 40 feet.
4. When the transducer is remotely mounted from the transmitter, it shall have a waterproof shielded cable whose length is long enough to reach the transmitter. In no way shall splicing of the transducer cable be allowed.
5. Each transmitter shall provide a 4-20mA output signal that is programmable to a user desired level range.
6. Remote transmitters shall be provided to accept two transducers for differential level monitoring or for monitoring two separate levels. A second 4-20mA output signal shall be provided for the second level. The remote transmitter shall have six programmable relays rated at 5A up to 250VAC.
7. Manufacturers: a. Siemens SITRANS Probe LU (transducer/transmitter assembly); Hydroranger 200 (remote transmitter) with XPS-15 or greater (transducer). b. Or Approved Equal.
F. RADAR LEVEL MEASURING SYSTEM
1. The radar level measuring system shall be setup as a single loop powered transducer/transmitter assembly. For hazardous locations, it shall be installed with an appropriate intrinsically safe barrier to guarantee the circuit may not abnormally create an ignition.
2. All transducer/transmitter assemblies shall be rated IP68 for permanent submergence. Transmitters shall have an LCD display and shall be programmable by buttons on the
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transmitter or with a handheld programmer. When programmed with a handheld programmer, each transmitter shall be supplied with an accompanying programmer.
3. The transducer shall be encapsulated in chemical and corrosion resistant material and shall be hermetically sealed. The antenna supplied (horn or rod) shall be per the recommendation of the manufacturer. It shall be capable of operating from -40 F to 158 F. The transducer shall be compatible with the level range as indicated on the Contract Drawings. As a minimum, the transducer shall be capable of measuring a range of 40 feet.
4. Coordinate with the mechanical installers the method of installing the radar system (flanged or threaded connection). It is critical that the radar level measuring system be installed according to the manufacturer’s installation guidelines. Install shield sections if required. Keep the radar emission cone free of interference from pipes, beams, pouring liquids, etc. Locate the assembly away from side walls of tanks or vessels.
5. Each transmitter shall provide a 4-20mA output signal that is programmable to a user desired level range.
6. Provide a software package by the same manufacturer as the radar system that is used to commission and maintain the system. The software shall be able to configure the system, view radar echo profiles and modify the programming to suppress false echos.
7. Manufacturers: a. Siemens SITRANS LR200 with SIMATIC PDM Software b. Or Approved Equal.
2.5 TURBIDITY PROCESS MEASUREMENT DEVICES
A. Each turbidity analyzer/transmitter shall be rated for operation with ambient temperature within -4 F to 122 F. If the analyzer/transmitter is to be installed in locations that may experience temperatures less than -4 F, it shall be housed in an enclosure which is equipped with a thermostatically controlled heater. If the analyzer/transmitter is to be installed in locations that may exceed 122 F, it shall be housed in an air conditioned enclosure. All enclosures and air conditioners shall be rated NEMA 4X.
B. The Turbidity Sensor assembly shall meet the following criteria:
1. Contain the sensing elements and electronics for digital communications to the analyzer/transmitter in a self-contained, corrosion-resistant housing. 2. The turbidity sensor shall be meet the performance criteria of the U.S. Environment Protection Agency in Method 180.1, making it suitable for regulatory reporting. 3. The sensor shall utilize a light source that directs light through the process water to a submerged photocell which detects the amount of light that passes through the water. 4. Allowed to be installed in liquids whose temperatures are 32 to 122 F. 5. The sensor shall have a measuring range of 0 to 100 NTU. 6. Shall not require sample conditioning or electrolyte solutions.
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C. Acceptable Manufacturers: 1. Hach model 1720E Turbidity System with SC200 or SC1000 analyzer/transmitter.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers’ recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
B. Install all analyzers/transmitters five feet off of floor level. Install in a location that is easily accessible while as near to the sensor(s) as possible.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 409000 and per the manufacturer’s documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble-free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
2. Test the process measurement system for proper operation at low, mid and high process conditions.
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 409000.
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END OF SECTION 409123
MISCELLANEOUS PROPERTIES WRCRWA PROCESS MEASUREMENT DEVICES PLANT EXPANSION PROJECT 409123 - 13
SECTION 409433 – HUMAN-MACHINE INTERFACES
PART 1 - GENERAL
1.1 SUMMARY
A. This section covers the human-machine interfaces (HMI) used for control and monitoring as indicated on the Contract Documents. HMI’s include the following: 1. Operator Interface Terminals (OIT) or touch screens. 2. Personal Computers or Servers used as HMI’s to the SCADA System.
B. For software related to HMI equipment, refer to Section 409600.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.3 QUALITY ASSURANCE
A. Hardware to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that HMI equipment and software being provided is compatible with the requirements. Provide all necessary accessories to the HMI equipment for a complete and operable system.
1.4 DELIVERY, STORAGE, AND HANDLING
A. Deliver the HMI hardware as a complete system in accordance with Section 409000.
PART 2 - PRODUCTS
2.1 OPERATOR INTERFACE TERMINALS
A. OITs shall be furnished with hardware to monitor and control equipment, as listed in the specifications, and shown on the Contract Drawings.
B. OITs shall be 10” color touch screens unless otherwise indicated on the Contract Drawings. Each OIT shall have the following features: 1. Has serial and Ethernet ports with built-in communications protocols drivers as required by the project.
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2. Has associated software for programming the OIT and its screens, database, alarms, etc. 3. Has a 640 x 480 minimum resolution with TFT color screen. 4. Has at least 64MB of memory. 5. Has no limitations on the number of screens or tags that may be used as long as within the memory limitations of the OIT.
C. Acceptable Manufacturers 1. Allen Bradley Panelview Plus 6
2.2 SCADA PC HARDWARE
A. Provide SCADA-PC Hardware as indicated on the drawings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. OIT’s and Panel PC’s shall be installed on the doors of control panels as shown in the Contract Drawings. The control panel assembly and installation shall be as required by Section 409513.
B. Following control panel Factory Acceptance Testing, OIT’s and Panel PC’s shall be removed from the control panels and put back in their original packaging and shipped to the Site loose. The OIT’s and Panel PC’s shall not be re-installed until they are needed for loop testing. The goal of doing this is to protect the screens from damage during construction. While the OIT’s and Panel PC’s are not in the control panel, cover and seal the open space on the door of the control panels to protect the interior of the panel.
C. OIT’s and Panel PC’s]shall be installed in accordance with the manufacturer’s installation guidelines and instructions.
D. Insert SCADA PC Hardware installation requirements here if being supplied by the Contractor.
3.2 TRAINING
A. Provide training for the OIT and SCADA PC hardware supplied for the project as required by Section 409000.
END OF SECTION 409433
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SECTION 409443 – PROGRAMMABLE LOGIC CONTROLLERS
PART 1 - GENERAL
1.1 SUMMARY
A. This section covers the programmable logic controllers (PLC) used for control and monitoring as indicated on the Contract Documents.
B. Provide one full version of PLC programming software that is applicable to the PLC hardware being supplied for the project. Include auxiliary software (such as communications software, drivers, networking configuration software, etc.) that may be required for a complete and operable system.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Wiring diagrams showing connections to all devices; input and output (I/O), analog and discrete. The wiring diagrams shall indicate the I/O address point to be used in the PLC programs.
C. Submit calculations that show the following: 1. PLC Power Supply Budget 2. Calculated number of I/O quantities required 3. Estimated PLC memory usage
1.3 QUALITY ASSURANCE
A. Hardware and software to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that PLC equipment and software being provided is compatible with the requirements. Provide all necessary accessories to the PLC equipment for a complete and operable system.
1.4 DELIVERY, STORAGE, AND HANDLING
A. Deliver the PLC hardware and software as a complete system in accordance with Section 409000.
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PART 2 - PRODUCTS
2.1 GENERAL
A. PLCs shall be furnished with hardware and software necessary to monitor and control equipment, as listed in the specifications, and shown on the Plans.
B. Each field input and output shown as an I/O Point shall be connected as per the manufacturers’ recommendations.
C. The Contractor shall provide the hardware, software, and installation necessary for connecting additional future equipment as indicated on the Plans. In addition to allocating for future I/O, each PLC shall be supplied with a minimum of 20% spare I/O of each type. In other words, the total I/O for each type shall be (current I/O + future I/O) * 120%. Provide enough panel space to install up to 200% of future I/O modules and/or PLC racks/bases.
D. The type of field input and output shall be defined as follows unless specified otherwise on the plans: 1. Analog inputs and outputs: 4-20mA DC. 2. Discrete inputs: I/O device shall be a dry contact, inputs shall be powered by the PLC at 24VDC (preferred) or 120VAC. 3. Discrete outputs: Isolated dry contact outputs.
E. All PLC I/O shall have I/O modules that are installed and wired at a UL508 Panel Shop. All I/O points shall be wired down to terminal blocks. In no way should field wiring go to any part of the PLC assembly.
F. Vendor and Contractor supplied PLC’s shall meet the requirements of this Section and of Division 40. Vendor supplied PLC’s shall have a Factory Acceptance Test (FAT) performed by the Vendor as required by Section 409000. Contractor supplied PLC’s shall have a FAT performed by the Contractor as required by Section 409000.
G. The PLC shall be capable of handling online program modifications without taking the system offline or requiring a download.
H. Acceptable Manufacturers 1. Allen Bradley CompactLogix
2.2 PROCESSORS
A. The PLC processor shall be a microprocessor based industrial controller with a temperature rating of 0 to 60 degrees C, and a humidity rating of 5 to 85% non-condensing, minimum.
B. The processor’s memory shall be sized according to the number of I/O points and amount of logic required for the application. As a minimum, the memory shall be at least 1 megabyte.
C. The processor shall retain its memory and programming when power is removed.
D. The processor shall have tag-based memory.
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E. Processors shall be the CompactLogix L3 or L4 Series
2.3 PLC POWER SUPPLY
A. The power supply shall provide power for the processor, and I/O modules. The power supply shall have built-in over voltage and under voltage detection circuitry, protection against overcurrent conditions, and automatic power-up sequence that enables outputs only when proper operating tolerances are reached. Power requirements shall be 24 VDC unless shown as otherwise on the Contract Documents.
2.4 COMMUNICATIONS NETWORKS
A. Each PLC shall be equipped with network ports (and corresponding network modules if necessary) as shown on the Contract Drawings. Each PLC shall be equipped with an Ethernet port for connection to the Plant SCADA System.
B. Ethernet ports shall be setup to communicate with the Allen-Bradley Ethernet/IP protocol.
C. The PLC shall be programmable through the Ethernet port or through a USB port.
2.5 INPUT/OUTPUT MODULES
A. Only I/O modules that have typical wiring diagrams shown in the Contract Drawings shall be allowed for each PLC.
B. Analog I/O modules shall have a minimum of 12 bits of resolution and shall be setup as 4 to 20 mA signals unless indicated otherwise on the Contract Drawings. Analog inputs shall be setup to be connected to loop powered (2-wire) or self-powered (4-wire) signals. All analog inputs and outputs shall be protected by a fuse. 4 to 20 mA signals shall be protected by a 32mA fuse.
C. Each discrete I/O module shall be fused (fuse body shall be equipped with a blown fuse indicator). Each discrete output module and shall have interposing relays for each point with form C relay contacts. Indicator lights shall also be provided on each I/O point to indicate status of each signal. Each individual input or output point shall be optically isolated to protect the controller I/O circuitry from high voltage transients.
2.6 SPARE PARTS 1. In addition to the spare parts requirements of Section 409000, provide the following: a. One spare processor for each type of PLC processor supplied for the project. b. One spare I/O card for every type of I/O card supplied for the project. c. One spare PLC power supply for every type supplied for the project. d. One spare network adapter for each type of network adapter supplied for the project. e. One spare base for rack style PLC’s.
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PART 3 - EXECUTION
3.1 FACTORY ACCEPTANCE TESTING
A. All PLC assemblies shall be built up in control panels and shall be part of a Factory Acceptance Test as required by Section 409000.
3.2 INSTALLATION
A. The PLC assemblies shall be installed in control panels made specifically for the PLC. The control panel assembly and installation shall be as required by Section 409513.
B. The PLC assemblies shall be installed in accordance with the manufacturer’s installation guidelines and instructions.
3.3 TRAINING
A. Provide training for the PLC hardware supplied for the project as required by Section 409000.
END OF SECTION 409443
WRCRWA PROGRAMMABLE LOGIC CONTROLLERS PLANT EXPANSION PROJECT 409443 - 4
SECTION 409513 – PROCESS CONTROL PANELS AND HARDWARE
PART 1 - GENERAL
1.1 SUMMARY
A. This section includes the requirements for all control panels and associated hardware for the project. This includes, but is not limited to, vendor control panels, PLC panels, local control panels and instrumentation panels.
B. Related Requirements: 1. The requirements of Division 26 shall apply to this section.
1.2 ACTION SUBMITTALS
A. Submit the Control Panels Submittal as required by Section 409000.
1.3 CLOSEOUT SUBMITTALS
A. Submit the operation and maintenance data, including record control panel drawings for all control panels as required by Section 409000.
1.4 QUALITY ASSURANCE
A. Referenced Standards:
1. National Electric Code (NEC). 2. American Society for Testing and Materials (ASTM). 3. Joint Industrial Council (JIC). 4. National Electrical Manufacturers Association (NEMA): a. ICS 4, Terminal Blocks for Industrial Use. b. ICS 6, Enclosures for Industrial Controls and Systems. c. 250, Enclosures for Electrical Equipment (1000 V Maximum). 5. Underwriters Laboratories Inc. (UL): a. 50, Enclosures for Electrical Equipment. b. 508, Industrial Control Equipment. c. 508A, Standard for Industrial Control Panels.
B. Hardware to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. All panels shall be assembled in and labeled by a listed UL 508A panel shop. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
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C. Examine the Contract Documents and verify that control panel hardware being provided is compatible with the requirements. Provide all necessary accessories to the control panels for a complete and operable system.
D. The Contractor shall not place any conduit feeds for any control panel until the Control Panel Submittal has been approved. Once approved, conduits shall be placed strategically to best suit the layout of the control panel. Power entry and separation of power, controls and signal shall be considered.
E. All painted control panels shall have matching paint colors and tones.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the control panel hardware as required by Section 409000.
PART 2 - PRODUCTS
2.1 GENERAL
A. All control panels shall have an overall NEMA rating suitable for withstanding the mechanical, electrical, thermal stresses, humidity and corrosion that the panel will be subjected to in its installed location.
B. The following rules shall be followed when determining the NEMA rating requirement for each control panel:
1. NEMA 1, 3 & 3R shall not be allowed for control panels. 2. NEMA 4 shall be utilized for outdoor or wet locations in non-corrosive, unclassified areas. NEMA 4 control panels shall be painted steel. 3. NEMA 4X shall be utilized in corrosive, unclassified areas. NEMA 4X enclosures shall be 316SS except for the following exceptions with which the enclosure shall be polycarbonate or fiberglass reinforced polyester (FRP): a. Chemical areas or rooms. b. Locations where stainless steel is incompatible. c. Where specifically noted on the Contract Drawings. 4. NEMA 7 shall be utilized for classified areas as required by NEC. NEMA 7 enclosures shall be constructed of cast aluminum. 5. NEMA 12 shall be utilized in dry, non-corrosive, unclassified areas. NEMA 12 control panels shall be painted steel.
C. Each source of foreign voltage shall be isolated by providing disconnecting or pull-apart terminal blocks or a disconnect operable from the control panel front. Each control panel shall be provided with identified terminal strips for the connection of external conductors. The SUPPLIER shall provide sufficient terminal blocks to connect 30 percent additional conductors for future use.
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D. PLC Discrete outputs from the control panel shall be provided by electrically-isolated contacts rated for 10 amps at 120 VAC. Analog inputs and outputs shall be isolated 4 to 20 mA, 2 wire signals with power supply.
E. Control panel mounted devices shall be mounted a minimum of 3-feet above finished floor elevation. Touchscreens shall be mounted at a height of 66” from the finished floor to the center of the touchscreen. All control panels will be situated on housekeeping pads, this is not considered the finished floor elevation.
2.2 ENCLOSURES
A. Enclosures shall be either freestanding, pedestal-mounted or equipment skid-mounted, as indicated. Internal control components shall be mounted on an internal back-panel or side-panel as required.
B. Enclosure dimensions indicated on the Contract Drawings are based upon non-certified information and shall be considered the minimum panel size. It is the responsibility of the Contractor to design the size of all control panels. When sizing the control panels, adhere to the following criteria: 1. Maximum panel depth is 24”. If there are special reasons for a deeper enclosure, approval must first be obtained from the Engineer. 2. The panel size shall provide space for all equipment, wire-ducts, wire, terminations, and space for future expansion. 3. If the panel size needs to be enlarged, coordinate with the installing Contractor that there is adequate space for the larger size. If there is not space, coordinate with the Engineer to come up with a solution.
C. Materials 1. Steel panel section faces shall be 12-gauge minimum thickness for free standing panels and 14-gauge minimum thickness for wall-mounted or pedestal-mounted panels. Materials shall be selected for levelness and smoothness. 2. Structural shapes and strap steel shall comply with ASTM A 283 - Low and Intermediate Tensile Strength Carbon Steel Plates, Grade C. 3. Bolting Material: For outdoor, wet or corrosive areas, all bolting materials shall be 316SS. In dry, non-corrosive locations, carbon stell may be used. Commercial quality bolts, nuts, and washers shall be 1/2-inch diameter with UNC threads. Carriage bolts shall be used for attaching end plates. Other bolts shall be hex end machine bolts. Nuts shall be hot pressed hex, American Standard, heavy. Standard wrought washers shall be used for foundation bolts and attachments to building structures. Other bolted joints shall have SAE standard lock washers. 4. Control panels shall be structurally designed such that the completed and installed control panels shall safely withstand seismic requirements for the project. All equipment mounted within the panel shall be properly braced to prevent damage during a seismic event.
D. Acceptable Manufacturers 1. Hoffman. 2. Saginaw. 3. Or Approved Equal.
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2.3 CONTROL PANEL ASSEMBLY
A. General
1. The following requirements must be met when mounting to the back panels or side panels of the control panel: a. Holes shall be drilled and tapped with less than 50% diminishment in thread. b. Backpan shall be cleaned front and back after any drilling and tapping. c. Tek Screws are not acceptable. d. Any component mounted to a back panel or side panel shall be mounted at an exact square to the vertical and horizontal planes. e. Any duct running between back panels and side panels shall align horizontally with no overlaps. f. All DIN rail mounted to the panels shall have ½” stand-offs allowing for wires and other equipment to be routed beneath the rail if necessary. 2. Enclosure doors shall be flush fitting, gasketed, and be of the hinged lift-off type with lockable door handles. A common key shall be provided for the doors on each panel assembly. Removable access panels shall be provided with dished handle fasteners. Screw driver 1/4 turn or Dzus type fasteners are not acceptable. a. The flanged edges of panels shall be straight and smooth. Corners shall be welded and ground smooth. b. The face of the panel shall be true and level after flanging. c. Panel cutouts and holes may be cut or drilled by any standard method that does not cause deformation. Burrs shall be ground smooth. d. Adjacent panels shall assemble with faces flush. Gaps or cracks shall not be visible from the front of the assembled instrument board. e. Panels shall be self-supporting as defined below.\ 3. Control panels that are supplied with three phase power and/or are powering motor loads shall be supplied with a main feeder disconnect that is door operated. The door operator for the disconnect shall be defeat-able with a screwdriver. If the upstream overcurrent protection device feeding the control panel is not in the same room as the control panel, provide a main circuit breaker as part of the main disconnect assembly. Fused disconnects shall not be used unless specifically shown on the Contract Drawings.
B. Preparation of Bare Metal Panel Surfaces
1. Grind high spots, burrs, and rough spots. 2. Sand or sandblast to a smooth, clean, bright finish. 3. Every trace of oil shall be removed with a solvent. 4. Apply the first coat of primer immediately.
C. Panel Finishing
1. Repair damaged primer on inside surfaces. 2. Apply primer to the entire panel surface. 3. Apply 2 coats of satin finish lacquer enamel over the entire surface. 4. Colors shall match original paint color.
D. Instrument Finishing: The final coat applied to painted surfaces of instrument cases, doors, or bezels which are visible from the front of panels shall be manufacturer's standard unless otherwise indicated. Black japan or "crinkle" finishes on instrument cases are not acceptable.
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E. Mounting of Instruments
1. The panel shop shall provide cutouts and shall mount instrument items indicated to be panel mounted, including any instruments indicated to be furnished by other vendors but installed in the panel. 2. The panel shop shall also mount behind the panels other instrument accessory items as required. 3. Equipment mounted at the rear of panel shall be installed to allow for commissioning adjustments, servicing requirements, and cover removal 4. Spare space shall be kept clear of wiring, etc., to give maximum space for future additions. 5. All equipment mounted with fasteners shall be mounted with grade 5 or greater Phillips head fasteners.
F. Electrical Requirements 1. Each panel shall be serialized with its own UL serial number and label. 2. Each terminal block shall have a printed label as shown on the panel drawings. Hand written labels in any location of the panel will not be accepted. Wiring shall be identified with printed tubular wire end markers. 3. Back panels and side panels shall have visible machine printed adhesive labels that detail the following items: a. Terminal block torque ratings for field connections. b. Terminal block sections as detailed in the panel drawings. c. All equipment within the panel including, but not limited to, PLCs, switches, circuit breakers, UPS, Power Supplies, and any other piece of equipment. 4. Screw torque shall not exceed 0.4 N*M (4.4 Lb*In) (7 Lb-In). 5. Wire duct for AC signals and wiring shall be light grey. All duct for DC signals shall be white. Wiring for AC circuits and DC circuits must be kept within their respective ducts. 6. Freestanding panels shall be provided with switched lighting as indicated in the panel drawings. 7. Freestanding panels shall be provided with a 15 amp, 120 volt, service outlet circuit within the back-of-panel area as shown in the panel drawings. 8. Wall-mounted or pedestal-mounted panels shall be sized to adequately dissipate heat generated by equipment mounted in or on the panel. 9. Outdoor panels shall be provided with thermostatically-controlled heaters to maintain inside temperatures between above 40 F. 10. Any panel with heat producing equipment such as a PLC, UPS or VFD shall have cooling capabilities to maintain the inside temperature below 104 F. 11. All outdoor panels equipped with heating and/or cooling shall be insulated with a minimum R value of 2.0. 12. Provide a laminated fuse list matrix detailing fuse numbers and sizes mounted on the inside of the enclosure door. The fuse list matrix must be easily visible and at minimum size 14 font. Hand written fuse matrices will not be accepted. See panel drawings approximate locations. 13. Provide a pocket mount on the inside of each panel door large enough to hold type 8.5 x 11 size paper. See panel drawings for approximate locations. Pockets must be accessible with no equipment obstructing the entrance of the pocket for at least ten inches above the pocket. The pocket mount shall be fastened. No adhesive type pockets allowed. 14. Where required crimped fork or ring terminals will be properly installed on the conductors for connection integrity. 15. Signal and Control Circuit Wiring
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a. Wire type and sizes: Conductors shall be flexible stranded tin machine tool wire, UL 1015 listed Type MTW, and shall be rated 600 volts. Wires for instrument signal circuits and alarm input circuits shall be 14 AWG. Other wires, including shielded cables, shall be 16 AWG minimum. b. Wire Insulation Colors: Conductors supplying 120 VAC power on the line side of a disconnecting switch shall have a black insulation for the ungrounded conductor. Grounded circuit conductors shall have white insulation. Insulation for ungrounded 120 VAC control circuit conductors shall be red. Wires energized by a voltage source external to the control panel shall have yellow insulation. Insulation for DC conductors shall be blue. c. Wire Marking: Wire numbers shall be marked using white numbered wire markers made from plastic-coated cloth, Brady Type B 500 or equal, or shall be heat shrink plastic. Wire labels must be machine printed. All conductors within the control panel are to be permanently marked with wire labels at each end. Wire labels are to correspond to the labels on the approved shop drawings. d. For case grounding, panels shall be provided with a ground lug complete with solderless connector for one no. 1 AWG bare stranded copper cable. e. Panel doors shall be connected to panel ground. f. Wire Fastening: Provision shall be made utilizing cable tie bases such as type CTM1 or equivalent, fastened inside the wire duct to allow for the fastening of the shop wire harnesses upon final installation. 16. Power Supply Wiring a. Unless otherwise indicated, control power shall be 120 VAC. Where the electrical power supply to the control panel is something other than 120 VAC, the control panel shall be provided with a control panel transformer. Control conductors shall be provided in accordance with the indicated requirements. b. At a location near the top of the panel (or bottom), the panel fabricator shall provide terminal box connections for the main power supply entry. 17. Signal Wiring a. Signal wire shall be shielded twisted pair or triads. Cable shall be 18 AWG copper signal wires. b. Color code for instrument signal wiring shall be as follows: 1) Positive (+) – Red or Clear 2) Negative (-) – Black c. Multiconductor cables where indicated shall consist of no. 16 AWG copper signal wires twisted in pairs with 90-C, 600 V fault insulation. A copper drain wire shall be provided for the bundle with a wrap of aluminum polyester shield. The overall bundle jacket shall be PVC. d. RTD cabling shall be Belden 8770 cabling or equal. e. Multi-conductor cables, wireways, and conduit shall be sized to allow for 25 percent spare signal wire. 18. Wiring run to control devices on the front panels shall be tied together at short intervals with nylon wire ties and be secured to the inside face of the panel using adhesive mounts. 19. Wiring to rear terminals on panel-mount instruments shall be in plastic wireways secured to horizontal brackets above or below the instruments in about the same plane as the rear of the instruments.
G. Labor and Workmanship: Panels shall be fabricated, piped, and wired by fully qualified workmen who are properly trained, experienced, and supervised.
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2.4 CONTROL PANEL COMPONENTS
A. Nameplates and labels
1. All control components within the control panel shall be labeled with adhesive labels that have a thermal transfer type ink system on a UL-508A approved label. Labels shall be provided for marking wire ducts, terminal block sections, PLC modules, networking modules, signal isolators, intrinsic barriers, relays, breakers, power supplies, surge suppressors and all other pertinent components within the control panel. 2. All components on the exterior of the control panel shall have nameplates fabricated from black-letter, white-face laminated plastic engraving stock, Rowmark Ultramatte or equal. Engraved characters shall be block style with no characters smaller than 1/8 inch. Adhesive shall be high strength, low profile double strength, double sided as produced by Bron or Tessa or approved equal. Stainless steel fasteners shall be used in addition to the adhesive on all equipment where the fasteners do not derate the NEMA rating of the enclosure.
B. Pilot Devices
1. Provide pilot devices from a single manufacturer. 2. Pilot devices shall have NEMA ratings that match the overall control panel rating. They shall be 30mm in diameter and heavy duty. 3. All pilot devices shall have an associated nameplate that clearly describes the function of the device. 4. Pilot lights shall be LED and shall have colors as follows: a. The Contract Drawings shall take precedence for light colors. Refer to the P&ID’s and schematics. b. On/Running/Opened: Green. c. Off/Stopped/Closed: Red. d. Power: White. e. Alarm/Fail: Red. 5. Acceptable Manufacturers a. Square D Types K (for NEMA 4 or 12) or Types SK (NEMA 4X). b. Allen-Bradley Types 800T (NEMA 4/12) or Types 800H (NEMA 4X, 7). c. Or Approved Equal.
C. Door Mounted Meters
1. Digital Process Meters a. Provide digital process meters to display a numeric process value as required by the Contract Drawings. b. The meter shall accept and re-transmit an analog input signal which is in proportion with the process value. The meter shall be capable of receiving the following signals: 1) 0 or 4 to 20 mA current. 2) 0 to 5 or 10 DC volts. 3) RTD and Thermocouple type inputs. c. The meter shall be programmable to scale the numeric display to process engineering units. It shall be capable of showing up to three decimal points. d. The meter shall be capable of powering the input and re-transmitted signal. e. Acceptable Manufacturers:
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1) Precision Digital Trident Series. 2) Red Lion PAX Series. 3) Or Approved Equal. 2. Elapsed Time Meters (ETM) a. Provide ETM’s for each motor and/or machine provided for the project. Each ETM shall accumulate hours in tenths of an hour. b. The ETM enclosure shall be panel mount, polycarbonate, shock resistant and totally sealed. c. Acceptable Manufacturers: 1) Hobbs 20000 Series. 2) Or Approved Equal.
D. Terminal Blocks
1. Terminal blocks shall mount on standard DIN rail, and be of the size required for conductors therein. A minimum of 25 percent spares shall be provided in each terminal box. No more than 2 conductors shall be allowed per termination. Jumper bar assemblies shall be installed for interconnecting terminal blocks, distributing power and signal commons. Terminal blocks shall be U.L. rated for 600 Volts, and 30 Amps, minimum. 2. Grounding terminal blocks shall be provided for instrumentation cable shields. The terminal blocks shall have distinctive 2-color bodies yellow and green, and shall be mounted to the DIN rail with metal screw down type clamps, providing a positive ground connection. One grounding terminal block shall be installed for every 2 instrument cables terminated. Grounding terminal blocks shall be U.L. rated for 600 Volts, and 20 Amps, minimum. 3. Terminal blocks shall be available in a variety of colors, including red, green, blue, gray, black, yellow, and orange. 4. DIN mount fuse holders shall have blown fuse indicators for DC and AC circuits. Fuse holders shall be of the compression clamp type. Fuse holders shall be U.L. listed, and rated for 600 Volts. Fuse sizes shall not exceed the U.L. current rating for the fuse holders. 5. Terminal blocks for 4 to 20 milliamp signals shall have knife disconnect switches, and accessible test points for testing and measurement of current loop signals, without the need for removing wire terminations. 6. Approved Manufacturers a. Phoenix Contact UT Series. b. Allen-Bradley 1492 Series. c. Or Approved Equal.
E. DIN Rail
1. DIN rail shall be prepunched, RoHS compliant, treated with galvanic zinc plating and passivation. Symmetrical DIN rail shall be 35 mm X 15 mm. 2. Acceptable Manufacturers a. Iboco Omega 3AF. b. Or Approved Equal.
F. Wire Ducts
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1. Wire ducts shall have narrow slots (approximately every ½”) to accommodate high- density terminal blocks and other hardware. 2. Wire ducts shall be made of lead-free PVC, shall be UL rated for continuous use up to 122 F, and shall be flame retardant. 3. Wire duct colors shall be as follows: a. Light grey for all wiring 120V and higher. b. White for all wiring 48V and lower. c. Blue for all intrinsically safe wiring. 4. Acceptable Manufacturers a. Panduit Type F Series. b. Or Approved Equal.
G. Surge Protection Devices
1. Provide a Surge Protection Device (SPD) for power feeds which feed power to the control panel. 2. Each SPD shall have a short circuit current rating that exceeds the rating of the power feed that it is protecting. 3. All SPD’s shall be properly grounded to the ground grid per NEC and per the SPD manufacturer’s recommendations. 4. Three phase power feeds and single phase power feeds for non-sensitive loads. a. Provide a parallel, DIN rail mountable, SPD whose location is immediately downstream of the main panel disconnect or circuit breaker. b. Capable of handling a 10kA surge current. c. Acceptable Manufacturers 1) Transtector 12R Series. 2) Or Approved Equal. 5. Single phase power feeds for control panels with sensitive electronics a. Provide an inline, DIN rail mountable, SPD that also provides EMI filtering. b. The SPD shall be capable of handling a 10kA surge current. c. The inline SPD shall have a set of dry contacts that indicate when the unit is healthy and operating correctly. d. Acceptable Manufacturers 1) Phoenix Contact SFP Series. 2) Or Approved Equal. 6. Low Voltage Signals a. Provide surge protection for low-voltage signals where shown on the Contract Drawings. b. Acceptable Manufacturers 1) Phoenix Contact Termitrab. 2) Or Approved Equal. 7. Coaxial Transmission Lines a. For radio type systems, provide surge/lightning protection for all coaxial lines leaving the control panel. b. Surge/lightning protectors shall be rated for the frequency at which signals are to be transmitted on the cabling. c. Acceptable manufacturers 1) Polyphaser. 2) Or Approved Equal.
H. Circuit Breakers
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1. Circuit breakers shall meet the requirements of Section 262816. 2. Provide a main circuit breaker with panel disconnect if required as described in 2.3.A. 3. All control panels fed by 120VAC shall have a main DIN rail mounted circuit breaker. 4. The following types of loads shall be individually fed by circuit breakers: a. Panel mounted receptacles. b. UPS equipment. c. DC Power Supplies. 5. Circuit breakers shall be sized according to the loads they are powering. 6. Acceptable Manufacturers a. Square D. b. Cutler Hammer. c. Or Approved Equal.
I. Motor Controllers
1. All motor controllers shall meet the requirements of Division 26.
J. Uninterruptible Power Supplies (UPS)
1. All UPS equipment shall meet the requirements of Section 263353. 2. UPS equipment intended to be installed in control panels shall meet the following criteria: a. The UPS shall be UL listed and shall maintain the UL listing of the control apnel. b. The UPS shall be properly mounted to withstand vibration and seismic requirements for the project. c. The UPS shall be sized for 200% of the calculated panel load. d. The UPS shall have a minimum backup time of 30 minutes unless specifically stated as otherwise on the Contract Drawings. e. For PLC panels, the UPS shall be equipped with dry contacts for monitoring the UPS for any alarm conditions and low battery. 3. Where specifically shown on the Contract Drawings, an industrial DC UPS may be used as backup power for the control panel. This will typically be the case where all critical loads are at 24VDC. 4. Unless indicated as otherwise on the Contract Drawings, the UPS equipment shall be the line-interative type and operate at 120VAC. 5. UPS equipment shall provide surge, EMI 6. Acceptable Manufacturers a. Powerware 5000 series (line-interactive) or 9000 series (online). b. Sola SDU Series (24VDC UPS). c. Or Approved Equal.
K. Power Supplies
1. Provide 24VDC Power Supplies or other DC voltages as required for the application. 2. All power supplies shall be oversized for a minimum 150% of the calculated load. 3. All power supplies shall be properly protected by a DIN rail mount circuit breaker whose trip rating is per the manufacturer’s recommendation. 4. All power supplies shall have a set of dry contacts that indicate when the power supply is operating normally.
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5. Where shown on the Contract Drawings, provide redundant power supplies and corresponding diodes. 6. Power supplies shall meet the following criteria: a. Input Voltage: 100 to 240VAC. b. Output Voltage: ±1% of rated output. c. Operating Temperature: 0 C to 60 C. d. Built in transient surge protection. e. DIN rail mountable, metal housing. 7. Acceptable Manufacturers a. Phoenix Contact Quint Series. b. Or Approved Equal.
L. Signal Isolators/Converters
1. Furnish signal isolators as required that optically isolate the input signal from the output signal. If output signal is to be a different type of signal than the output than the isolator shall convert the signal as required. 2. Isolators output shall be adjustable for zero and span. 3. If input signal is part of a Hart system, the isolator shall be made specifically to pass on the Hart signal. 4. Acceptable Manufacturers a. Phoenix Contact. b. Action Instruments. c. Or Approved Equal.
M. Intrinsically Safe Barriers
1. Provide intrinsically safe barriers wherever analog or discrete input signals are coming from classified areas. 2. Intrinsically safe barriers shall be located in their own enclosure whose assembly is UL rated. Install the barriers and field wiring as per the requirements of NEC and the manufacturer’s installation guidelines. 3. If input signal is part of a Hart system, the isolator shall be made specifically to pass on the Hart signal. 4. Acceptable Manufacturers a. Phoenix Contact. b. Pepperl Fuchs. c. Or Approved Equal.
N. Relays
1. Provide relays whose contact ratings are sized according to the load requirements and size of the protection device associated with the circuit in which the contacts are wired. As a minimum contact ratings shall be 10A resistive up to 250VAC. 2. Provide relays whose coil voltage is as required by the application. 3. Relays with DC rated coils shall have a freewheel diode installed across the coil. 4. Relays with AC rated coils shall have a surge suppressor installed across the coil. 5. Relays shall have based with relays which plug into the base. Bases shall have screw- type connections. 6. Relays shall have an LED indicating when the relay is coil is energized.
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7. Provide enough relay contacts for each relay as required by the application. If the number of contacts required exceeds the number of contacts on the relay, provide additional relay(s) to provide enough sets of contacts. 8. Acceptable Manufacturers a. Idec R Series. b. Allen-Bradley 700H Series. c. Or Approved Equal.
O. Time Delay Relays
1. Provide time delay relays to control on and off delay times as required by the application. 2. Time delay relays shall meet the requirements of relays as listed above with the following additional requirements: a. Time delay shall be adjustable from 0.1 seconds to 600 hours. b. Timers shall be multi-function and shall be capable of providing on-delay, off- delay, cycle timing and one-shot type timing control. 3. Acceptable Manufacturers a. Idec RTE Series. b. Phoenix Contact ETD Series. c. Or Approved Equal.
P. Panel HVAC Components 1. Provide heating, ventilation, and air conditioning, devices in order to maintain all components within the control panel within the acceptable range as specified in Section 409000. 2. HVAC equipment shall maintain the required NEMA rating for the control panel assembly. 3. Externally mounted HVAC equipment (such as air-to-air exchangers or air conditioners) shall be housed in an enclosure whose material matches the material of the control panel. Where in corrosive environments, all components that will come in contact with outside air shall be corrosion resistant for that environment. 4. All HVAC equipment shall be UL rated. For equipment mounted on the control panel, the equipment shall have a corresponding NEMA rating. 5. Provide power as required for the HVAC equipment. HVAC loads shall be included in feeder and control power transformer sizing calculations. 6. Panel Heating a. Heating shall be provided when ambient temperatures are expected to fall below the allowed range as specified in Section 409000. As a minimum, heating shall be sized to keep the panel temperature at or above 50 F. b. Except for small anti-condensating heaters, heating equipment shall have fans which distribute the heat throughout the enclosure. Heaters shall be installed according to the manufacturer’s installation instructions. Provide enough space between the heating equipment and other components such that the other components to not experience abnormally high temperatures. c. Provide anti-condensating heaters for all outdoor enclosures which house electronics, instrumentation and/or motor controllers. d. All heaters shall be thermostatically controlled by a DIN rail mounted thermostat. e. Acceptable Manufacturers 1) Hoffman. 2) Or Approved Equal. 7. Panel Ventilation
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a. Where ventilation is determined to maintain the control panel’s maximum temperature as required by Section 409000, the following requirements shall be adhered to: 1) Ventilation shall maintain the required NEMA rating for the control panel assembly. 2) For indoor, non-corrosive locations (panels with NEMA 12 ratings), conventional ventilation with fans and vents may be used. 3) For corrosive or outdoor locations, side or top mounted air-to-air heat exchangers shall be used. b. The fan(s) and corresponding vents or air-to-air heat exchangers shall be properly sized and located to move enough air through the panel to remove the generated heat as well as allow air flow across all heat generating equipment. c. All ventilation shall be thermostatically controlled by a DIN rail mounted thermostat. d. Acceptable Manufacturers 1) Hoffman. 2) Pfannenberg. 3) Or Approved Equal. 8. Panel Air Conditioning a. Where it is deemed necessary to air condition a control panel to maintain the control panel’s maximum temperature as required by Section 409000, the following requirements shall be adhered to: 1) Air conditioners shall be side or top mounted and shall be sized based upon the heat generated within the control panel, the maximum outside air temperature, and the amount of sunlight the control panel may be exposed to. Air conditioners shall be oversized by a safety factor of 25%. 2) Air conditioners shall be thermostatically controlled by a DIN rail mounted thermostat. In addition, the air conditioner shall turn off if the panel door(s) are not closed. b. Acceptable Manufacturers 1) Hoffman. 2) Pfannenberg. 3) Thermal Edge. 4) Kooltronics.
PART 3 - EXECUTION
3.1 FACTORY ACCEPTANCE TESTING
1. All control panels shall be factory acceptance tested (FAT) as required by Section 409000.
3.2 INSTALLATION
A. All control panels shall be installed according to the requirements of Section 409000.
B. All control panels shall be installed so that their surfaces are plumb and level.
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C. All control panels shall be properly mounted so as to withstand the seismic requirements for the Site. Anchor panels securely to the wall or floor at each corner as a minimum.
D. Control panels shall have been designed according to locations for conduit entry. Floor mounted panels in electrical rooms shall have cutouts in the bottom of the enclosure that were cutout by the panel shop. All conduit holes shall be cut in the field.
E. Field wiring 1. Wires that are terminated in control panels after permanent panel installation are deemed as field wires. Field wiring shall be installed in the allocated wire ducts and shall be properly labeled and terminated. 2. All field wires shall be long enough to reach each corner of the enclosure. Neatly coil up extra wire length at the bottom of the enclosure. Do not use the wire ducts for storing extra wire length.
3.3 FIELD QUALITY CONTROL
A. Refer to Section 409000.
END OF SECTION 409513
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SECTION 409533 – PROCESS CONTROL NETWORKS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Structured Cabling System (SCS). 2. Communications Termination Cabinets (CTC). 3. Process Control Network Components.
B. Related Sections
1. The requirements of Division 26 shall apply to this section.
1.2 DEFINITIONS
A. The following definitions may be used throughout this section and subsections (refer to the contract drawings sheet GI-1 for instrumentation abbreviations):
1. CTC: Communications termination cabinet. 2. HMI: Human machine interface. 3. LAN: Local area network. 4. LCP: Local control panel. 5. OIT: Operator interface terminal. 6. OSP: Outside Plant. 7. PC: Personal computer. 8. PLC: Programmable logic controller. 9. SCADA: Supervisory control and data acquisition. 10. SCS: Structured Cabling System. 11. UPS: Uninterruptible power supply. 12. WAN: Wide area network.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Shop Drawings: For each CTC cabinet supplied.
C. Network Drawings: Submit drawings for physical connections between all network hardware.
D. Exchange of Technical Information: During the period of these submittals, the Contractor shall authorize a direct, informal liaison with the Engineer for exchange of technical information. As a result of this liaison, certain minor refinements and revisions in the systems as indicated may be authorized informally by the Engineer, but will not alter the scope of work or cause increase or decrease in the Contract Price. During this informal exchange, no oral statement by the
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Engineer shall be construed to give approval of any component or method, nor shall any statement be construed to grant exception to or variation from these Contract Documents.
1.4 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.5 CLOSEOUT SUBMITTALS
A. Submit the operation and maintenance data, including record drawings as required by Section 409000.
1.6 QUALITY ASSURANCE
A. Referenced Standards:
1. National Electric Code (NEC). 2. American Society for Testing and Materials (ASTM). 3. National Electrical Manufacturers Association (NEMA). 4. Underwriters Laboratories Inc. (UL). 5. Telecommunications Industry Association / Electronic Industries Association (TIA/EIA) 568B – Commercial Building Telecommunications Cabling Standards. 6. TIA/EIA 569B – Commercial Building Standard for Telecommunications Pathways and Spaces. 7. International Standards Organization/International Electrotechnical Commission (ISO/IEC) 11801 – Information Technology – Generic cabling for customer premises. 8. Institute of Electrical and Electronic Engineers (IEEE)
B. Hardware and software to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
C. Examine the Contract Documents and verify that Process Control Network equipment and software being provided is compatible with the requirements. Provide all necessary accessories for the Process Control Network for a complete and operable system.
1.7 DELIVERY, STORAGE, AND HANDLING
A. Deliver the Process Control Network hardware and software as a complete system and as required by Section 409000.
1.8 SPECIAL WARRANTY REQUIREMENTS
A. The Contractor shall provide a Ten (10) year warranty on the following items:
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1. Fiber Optic Cabling. 2. Fiber Optic Terminations and Cross-Connect Equipment. 3. Outside-Plant (OSP) Category 6 Cabling. 4. Copper Patch Panels and Indoor Category 6 Cabling. 5. CTC Hardware (excluding UPS and other electronic devices).
B. Extended Period for Correction of Defects: The Contractor shall correct all defects in the SCS upon notification from the OWNER within 2 years from the date of Substantial Completion. Corrections shall be completed within 5 days after notification.
PART 2 - PRODUCTS
2.1 GENERAL
A. Current Technology: Cabling, Hardware and other components shall be the most recent field- proven models marketed by their manufacturers at the time of submittal of the Shop Drawings unless otherwise required to match existing equipment.
B. Hardware Commonality: All like equipment shall be provided by a single manufacturer.
2.2 EQUIVALENT PRODUCTS
A. Equivalent products may be considered for substitution for those products specified, however, the equivalent product must be approved and show demonstrated and documented equivalence to the product specified. Documentation shall include, but is not limited to: product samples, data sheets, and actual test data. The request for product substitution and supporting documentation must be submitted in writing prior to submitting the bid. Written approval for product substitution must be submitted with the bid.
2.3 FIBER OPTIC CABLING
A. Fiber optic cabling shall be provided between facilities and furnished with the quantity of fibers as designated on the contract drawings.
B. All fiber in a cable run shall be from the same manufacturer and shall be the same type. A mix of fibers from different manufacturers may not be used without written permission.
C. Fiber optic cabling exposed to the elements shall be an armored type fiber optic cable.
D. No fiber splicing or closures are allowed except to replace existing splices.
E. Singlemode Fiber
1. All singlemode fiber optic cables within the premises shall use graded-index fibers with 9 micron cores only. 2. Optical Specifications a. Fibers shall have dual wavelength capability at 1310nm and 1550nm. b. Attenuation: ≤ 0.4 dB/km at 1310nm and 0.3 dB/km at 1550nm.
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c. Bandwidth: Operation of 10 Gigabit Ethernet at 10,000 meters at 1310nm and 30,000 meters at 1550nm. d. Numerical Aperture: 0.14. 3. All fibers shall be color coded to facilitate individual fiber identification. Fibers shall have CPC¨ or approved equivalent color coatings that resist color degradation, minimize microbending losses and improve handling. The coating shall be mechanically strippable. 4. Dimensional Specifications a. Core Diameter: 8.2 µm b. Cladding Diameter: 125.0 ± 0.7 µm c. Core-Clad Concentricity: ≤ 0.5 µm d. Cladding Non-Circularity: ≤ 0.7% e. Coating Diameter: 242 ± 5 µm f. Coating-Cladding Concentricity: < 12 µm 5. Environmental Specifications a. Operating Temperature: -60¼C to +85¼C b. Cable shall be UV resistant, waterproof and corrosion resistant. 6. Mechanical Specifications a. Minimum tensile strength: 100,000 psi b. Fiber Minimum Bending Radius: 0.75 Inches c. Cable Minimum Bending Radius (During Installation): 20 times cable diameter d. Cable Minimum Bending Radius (After Installation): 10 times cable diameter e. Cable shall be rated for Underground, Buried and Aerial, OSP f. Cable shall bear OFNP (Plenum Rated), OFNR (Riser Rated) and/or appropriate markings for the environment in which they are installed. g. Cable shall utilize 3.0mm buffer tubes containing up to twelve 250 µm color-coded optical fibers. 7. Fiber Cabling shall contain the number of fibers specified in the Drawings. 8. Acceptable Manufacturers a. Corning SMF-28e+. b. Or approved equal.
F. Multimode Fiber
1. All multimode fiber optic cables shall use graded-index fibers with 50 micron cores only. 2. Optical Specifications a. Fibers shall have dual wavelength capability at 850nm and 1300nm. b. Attenuation: ≤ 3.0 dB/km at 850nm and 1.5 dB/km at 1300nm. c. Bandwidth: Effective Modal Bandwidth of 4700 MHz*km and shall guarantee operation of 10 Gigabit Ethernet at 550 meters at 850nm. d. Numerical Aperture: 0.200 ± 0.015. 3. All fibers shall be color coded to facilitate individual fiber identification. Fibers shall have CPC¨ or approved equivalent color coatings that resist color degradation, minimize microbending losses and improve handling. The coating shall be mechanically strippable. 4. Dimensional Specifications a. Core Diameter: 50 ± 2 µm b. Cladding Diameter: 125.0 ± 2.0 µm c. Core-Clad Concentricity: ≤ 1.5 µm d. Cladding Non-Circularity: ≤ 1.0% e. Core Non-Circularity: ≤ 5.0%
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f. Coating Diameter: 245 ± 5 µm g. Coating-Cladding Concentricity: < 12 µm 5. Environmental Specifications a. Operating Temperature: -60¼C to +85¼C b. Cable shall be UV resistant, waterproof and corrosion resistant. 6. Mechanical Specifications a. Minimum tensile strength: 100,000 psi b. Fiber Minimum Bending Radius: 0.75 Inches c. Cable Minimum Bending Radius (During Installation): 20 times cable diameter d. Cable Minimum Bending Radius (After Installation): 10 times cable diameter e. Cable shall be rated for Underground, Buried and Aerial, OSP f. Cable shall bear OFNP (Plenum Rated), OFNR (Riser Rated) and/or appropriate markings for the environment in which they are installed. g. Cable shall utilize 3.0mm buffer tubes containing up to twelve 250 µm color-coded optical fibers. 7. Fiber Cabling shall contain the number of fibers specified in the Drawings. 8. Acceptable Manufacturers a. Corning LANScape Class. b. Or approved equal.
G. Innerduct
1. Inner duct shall be used where space is available. All new and spare 2” conduits shall use inner duct with the fiber optic cable.
H. Buffer Tube Fiber Fan-Out Kits
1. Buffer Tube Fan-Out Kits shall be supplied for the termination of each buffer tube at end of the installed fiber cables. 2. Fan-Out Kits shall be color coded to match the color scheme of the fiber cabling. 3. Fan-Out Kits shall have a minimum length of 25 inches. 4. Acceptable Manufacturers a. Corning FAN-BT25-12. b. Or Approved Equal.
I. Fiber Optic Connectors
1. Fiber Optic Connectors shall be of ceramic construction and shall have a loss ≤ 0.5 dB. They shall be made specifically for the type of fiber being connected to and required bandwidth. The connector shall have no metal parts. 2. Fiber Optic Connectors shall utilize the ST type connector. 3. Acceptable Manufacturers a. Corning 95 Series. b. Or Approved Equal.
J. Fiber Patch Cords
1. The fiber patch cord shall be duplex and consist of buffered, graded-index fiber with a 50 or 62.5 µm core for multimode and 9 µm for singlemode and a 125 µm cladding. The fiber cladding shall be covered by aramid yarn and a jacket of flame-retardant PVC. 2. The fiber patch cord shall be rated for 10 Gigabit Ethernet.
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3. For 50 µm multimode the cords shall be Aqua in color. 4. For 62.5 µm multimode the cords shall be Orange in color. 5. For singlemode the cords shall be Yellow in color.
2.4 Fiber Testing and Termination Toolkits and Training
A. Fiber Termination Toolkit shall be provided to the Owner following the completion of the SCS installation. The Toolkit shall be compatible with the Connectors used for terminating the fiber cabling and shall have the necessary components to make at least 100 additional terminations.
B. The Toolkit shall contain hard copies of installation instructions as well as an installation video that illustrates the step-by-step procedure for installing the Fiber Optic Connectors.
C. The Toolkit shall have test equipment that is capable of determining if a Connector was installed correctly.
D. The Toolkit must be an approved installation system of the manufacturer of the fiber optic cabling and connectors.
E. Acceptable Manufacturers 1. Corning SP1000 (polishing/termination kit). 2. Fluke FTK 1450 (fiber testing kit). 3. Or Approved Equals.
F. The Contractor is to provide two four hour sessions of training. These sessions will be with select city staff and focus on the use of the polishing kit to replace damaged terminations. Each trainee shall have the opportunity to use the polishing kit during these training courses. The Contractor shall also provide a DVD with step by step instructions and demonstrations on the polishing process.
2.5 COPPER NETWORK CABLING
A. Outside Plant Cabling (OSP)
1. All building-to-building copper network cabling shall be shielded and shall be rated as outside plant (OSP), Category 6 cables. 2. The cabling shall be terminated in the CTC in each building and shall be punched down at the patch panel on the CTC. The shield shall be grounded only on one end of the cable inside the CTC. 3. Shielded OSP Category 6 Specifications a. Category 6 Transmission performance characterized to 500MHz. b. Aluminum metallic shield tape for protection against EMI/RFI c. Four 23 AWG solid twisted pairs d. UV/Sunlight resistant black jacket e. Acceptable Manufacturers 1) Superior Essex BBDN6. 2) Or Approved Equal.
B. Indoor Cabling
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1. Network cabling from the CTC’s to wall jacks, control panels, MCCs, phones and all other Ethernet devices shall utilize Category 6 unshielded cable. The Category 6 cable shall be rated for Plenum use if it is ran through any Plenum rated areas, otherwise it shall be rated for Riser use. 2. The following color scheme shall be utilized for indoor network cabling: a. Blue – Wall Jacks network connections b. Gray – Control Panels or MCCs c. Yellow – Patch Cables within the CTC d. Black – Outside Plant (OSP) cables e. Red – Security System / Fire System Cables f. White – Wall Jack phone connections g. Pink – Miscellaneous Ethernet devices 3. Unshielded Category 6 Specifications a. Category 6 Transmission performance characterized to 500MHz. b. Four 23 AWG solid twisted pairs c. Plenum rated cable shall have FEP insulation with a FRPVC jacket d. Riser rated cable shall have FRPE insulation with a PVC jacket. 4. Acceptable Manufacturers a. Superior Essex Series 77. b. Or Approved Equal. 5. Patch Cords a. Patch cords shall be TIA/EIA Category 6 Compliant. Cords shall be straight through unless cross-over is necessary. Cords shall be 24AWG stranded copper with FRPE insulation and a PVC jacket. RJ45 jack shall have contacts with 50 micro-inch gold plating and a high-impact, UL 94V-0 rated thermoplastic housing. b. Patch cords shall have a molded boot cover for protecting the RJ45 connector. c. All patch cords in the CTC shall be yellow.
2.6 CROSS-CONNECT EQUIPMENT
A. Cross-Connect Housings shall be provided within each CTC for permanent termination of the fiber optic cabling. The Housing shall be 19” rack mountable and shall be capable to support the termination of four 12-strand fiber optic cables.
B. Cross-Connect Housings when being provided in industrial enclosures such as PLC panels shall be panel mounted. The Housing shall be capable to support the termination of four 12-strand fiber optic cables.
C. The Housing shall be suitable for both loose tube, tight-buffered and optical fiber ribbon cables.
D. Acceptable Manufacturers 1. Panduit FMD Series (19” Rack Mount). 2. Panduit FWME Series (Wall Mount). 3. Or Approved Equal.
E. Adapter Panels for the Cross-Connect Housings shall utilize ST type connectors. Multimode adapter panels shall have ST Duplex Connectors, shall be of ceramic construction for bandwidths of 4700 MHz, shall have a loss ≤ 0.5 dB. Singlemode adapter panels shall have 6
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ST Duplex Connectors, shall be of ceramic construction for singlemode fiber, shall have a loss ≤ 0.5 dB.
2.7 COMMUNICATIONS TERMINATION CABINETS (CTC)
A. CTC’s shall be 19” rack type systems that shall be able to support and organize electronic equipment, cross-connection and/or termination hardware for fiber optic cabling, station cabling, riser cabling, or building entrance cabling as may be required by design. The rack face shall have a conventional equipment mounting width of 19”.
B. The rack must be designed for cable and jumper management and have hardware to organize and support cabling and patch cords in the vertical and horizontal planes. The rack system shall be equipped for electrical grounding to meet EIA/TIA 606 Standards. The fastening system for the equipment shall facilitate easy installation with roll-formed threads in the screw holes for greater strength and durability. The mounting screws shall have pilot points.
C. For NEMA 1 enclosures, all rack components shall be charcoal black in color and made of lightweight 6061-T6 extruded aluminum. For NEMA 4X enclosures the enclosure shall be 304SS.
D. The rack shall be shipped with all necessary hardware to assemble the included frame. It shall be packed in cartons with suitable shipping inserts such that no damage occurs to the rack finish. The finish shall not be scratched, chipped or marred.
E. Each CTC cabinet shall be supplied with a dedicated 20A, 120VAC circuit with associated receptacle mounted in the back of the cabinet.
F. Free Standing Rack Specifications
1. Self-Supported Rack Framework a. The self-supporting equipment rack shall be inside the CTC. Standard grade frames shall be capable of supporting equipment to be mounted inside the CTC. b. Dimensions: As required to fit in CTC with 19 inch center mounting and a minimum of 67” of usable vertical space. Base Footprint of 20.25” wide by 36” deep. c. Hole Pattern: EIA310-D 5/8” – ½” alternating. d. Mounting Screws: #12-24 thread combination Phillips/straight heads and pilot points. e. Materials: 6061-T6 high strength aluminum. f. Flanges: Flange edge to edge internal measurement is 17.75” 2. Racks shall be mounted inside NEMA 1 Enclosures with front and rear access doors. 3. Enclosures shall have glass front doors and solid vented rear doors. 4. Approved ground lug and #6 AWG jacketed green ground wire. 5. CTC shall be installed with at least 36” clear working space in front and behind cabinet. 6. Minimum 72” tall free standing enclosures. 7. Equipped with a slide-out shelf suitable for a laptop computer to be placed on it for system configuration/programming. The shelf shall be vented. 8. Equipped with a vertical power strip installed with a minimum of 10 outlets rated at 15 amps. The vertical power strip shall be surge protected. 9. Approved Manufacturers
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a. Great Lakes. b. Rittal. c. CPI. d. Or Approved Equal.
G. NEMA 1 Wall Mount Rack Specifications
1. Self-Supported Rack Framework a. The self-supporting equipment rack shall be inside the CTC. Standard grade frames shall be capable of supporting equipment to be mounted inside the CTC. b. Dimensions: As required to fit in CTC with 19 inch center mounting. Base Footprint of 20.25” wide by 24” deep. c. Hole Pattern: EIA310-D 5/8” – ½” alternating. d. Mounting Screws: #12-24 thread combination Phillips/straight heads and pilot points. e. Materials: 6061-T6 high strength aluminum. f. Flanges: Flange edge to edge internal measurement is 17.75” 2. Racks shall be mounted inside NEMA 1 Wall Mount Enclosures with a double hinge system allowing front and rear access. 3. Enclosures shall have glass or plexiglass front doors and solid vented rear doors. 4. Approved ground lug and #6 AWG jacketed green ground wire. 5. CTC shall be installed with at least 36” clear working space in front and 36” on the hinge side of the cabinet to allow access to the rear. 6. Panel mounting height shall be such that the top of the wall mount CTC does not exceed 80” above the finished floor. 7. Approved Manufacturers a. Great Lakes. b. Rittal. c. CPI. d. Or Approved Equal.
H. NEMA 4X Wall Mount Rack Specifications
1. Self-Supported Rack Framework a. The self-supporting equipment rack shall be inside the CTC. Standard grade frames shall be capable of supporting equipment to be mounted inside the CTC. b. Dimensions: As required to fit in CTC with 19 inch center mounting. Base Footprint of 20.25” wide by 24” deep. c. Hole Pattern: EIA310-D 5/8” – ½” alternating. d. Mounting Screws: #12-24 thread combination Phillips/straight heads and pilot points. e. Materials: 6061-T6 high strength aluminum. f. Flanges: Flange edge to edge internal measurement is 17.75” 2. Racks shall be mounted inside NEMA 4X Wall Mount Enclosures with a double hinge system allowing front and rear access. 3. Enclosures shall have glass or plexiglass front doors and solid vented rear doors. 4. Approved ground lug and #6 AWG jacketed green ground wire. 5. CTC shall be installed with at least 36” clear working space in front and 36” on the hinge side of the cabinet to allow access to the rear. 6. Panel mounting height shall be such that the top of the wall mount CTC does not exceed 80” above the finished floor.
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7. Approved Manufacturers a. Hoffman Protek Series. b. Or Approved Equal.
2.8 CTC HVAC EQUIPMENT
A. All CTC cabinets shall be properly designed to maintain the inner temperatures of the enclosure within the allowed limits defined in Section 409000.
B. Any HVAC equipment shall maintain the NEMA rating of the CTC assembly.
C. Preferably, fans, air-to-air exchangers and AC units are mounted on the top of each CTC.
2.9 PATCH PANELS
A. Each CTC cabinet shall be supplied with a 19” rack mountable 110 punch down to RJ45 jack patch panel. The panel shall be rated for CAT6 cabling.
B. The 110 punch blocks shall support wiring and be labeled for both T568A and T568B standards. The patch panel shall have at a minimum 24 RJ45 ports and at least 12 spare ports. Each RJ45 port shall have a plastic label holder for custom labels.
2.10 WALL JACKS AND PLATES
A. Jacks shall be TIA/EIA Category 6 Compliant and shall support wiring and be labeled for both T568A and T568B standards. Plates shall be constructed of high-impact, flame-retardant, UL 94V-0 thermoplastic. Plates shall be available in single gang with 1-4 ports and double gang with 8 ports. Color of jacks and plates shall be determined by the Owner.
2.11 UNINTERRUPTIBLE POWER SUPPLY (UPS)
A. Each CTC shall have a UPS installed in it for surge protection and battery backup of critical network equipment. The UPS shall be 19” rack mountable and shall be mounted with sliding rails where possible.
B. Each UPS shall be capable of running the connected load for a minimum of 30 minutes.
C. UPS Electrical Input Specifications
1. Nominal Voltage: 120VAC 2. Voltage Range: 80-144VAC 3. Input Power Factor: > 0.95 4. Frequency: 60 Hz ±3 Hz.
D. UPS Electrical Output Specifications
1. Voltage Regulation: ± 3% of Nominal 2. Efficiency: > 85%
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3. Frequency Regulation: ± 3 Hz on utility, ± 1 Hz on battery
E. UPS Communications Specifications
1. A USB port shall be available for monitoring and configuring the UPS. An appropriate cable shall be supplied to connect to the UPS with a PC. 2. An Ethernet port shall be available as an option with the ability to monitor and configure the UPS over an Ethernet network.
F. UPS Battery Specifications
1. All batteries shall be sealed, lead-acid batteries and shall be maintenance free. Batteries shall be hot-swappable. The UPS will indicate when the battery is weak and needs to be replaced. 2. The UPS shall be able to accept additional battery modules to extend the runtime of the UPS.
G. Acceptable Manufacturers 1. Powerware 5 or 9 Series. 2. APC Smart-UPS Series. 3. Or Approved Equal.
2.12 NETWORK SWITCHES
A. Each CTC shall contain a rack mountable network switch as indicated in the Contract Drawings.
B. Each PLC cabinet shall contain a DIN rail mountable network switch as indicated in the Contract Drawings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The Contractor shall utilize personnel to accomplish, or supervise the physical installation of all elements, components, accessories, or assemblies which it provides. The Contractor shall employ installers who are skilled and experienced in the installation and connection of all elements, components, accessories, and assemblies it provides.
B. All components of the SCS shall be the installation responsibility of the Contractor unless specifically noted otherwise. After the installation of the SCS is completed, the installation shall be inspected jointly by the Contractor and the Equipment Manufacturer’s representatives. Any problems shall be corrected, and when both are satisfied with the installation, a written certification of the installation shall be delivered to the Engineer. The certification shall state that all cabling and terminations have been inspected and are installed in accordance with the manufacturer’s guidelines.
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C. All installations shall be done in conformance with EIA/TIA 568B standards and with the manufacturer’s installation requirements. The Contractor shall ensure that the maximum pulling tensions of the specified distribution cables are not exceeded and cable bends maintain the proper radius during the placement of the facilities. Failure to follow the appropriate guidelines will require the Contractor to provide in a timely fashion the additional material and labor necessary to properly rectify the failure. Any and all damage to the cables during the construction of this project is the sole responsibility of the Contractor.
D. Separation from EMI Sources:
1. Comply with BICSI TDMM and TIA/EIA-569-A recommendations for separating unshielded copper voice and data communication cable from potential EMI sources, including electrical power lines and equipment. 2. Separation between open communications cables or cables in nonmetallic raceways and unshielded power conductors and electrical equipment shall be as follows: a. Electrical Equipment Rating Less Than 2 kVA: A minimum of 12 inches. b. Electrical Equipment Rating between 2 and 5 kVA: A minimum of 24 inches. c. Electrical Equipment Rating More Than 5 kVA: A minimum of 48 inches.
3. Separation between communications cables in grounded metallic raceways and unshielded power lines or electrical equipment shall be as follows: a. Electrical Equipment Rating Less Than 2 kVA: A minimum of 6 inches. b. Electrical Equipment Rating between 2 and 5 kVA: A minimum of 12 inches. c. Electrical Equipment Rating More Than 5 kVA: A minimum of 24 inches.
4. Separation between communications cables in grounded metallic raceways and power lines and electrical equipment located in grounded metallic conduits or enclosures shall be as follows: a. Electrical Equipment Rating Less Than 2 kVA: 3 inches. b. Electrical Equipment Rating between 2 and 5 kVA: A minimum of 6 inches. c. Electrical Equipment Rating More Than 5 kVA: A minimum of 12 inches.
5. Separation between Cables and Electrical Motors and Transformers: A minimum of 48 inches. 6. Separation between Cables and Fluorescent Fixtures: A minimum of 6 inches.
E. Miscellaneous Equipment. The Contractor shall provide any necessary screws, anchors, clamps, tie wraps, distribution rings, wire molding, and support hardware, etc., necessary to facilitate the installation of the CTCs within the SCS. All metal fasteners and straps in corrosive or wet areas shall be 316SS.
F. Special Equipment and Tools. It shall be the responsibility of the Contractor to furnish any special installation equipment or tools necessary to properly complete the SCS. This may include, but is not limited to, tools for terminating cables, testing and splicing equipment for copper/fiber cables, communication devices, jack stands for cable reels, or cable wrenches.
G. Labeling. The Contractor shall be responsible for printed labels for all cables and cords, distribution frames, and outlet locations, according to Owner specifications. No labels are to be written by hand.
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H. Cable Storage. The Contractor shall not roll or store cable reels without an appropriate underlay and the prior approval of the Owner.
I. Damages. The Contractor will be held responsible for any and all damages to portions of the building caused by it, its employees or subcontractors; including but not limited to:
1. Damage to any portion of the building caused by the movement of tools, materials or equipment. 2. Damage to any component of the construction of spaces “turned over” to the Contractor. 3. Damage to the electrical distribution system and/or space “turned over” to the Contractor. 4. Damage to the electrical, mechanical and/or life safety or other systems caused by inappropriate operation or connections made by the Contractor or other actions of Contractor.
J. Penetrations of Walls, Floors, and Ceilings. The Contractor shall make no penetration of existing walls, floors and/or ceilings without the prior consent of the Owner. Where penetrations through acoustical walls, fire-rated doors or other walls for cableways are to be installed, such penetrations shall be sealed by the Contractor in compliance with applicable code requirements.
K. The CTC’s and all components of the system shall be installed in a neat, workmanlike manner. Wiring color codes shall be strictly observed and terminations shall be uniform throughout the system. Identification markings and systems shall be uniform. TIA/EIA 568B wiring codes as shown on the drawings shall standardize all SCS wiring. The CTC shall be level and plumb.
L. All structured wiring shall be neatly routed, protected and tied down. Install Velcro wrap on all cable bundles within the network rack/enclosure. All cabinets shall be cleaned out. All spare parts and documentation shall be turned into the Owner.
M. At the completion of the SCS, the Contractor shall restore to its former condition, all aspects of the project site and on a daily basis, shall remove all waste and excess materials, rubbish debris, tools and equipment resulting from or used in the services provided under this Contract. All clean up, restoration, and removal noted above will be by the Contractor and at no cost to the Owner. If the Contractor fails in its duties under this paragraph, the Owner may upon notice to the Contractor perform the necessary clean up and deduct the costs thereof from any amounts due or to become due to the Contractor.
3.2 NETWORK PROGRAMMING AND COMMISSIONING
A. Programming and Commissioning of the Network shall be by the Owner’s System Integrator.
3.3 TESTING
A. Optical Fiber Cable Testing
1. All fiber testing shall be performed on all fibers in the completed end to end system. There shall be no splices unless approved in writing by the Engineer. Testing shall consist of a bidirectional end to end OTDR trace performed per EIA/TIA 455-61. All tests shall be conducted using 200ft launch cables. The system loss measurements shall
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be provided at 850 and 1310 nanometers for multimode fibers and 1310nm and 1550 nm for singlemode fibers. 2. The Contractor shall test all fiber optic cable prior to the installation of the cable. The Contractor shall assume all liability for the replacement of the cable should it be found defective at a later date. 3. Loss Budget: Fiber links shall have a maximum loss of: a. (3.0 dB loss/km)*(km of fiber in link) + (0.5dB) * (number of connectors) b. Note that a mated connector to connector interface is defined as a single connector for the loss calculation. c. Any link not meeting the requirements of the standard shall be brought into compliance by the Contractor, at no charge to the Owner. 4. Documentation of all fiber optic cabling tests shall be provided in both hard and electronic copies to the Engineer.
B. Copper cable testing
1. Testing of all copper wiring shall be performed prior to system commissioning. All Ethernet cabling shall be certified for conformance to EIA/TIA 568B for Category 6. Testing shall be done with a TIA/EIA Certified Level 3 test set. Test shall include length, mutual capacitance, characteristic impedance, attenuation, near-end and far-end crosstalk. Any pairs not meeting the requirements of the standard shall be brought into compliance by the Contractor at no charge to the Owner. 2. Documentation of all copper cabling tests shall be provided in both hard and electronic copies to the Engineer.
3.4 FIELD QUALITY CONTROL
A. On-going inspections shall be performed during construction by the Contractor and by the Engineer to ensure that all work is performed in a high quality manner and the overall appearance is clean, neat and orderly. The following points will be examined and must be satisfactorily complied with:
1. Is the design documentation complete? Are all cables properly labeled, from end-to-end? 2. Have all terminated cables been properly tested in accordance with the specifications for the specific category as well as tested for opens, shorts, polarity reversals, transposition and presence of AC and/or DC voltage? 3. Is the cable type suitable for its pathway? Are the cables bundled in parallel? 4. Have the pathway manufacturer's guidelines been followed? Are all cable penetrations installed properly and fire stopped according to code? 5. Has excessive cable bending been avoided? 6. Have potential EMI and RFI sources been considered? 7. Is Cable fill correct? 8. Are hanging supports within 1.5 meters (5 feet)? 9. Does hanging cable exhibit some sag? 10. Are telecommunications closet terminations compatible with applications equipment? 11. Have Patch Panel instructions been followed? 12. Are identification markings uniform, permanent and readable?
END OF SECTION 409533
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SECTION 409600 – PROCESS CONTROL SOFTWARE
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. PLC Programming Software 2. OIT Programming Software 3. SCADA System Software
B. Related Sections:
1. Refer to Section “409443 Programmable Logic Controllers” for PLC Hardware requirements. 2. Refer to Section “409433 Human Machine Interfaces” for OIT and SCADA System requirements.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 QUALITY ASSURANCE
A. Software to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment.
B. Examine the Contract Documents and verify that Software being provided is compatible with the requirements.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the Software to the Owner prior to startup and commissioning.
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PART 2 - PRODUCTS
2.1 PLC PROGRAMMING SOFTWARE
A. PLC Programming Software shall be provided by the Owner’s System Integrator.
2.2 OIT PROGRAMMING SOFTWARE
A. OIT Programming Software shall be provided by the Owner’s System Integrator.
2.3 SCADA SYSTEM SOFTWARE
A. SCADA System Software shall be provided by the Owner’s System Integrator.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Coordinate with the Owner the installation of all software on PC’s. Insure that each software package is compatible with the PC’s operating system.
B. Refer to the requirements of Sections 409000 and 409443 as well as the Contract Drawings.
3.2 TRAINING
A. Refer to the requirements of Section 409000.
END OF SECTION 409600
WRCRWA PROCESS CONTROL SOFTWARE PLANT EXPANSION PROJECT 409600 - 2
SECTION 409635 – PROCESS CONTROL SOFTWARE PROGRAMMING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. PLC Programming Requirements 2. OIT Programming Requirements 3. SCADA System Programming Requirements
B. Related Sections:
1. Refer to Section “409443 Programmable Logic Controllers” for PLC Hardware requirements. 2. Refer to Section “409433 Human Machine Interfaces” for OIT and SCADA System requirements. 3. Refer to Section “409600 Process Control Software” for software requirements
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
1.3 INFORMATIONAL SUBMITTALS
A. Field quality-control reports.
1.4 QUALITY ASSURANCE
A. Programming to be furnished under this section shall be the product of firms regularly engaged in the programming of this type of control system.
B. Examine the Contract Documents and verify that programming being provided is compatible with the requirements.
PART 2 - PRODUCTS
2.1 PLC PROGRAMMING REQUIREMENTS
A. PLC Programming shall be provided by the Owner’s System Integrator.
WRCRWA PROCESS CONTROL SOFTWARE PROGRAMMING PLANT EXPANSION PROJECT 409635 - 1
2.2 OIT PROGRAMMING REQUIREMENTS
A. OIT Programming shall be provided by the Owner’s System Integrator.
2.3 SCADA SYSTEM PROGRAMMING REQUIREMENTS
A. SCADA System Programming shall be provided by the Owner’s System Integrator.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Refer to the requirements of Sections 409000 and 409443 as well as the Contract Drawings.
3.2 TRAINING
A. Refer to the requirements of Section 409000.
END OF SECTION 409635
WRCRWA PROCESS CONTROL SOFTWARE PROGRAMMING PLANT EXPANSION PROJECT 409635 - 2
SECTION 431000-SPIRAL HEAT EXCHANGER
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall furnish and install, complete and operable, spiral heat exchangers as specified herein and in accordance with the requirements of the Contract Documents. The Contractor shall be responsible for assuring a complete and operable spiral heat exchanger installation, and shall establish the exact limits of work between the Contractor and the spiral heat exchanger supplier.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 013300, “Contractor Submittals”.
B. Shop Drawings 1. Complete fabrication, assembly, foundation, and installation drawings including dimensions, weights, specifications, data, and materials of construction of the spiral heat exchanger assembly. 2. Performance Criteria. 3. List any exceptions or deviations to the Contract Documents.
C. Technical Manual: Operation and maintenance information shall be submitted for the equipment specified herein in accordance with the requirements specified in Section 013300, “Contractor Submittals”.
D. Manufacturer’s Certificate: A manufacturer’s certificate of satisfactory installation is required for the equipment furnished under this Section in accordance with the requirements specified in Section 013300, “Contractor Submittals”.
1.3 CONTRACTOR SUBMITTALS
A. The manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 GENERAL
A. The Contractor shall furnish and install spiral-type heat exchangers for heating of digested sludge. The heat exchangers shall be of welded steel construction, ASME coded, and rated for min. 50 psig service. The sludge spiral shall be easily accessed by means of a hinged cover which shall expose the complete sludge channel for manual cleaning. In addition, a special
WRCRWA SPIRAL HEAT EXCHANGER PLANT EXPANSION PROJECT 431000 - 1
cleanout port located below the sludge inlet shall be provided for cleaning in case of blockage. There shall be no internal studs or other obstructions.
2.2 MANUFACTURERS
A. Subject to compliance with the specifications given herein, the following manufacturers are acceptable:
1. Alfa-Laval Inc. (Basis-of-Design) 2. Groth Corporation, 3. Or approved equal.
2.3 DESIGN REQUIRMENTS
A. The spiral heat exchanger shall be designed to heat the recirculating contents of the anaerobic digesters (CSL) using hot water circulated through the hot water loops. The anaerobic digesters receive influent feed consisting of thickened primary solids, primary scum, secondary scum, and thickened secondary solids.
B. The CSL is a non-Newtonian fluid (sludge) that will be expected to exhibit the following properties: 1. Maximum Dry Solids Content = 5.0% 2. Density = 62.5 lb/ft3 3. Specific Heat = 1.0 BTU/lb-deg F
C. The spiral heat exchanger shall be designed for continuous and intermittent operation to meet the following performance criteria
Criteria Parameter CSL Hot Water Design Flow Rate 555 gpm 350 gpm Inlet temperature 95 deg F 160 deg F Outlet temperature 104 deg F 145.4 deg F Maximum pressure drop 5 psi 2.4 psi
D. The heat exchanger shall have the capacity to transfer not less than 2,500,000 BTU/hr of heat from the hot water to the CSL.
E. The spiral heat exchanger shall be designed and fabricated to meet the following requirements:
Parameter Value ASME code rating 50 psi Nominal diameter 43 in Nominal depth 18 in Min. CSL channel spacing 1.0 in
WRCRWA SPIRAL HEAT EXCHANGER PLANT EXPANSION PROJECT 431000 - 2
2.4 CONSTRUCTION
A. The spiral heat exchanger shall be constructed of welded A 36 or better steel and ASME coded for the pressure specified.
B. The sludge and water spirals shall be easily accessed by means of a hinged cover which shall expose the complete channels for inspection and manual cleaning. The hinged cover shall be fastened with hook bolts; through bolts shall not be acceptable.
C. The sludge spiral channel shall be constructed without internal studs, pins, or other obstructions. The water spiral may be constructed with edge pins to maintain the required channel spacing.
D. The sludge inlets and outlets shall be 6-inch diameter with flanged ends, 150 lb dimensions. The sludge inlet shall be constructed with a pocket to introduce the sludge tangential to the sludge spiral channel at the top perimeter of the heat exchanger. The sludge outlet shall be positioned near the center of the heat exchanger face but shall be offset to center the outlet on the “half-center” exit from the sludge spiral channel to provide an unobstructed flow path.
E. The water inlets and outlets shall be 6-inch diameter with flanged ends, 150 lb dimensions. The water inlet shall be positioned near the center of the heat exchanger face but shall be offset to center the inlet on the “half-center” entrance into the water spiral channel to provide an unobstructed flow path. The water outlet shall be tangential to the perimeter of the heat exchanger, located at the top of the unit.
F. Standard manufacturer’s coating: 1. Surface preparation includes sandblasting in accordance to SSPC-SP-6. External carbon steel surfaces, except machined surfaces of flanges, painted with International Interlac 789 (single component modified alkyd primer/finish), 4.0 mil minimum, in Alfa Laval blue.
2.5 ACCESSORIES
A. Spare Parts: Spare parts shall be provided per manufacturer’s recommendation.
PART 3 - EXECUTION
3.1 GENERAL
A. All heat exchanger equipment with piping and accessories shall be installed in accordance with the manufacturer’s written instructions and as shown on the Drawings, with due allowance for thermal expansion, supports, anchors and drainage.
B. The piping connecting the inlets and outlets at the center face of the heat exchanger shall be installed in a manner to allow easy removal that will provide sufficient clearance for opening the hinged access door.
WRCRWA SPIRAL HEAT EXCHANGER PLANT EXPANSION PROJECT 431000 - 3
3.2 SERVICES OF MANUFACTURER
A. Inspection, Startup and Filed Adjustment: An authorized service representative of the manufacturer shall visit the site for not less than 1 day to furnish the indicated services. The authorized representative shall instruct and provide training for the Owner’s personnel for not less than 1 day. The Contractor shall schedule start-up and training with the Owner.
END SECTION 431000
WRCRWA SPIRAL HEAT EXCHANGER PLANT EXPANSION PROJECT 431000 - 4
SECTION 432100-DIGESTER GAS BOILER
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall provide two (2) hot water boilers of fire box design, dual-fired by either digester gas or natural gas, complete and operable with fuel burning equipment, safety and operating controls, and appurtenances in accordance with the Contract Documents.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 013300 - Contractor Submittals.
B. Shop Drawings
1. Manufacturer’s detailed drawings of equipment, controls, enclosure, and flue. 2. List of boiler component materials. 3. Control panel drawing. 4. Fuel system drawing. 5. List any exceptions or deviations to the Contract Documents.
C. Technical Manual: The Technical Manual shall contain information required for operation of the boiler/burner.
1.3 DESIGN CRITERIA
A. The hot water boiler shall meet the following design requirements:
1. Inlet temperature: 150 ¼F 2. Outlet temperature: 180 ¼F 3. Output: 3 million BTU/hr 4. Fuel source: Dual biogas/natural gas 5. Power: 480/3/60 6. Site Elevation: 600 MSL
B. The incoming digester gas shall have the following approximate properties:
1. Methane: 55 Ð 70% by volume 2. Carbon Dioxide: 20 - 30% by volume 3. Inerts: Balance 4. Lower Heating Value: 550 Btu/cu-ft. 5. Incoming Pressure: 2 psi 6. H2S Content: Less than 100 ppm 7. Moisture Content: Less than 2%
WRCRWA DIGESTER GAS BOILER PLANT EXPANSION PROJECT 432100 - 1
C. Subject to compliance with the requirements specified herein, the boiler shall be manufactured by the following:
1. Cleaver-Brooks (Basis-of-Design) 2. Or equal.
1.4 DESIGN CRITERIA
A. The manufacturer shall have at least five (5) similar installations in the US with a minimum of five (5) years of continuous operation.
PART 2 - PRODUCTS
2.1 GENERAL BOILER DESIGN
A. The boiler shall be a two-drum, flexible watertube design with a tangent-tube waterwall furnace mounted on a heavy steel frame. Top, bottom and sides of the furnace shall be water cooled.
B. The boiler pressure vessel shall be constructed in accordance with ASME Boiler Code, and must receive authorized boiler inspection prior to shipment. A copy of the inspection report shall be furnished to the purchaser. The complete packaged boiler - burner unit shall be listed by Underwriters Laboratories, and shall have the UL label affixed to the front head.
1. The boiler drums shall be furnished with handholes to facilitate boiler inspection and cleaning. 2. Boiler tubes shall be 1.5" diameter, with 0.095" wall thickness, and shall be easy to remove and replace without expanding or welding the tube attachment to the drums. 3. The boiler shall have a sufficiently sized downcomer to provide natural internal circulation. 4. The burner shall be mounted on a hinged backing plate for easy access to the furnace.
C. Observation ports for the inspection of flame conditions shall be provided at the rear of the boiler, and in the burner assembly at the front.
D. The tangent wall tubes shall be covered with 1-1/2 inches of insulation under a gas-tight, 16- gauge inner casing. There shall be 2 inches of insulation between the inner and outer casing. The outer casing shall be 20 gauge. The boiler base frame and other components shall be factory-painted before shipment, using a hard enamel finish.
2.2 HOT WATER BOILER TRIM
A. The following items will be installed on the boiler.
1. Low Water Cut-Off: A probe-type, low water cut-off control shall be mounted in the upper drum. It is to be wired to the burner control circuit to prevent burner operation if the boiler water falls below a safe level.
WRCRWA DIGESTER GAS BOILER PLANT EXPANSION PROJECT 432100 - 2
2. Miscellaneous: A combustion temperature and pressure gauge shall be mounted on the boiler. Temperature controls, for regulation of burner operation, shall be mounted on the boiler and the temperature sensing element shall be located adjacent to the boiler outlet. Water relief valves (shipped loose) shall be of a type and size to comply with ASME Code requirements.
2.3 BURNER AND CONTROLS
A. The boiler shall be provided with a UL approved fuel burning system in full accordance with the requirements of state, provincial and local codes, the local gas utility, and other applicable regulatory bodies.
B. Burner Description
1. The boiler shall include gas burners with a rated capacity to burn 3.0 MMBtu/hr of either of the following, at a pressure of2 psi at the inlet of the burner gas control train: a. Digester Gas: 50 Ð 60% CH4, with a minimum of 550 Btu/cu-ft. b. Natural Gas: A minimum of 1020 Btu/cu-ft. 2. The burner shall be forced draft type with full firing rate modulation. All combustion air shall be furnished by the burner fan, which shall be an integral part of the burner.
C. Emission Requirement
1. The boiler shall meet all applicable SCAQMD emission requirements including those given in Rule 1146.1 “Emissions of Oxides of Nitrogen from Small Industrial, Institutional, and Commercial Boilers, Steam Generators, and Process Heaters,” published by the California Department of Public Health. At a minimum, the boiler shall meet the following: a. Digester Gas: Less than 15 ppm NOx and 100 ppm CO emissions. b. Natural Gas: Less than 9 ppm NOx and 100 ppm CO emissions.
D. Primary-secondary air control shall be a design function of the combustion head. Combustion heads requiring an internal adjustment shall not be acceptable.
E. The burner shall be equipped with an aluminum reverse curve fan for lower fan motor hp requirements and self-cleaning characteristics.
F. A permanent observation port shall be provided in the burner to allow observation of both the pilot and main flame. Both the pilot and the flame scanner shall be easily accessible without opening or disassembling the burner.
G. Supply voltage available shall be 480 Volts, 3 phase, 60 Hz. All motors shall be suitable for use on this voltage. All burner controls are to be for use on 120 volts, 1 phase, 60 Hz.
H. The burner shall be factory fire-tested to ensure proper operation before shipment.
WRCRWA DIGESTER GAS BOILER PLANT EXPANSION PROJECT 432100 - 3
2.4 PILOT GAS TRAIN FOR EACH BURNER (MOUNTED, PIPED, AND WIRED)
A. A separate pilot gas cock, gas pressure regulator, and pilot safety shutoff gas valve, shall be provided for the ignition gas supply.
2.5 GAS VALVE TRAIN FOR EACH BURNER
A. Provide a pressure gauge to indicate the gas burner manifold pressure.
B. Furnish and install one manually operated ball valve upstream of all valves.
C. Provide one (1) main gas pressure regulator (of tight shutoff type) with vent to outside atmosphere, in accordance with local codes.
D. Provide one inch, automatically operated motorized safety gas valve. One safety shutoff valve shall be proven closed during pre- ignition by proof of valve closure interlock switch on valve.
E. Provide a second automatically operated gas safety shutoff valve to operate simultaneously with the above gas valve.
F. A manually operated gas valve shall be located downstream of both automatic gas valves to permit leakage testing of the valves.
G. Gas pressure monitoring shall be provided by approved pressure switches interlocked to accomplish a non-recycling safety shutdown in the event of either high or low gas pressure.
2.6 BURNER CONTROLS
A. The boilers will be located in a Class 1 Division 2 area. All panels, fittings and hardware shall be corrosion resistant NEMA 4X stainless steel and meet Class 1 Division 2 requirements.
B. The full modulation of the burner shall be controlled by water temperature by means of a temperature control.
C. An additional high limit safety temperature control of the manual reset type shall be provided to control the burner.
D. Pre- and post- operation of the burner fan shall be provided per current UL requirements.
E. The burner shall utilize a Fireyeª CB120E type flame safeguard programmer, incorporating LED indicator lights to annunciate the current operating status of the burner.
F. A manual restart of the burner shall be necessary in the event of shutdown due to flame failure.
G. All three-phase motors shall be controlled and protected by an automatic starter with thermal overload protection. The starter shall be inter-locked to prevent burner operation when over- load relays are tripped out.
WRCRWA DIGESTER GAS BOILER PLANT EXPANSION PROJECT 432100 - 4
H. Supply a burner-mounted diaphragm air flow switch to prevent energizing the main fuel valves in the event of insufficient combustion air, or to provide safety shutdown in the event of combustion air interruption.
I. A factory-wired control cabinet shall be supplied and mounted on the burner. The control cabinet shall house the flame safeguard control, programming timer, burner motor starter, fuses, control circuit transformer, control switches, indicating lamps, and relays as required.
J. Provide four individual lights with nameplates on the control cabinet to indicate “call for heat,” “main fuel valve on,” “low water,” and “main flame failure.”
K. Changing from one fuel to the other shall be automatically controlled by an outdoor temperature switch, or other external device. No burner adjustment shall be required to switch from one fuel to the other.
L. The burner shall be equipped with suitable fuel and air controls to assure smooth main flame ignition. The burner shall utilize a proportional air flow damper design, including independent low-fire and high-fire air flow shutter assemblies for ease of adjustment and consistent excess air performance throughout the firing range.
M. Fuel-air control shall be synchronized. The fuel air drive unit shall be provided with a position indicating switch interlocked with the flame safeguard system to assure starting at the low fire position. The flame safeguard system shall further program this drive unit to provide a full open louver of sufficient time to provide a four air change pre-ignition of the combustion chamber, heat exchanger, and flue passages.
N. Pre-ignition pure air flow rate shall not be less than 60% maximum firing rate air flow. Interlocks shall be provided to monitor and prove 60% air flow purge when air inlet louvers are automatically opened to obtain this rate.
O. Full modulation of fuel input shall be provided. A modulating temperature control shall be supplied to modulate a burner mounted damper motor, controlling both fuel and air supply by means of direct mechanical linkage.
P. Electronic safety combustion controls shall be supplied, complete with ultra-violet flame scanner to monitor the pilot and main flame. It shall be so utilized as to provide intermittent type gas-electric ignition and pre-ignition timer. Flame rod will not be permitted for proving pilot or main flame.
2.7 TOOLS AND SPARE PARTS
A. The Contractor shall furnish one complete set of special wrenches or other special tools necessary for the assembly, adjustment, and dismantling of the equipment. Tools shall be of best quality and furnished in labeled tool boxes of suitable design.
B. Six (6) fuses of each type/size used in the Control Panel and six (6) spare lights for the Control Panel shall be furnished.
WRCRWA DIGESTER GAS BOILER PLANT EXPANSION PROJECT 432100 - 5
PART 3 - EXECUTION
3.1 SERVICES OF MANUFACTURER
A. Inspection, Startup, and Field Adjustment: An authorized service representative of the manufacturer shall visit the Site for one day to witness the following and to certify in writing that the equipment and controls are properly installed, adjusted, and readied for operation.
1. Installation of the equipment. 2. Inspection, checking, and adjusting the equipment. 3. Startup and field testing for proper operation. 4. Performing field adjustments to ensure the installation and operation comply with the indicated requirements. 5. Provide written certification that the equipment has been properly installed, inspected, adjusted and in proper working order.
B. Instruction of the Owner’s Personnel
1. An authorized training representative of the manufacturer shall visit the Site for one day to instruct the Owner’s personnel in the operation and maintenance of the equipment, including step-by-step troubleshooting with necessary test equipment. Instruction shall be specific to the models of equipment provided. 2. Training shall be scheduled a minimum of 3 weeks in advance.
3.2 WARRANTY
A. All equipment is to be guaranteed against defects in material and/or workmanship for a period of 12 months from the date of start-up or 18 months from the date of shipment, whichever comes first. The boiler pressure vessel shall be warranted against damage resulting from thermal stress for a period of 20 years from date of shipment, provided the boiler is operated and maintained in accordance with the conditions specified in the owner’s Operating and Maintenance Manual. The boiler shall further be warranted to meet all emission requirements, as required by the South Coast Air Quality Management District.
3.3 FIELD ERECTABLE
A. The equipment specified herein shall be completely factory assembled as one unit.
3.4 INSTALLATION
A. Installation of the boilers shall be in strict accordance with the boiler manufacturer’s published recommendations.
B. Upon completion of the installation, each piece of equipment and each system shall be tested for satisfactory operation.
END OF SECTION 432100
WRCRWA DIGESTER GAS BOILER PLANT EXPANSION PROJECT 432100 - 6
SECTION 437000 - FIXED RADIAL BEAM DIGESTER COVER
PART 1 - GENERAL
1.1 SUMMARY
A. There shall be furnished and installed equipment for two (2) fixed dome steel digester cover. The cover shall be of the fixed beam type with dimensions as shown on the drawings. The equipment shall include support beams, compression ring and center dome, roof plates, side sheet, manholes, sampling ports, pressure relief vacuum breaker with flame arrester, assembly fasteners and anchor bolts, and all other appurtenances required or shown on the drawings.
1.2 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the requirements herein, the following manufacturers are acceptable:
1. WesTech, Inc. (Basis of Design) 2. Ovivo Technologies 3. Or approved equal.
1.3 DESIGN CRITERIA
A. The cover shall be designed given the following criteria:
1. Tank outside diameter (ft.): 84’-0” 2. Wall Thickness (inches): 12” 3. Top of Wall Elevation (ft.): 21’-8” 4. Maximum Operating Liquid Elevation (ft.): 19’-6” 5. Minimum Operating Liquid Elevation (ft.): 19’-0” 6. Operating pressure (inches W.C.): 12” 7. Gas relief pressure (inches W.C.): 15” 8. Live load (PSF): 40 9. Vacuum load (inches W.C.): 2” 10. Seismic Zone: D 11. Wind load (mph): In accordance with CBC 2010 and applicable ASCE 7 requirements.
1.4 WARRANTY
A. A written supplier’s warranty shall be provided for the equipment specified in this section. The warranty shall be for a minimum period of one (1) year from start up or 18 months from time of equipment shipment, whichever comes first. Such warranty shall cover all defects or failures of materials or workmanship which occur as the result of normal operation and service.
WRCRWA FIXED RADIAL BEAM DIGESTER COVER PLANT EXPANSION PROJECT 437000 - 1
1.5 SUBMITTALS
A. Copies of all materials required to establish compliance with these specifications shall be submitted for review. Submittals shall include at least the following:
1. Certified general arrangement drawings showing all important details and materials of construction, dimensions, loads on supporting structures, and anchor bolt locations. 2. Descriptive literature, bulletins, and/or catalogs of the equipment. 3. Complete structural calculations, prepared and signed by a registered professional engineer. 4. Calculations shall show the structural adequacy of the cover in two scenarios: a. All dead, live, snow, and vacuum loads imposed on the cover. b. The dead load only, in combination with an uplift pressure equal to 2" w.c. above the gas relief pressure setting.
1.6 EXPERIENCE
A. The equipment supplier shall have at least 15 years experience in the design, application, and supply of anaerobic digester covers in wastewater treatment plants, and shall submit a list of not less than 25 operating installations as evidence of meeting the experience requirement.
B. To show evidence of being able to provide the quality of equipment and services described in this specification, the equipment supplier shall submit their quality system ISO 9001 certification. The quality procedures shall provide for a means of qualifying all sub-vendors and shall specify that the fabrication facility is a critical vendor and shall require inspection. The quality system shall be audited by a third party independent inspector. Certification shall remain in effect throughout the project startup.
PART 2 - PRODUCTS
2.1 GENERAL DESIGN
A. Description: The digester cover shall be a rigid steel self supporting dome, designed to rest on the top of the digester tank wall. The digester cover shall be designed to support the specified external and internal loads. It shall be stable under all design load conditions.
B. Materials: All steel plates shall conform to ASTM A36. All structural steel shapes with shape series of M, MT, S, ST, C, MC, and L shall conform to ASTM A36. Structural shapes W, WT, and HP shall conform to ASTM A992/ A572. All pipe to be ASTM A53, grade B. All square and rectangular tubing to be ASTM A500, grade B. All steel members in contact with liquids or digester gas shall be of ¼” minimum thickness.
C. Fabrication: Shop fabrication and welding of structural members shall be in accordance with the latest edition of the Structural Welding Code, AWS D1.1, of the American Welding Society (AWS). All welded connections shall develop the full strength of the connected elements.
D. Edge Grinding: Sharp projections of cut or sheared edges of ferrous metals shall be ground with a power grinder as required to ensure satisfactory coating adherence.
WRCRWA FIXED RADIAL BEAM DIGESTER COVER PLANT EXPANSION PROJECT 437000 - 2
E. Shop Surface Preparation/Painting: None. All iron and steel surfaces shall be cleaned and painted in the field to insure paint compatibility and assign unit responsibility to the coating system contractor.
F. Structural Design: The cover shall be designed as a membrane with side sheet, compression ring, and cover properly proportioned to match deflections and stresses. Radial beams used in the cover shall be sized for erection purposes only and shall not be considered as part of the cover design structure. The cover shall be designed to withstand the specified live, snow, vacuum, wind, and seismic loads in addition to the maximum internal gas pressure stated above.
G. The ratio of unbraced length to least radius of gyration (slenderness ratio) shall not exceed the values listed in the AISC manual. All steel design shall be in accordance with the AISC Manual of Steel Construction, latest edition, and the California Building Code (CBC), latest edition.
2.2 ROOF
A. Roof (Cover) Plates: The cover framework shall be covered with 1/4" steel plates. The cover plates shall be welded to the top of the erection beams, side sheets, and center ring to form a gas tight cover. There shall be no bolt holes in the plates. The radial joints between cover plates shall be centered on the erection beams. All exterior seams and joints between the cover plates and the erection members shall be seal welded. Circumferential joints between cover plates shall be lap welded. Roof plates shall not span more than 8 feet between radial beams.
B. Beam Supports: The cover framework shall consist of arched radial ribs having a roof radius of 1.5 times the tank diameter held in position by a tension ring and a compression ring. The tension ring shall be welded with full penetration welds at joints using AWS procedures to insure that the full strength of the tension ring is developed.
C. Side Sheets: In order to achieve a liquid seal, the side sheets for the cover shall extend from the cover plates to a point 12" below the minimum operating level in the digester. The side sheet sections shall consist of 1/4" plates with adequate framing members. Side sheets plates are to be welded to the framing members and each other to form gas tight joints.
D. Wall Supports: The entire weight of the cover and the specified loadings shall be carried by evenly spaced wall supports. The wall supports shall be fabricated from closed steel sections and shall bear on the top of the digester wall. The supports shall be so designed as to prevent any radial loads from being transmitted to the digester wall. The wall support brackets shall be designed to distribute the vertical loads evenly over each of the support bracket anchor bolts.
E. Center Dome: One (1) 8’-6” diameter center gas dome shall be supplied with pipe connections, and nozzles as located on the plans. The compression ring shall be an integral part of the center dome. The center dome cover shall be equipped with lifting bars for easy removal. The center dome cover shall be bolted to the center dome providing a gas tight seal using a neoprene gasket.
F. Seal Plate: A seal plate shall be furnished for permanent attachment on the bottom of the side sheet after the cover has been erected. The seal plates shall conform to the radius of the tank to minimize gaps between the seal plate and the tank walls.
WRCRWA FIXED RADIAL BEAM DIGESTER COVER PLANT EXPANSION PROJECT 437000 - 3
G. Digester Seal: A seal shall be provided in the 3" annular space between the digester cover and tank wall. Seal and seal installation shall be provided by the contractor.
2.3 APPURTENANCES
A. The cover(s) shall be designed to include the following:
1. One (1) 102“ minimum diameter center compression ring with bolted and gasketed cover, (4) four lifting handles, and stainless steel fasteners. 2. Two (2) 36" diameter manholes openings. 3. Two (2) 8" diameter schedule 40 sample tubes extending below liquid level. 4. One (1) 4" diameter schedule 40 flanged connection for gas line. 5. One (1) 4” diameter schedule 40 flanged connection for pressure/vacuum relief valve (PRVB) and flame arrester installation, located on center compression ring.
2.4 ANCHORAGE AND FASTENERS
A. Anchor Bolts: All anchor bolts shall be a minimum of 5/8" diameter and made of type 304 stainless steel. The equipment supplier shall furnish all anchor bolts, nuts, and washers required for the equipment.
B. Fasteners: All flange and assembly fasteners shall be made of type 304 stainless steel. The equipment supplier shall furnish all fasteners required for the assembly of the equipment.
C. Temporary assembly fasteners: Temporary fasteners used to assemble structural members prior to field welding shall be A307 carbon steel.
2.5 FABRICATED ASSEMBLIES
A. Sub-assemblies shall be fabricated in as large as practical sections with the unassembled members fabricated for assembly by bolting or welding. Fabricated assemblies shall include sections of side sheet, compression ring with center dome, manholes and covers, sampling tubes, and main support beams.
B. The cover shall be assembled by bolting and welding all framing members, and field welding the roof plates to the framing members and each other.
PART 3 - INSTALLATION
3.1 GENERAL
A. The equipment shall be installed properly to provide a complete working system. Installation shall follow the supplier’s recommendations.
B. The cover shall be coated with a polyurethane insulation, in accordance with Section 072100, “Joint Sealants,” fully insulating the cover. Installation shall be by the Contractor. The annual space
WRCRWA FIXED RADIAL BEAM DIGESTER COVER PLANT EXPANSION PROJECT 437000 - 4
between the cover and the digester wall shall be sealed according to the manufacturer’s recommendations.
C. The cover shall be painted in accordance with Section 098000, “Protective Coatings,” and according to the manufacturer’s recommendations.
3.2 SHOP ASSEMBLY AND INSPECTION
A. The cover specified herein shall be completely factory assembled for units 40' in diameter and less. Units larger than 40' in diameter shall be assembled in at least a one quarter section and shall include all types of beams, purlins, side sheets, etc. The equipment specified herein shall be factory assembled as far as practical to verify that all mating parts can be field assembled. All mating parts shall be trial fit and match marked. The manufacturer shall submit certification of shop trial assembly and photographs of assembly before shipment. The customer and installing contractor shall be given the opportunity to witness the shop assembly.
B. Shop inspection shall be performed by a qualified inspector and certified by the manufacturer. The inspection shall be documented and all deficiencies noted, corrected, re-inspected and final completion formally authorized. Final shipment authorization shall be by the manufacturer to ensure completion of all fabrication, assembly, and inspection requirements. Inspection records and evidence of inspector qualification shall be submitted to the owner upon request.
3.3 FIELD SERVICE
A. The equipment supplier shall provide the service of a qualified representative for one (1) trip and one (1) day for pre erection training, one (1) trip and one (1) day to inspect the cover installation coinciding with the commencement of any permanent welding, and one (1) trip and one (1) day for final inspection, assist in start up, and instruct plant personnel in the proper operation and maintenance of the unit.
3.4 FIELD TESTING
A. After erection, the cover shall be tested for gas tightness. All welds shall be checked for leaks with a soap suds solution prior to the application of any paint or sealants. Any leaks shall be carefully ground out to good metal and then rewelded for further testing.
3.5 FIELD WELDING
A. Welding shall be in accordance with methods and instructions furnished by the manufacturer. All welds will be shielded arc, in accord with the latest standards of the American Welding Society.
3.6 JOINT SEALANT
A. The joints between the underside of the roof plates and the arched radial support beams shall be sealed with a mastic caulking before final coating is applied to the cover.
WRCRWA FIXED RADIAL BEAM DIGESTER COVER PLANT EXPANSION PROJECT 437000 - 5
END OF SECTION 437000
WRCRWA FIXED RADIAL BEAM DIGESTER COVER PLANT EXPANSION PROJECT 437000 - 6
SECTION 437100 - DIGESTER GAS H2S SCRUBBER SYSTEM
PART 1 - GENERAL
1.1 SUMMARY
A. Provide and install two (2) digester biogas scrubbers capable of removing H2S (hydrogen sulfide) gas as required below. Provide all components necessary for a complete and operable system.
1.2 DESIGN CRITERIA
A. The biogas scrubber shall perform according to the criteria listed below: 1. Maximum flow rate: 180 cubic feet per minute (cfm) 2. Influent H2S concentration: 2,000 parts per million (ppm) 3. Maximum Outlet Concentration: 100 ppm 4. Minimum Inlet Pressure: 10” w.c. 5. Minimum Allowable Outlet Pressure: 6” w.c.
1.3 ACCEPTABLE MANUFACTURERS
A. The accepted manufacturer shall have a minimum of 10 years’ experience designing systems and a minimum of 5 operating systems to remove H2S from biogas.
B. Subject to compliance with requirements, provide product indicated on Drawings or comparable product by one of the following:
1. Varec Biogas (Basis-of-Design) 2. MV Technologies, a SEER Company 3. Or equal
1.4 SUBMITTALS
A. Copies of all materials required to establish compliance with these specifications shall be submitted for review. Submittals shall be in accordance with Section 013300 and include at least the following:
1. Certified general arrangement drawings showing all important details and materials of construction, dimensions, loads on supporting structures, and anchor bolt locations. 2. Control panel drawings. 3. Certificate of performance guarantee to meet the outlet concentration and minimum pressure requirements, as given in Section 1.2.
WRCRWA DIGESTER GAS H2S SCRUBBER SYSTEM PLANT EXPANSION PROJECT 437100 - 1 PART 2 - PRODUCTS
2.1 MATERIALS OF CONSTRUCTION
A. The scrubbers shall be operated in either series or parallel, with each scrubber capable of meeting the design criteria given in Section 1.2 independently of the other. This will be required of each scrubber to maintain continuous treatment while the other scrubber is taken offline for media replacement or other maintenance.
B. The media used to remove the H2S shall be contained within the two vessels, constructed of reinforced fiberglass, and shall be insulated as required for the site conditions. The vessel shall have a minimum residence time of 3 minutes, based on the average flow rate above. The media and the layout of the vessels shall be such that the media shall not require replacement more than once per five months to meet the requirements of Section 1.2.
C. The vessels shall be capable of handling pressure up to 1 psig. The vessels shall be installed outdoors and shall be no larger than 8 feet in diameter. Each tank shall also include an automatic drip trap for automatic draining, which drip trap shall meet the requirements in Section 437600, “Waste Gas Handling Equipment”.
D. A removal system shall be provided to quickly and easily remove the media in a bulk configuration. The media shall be able to be removed and replaced within one working day.
E. Cover gaskets shall be nitril rubber or neoprene. The cover shall be flanged and fully removable.
F. Flanges shall be ANSI Class 150 flat face. Flanged inlet and outlet connections shall be provided with flexible connections.
G. The media must be capable of removing a minimum of 10 lbs of H2S per cubic foot of media.
H. Air Injection System: Compressed air shall be supplied by a compressor that will deliver up to 10 cfm at 90 psig to the air injection system. This system shall include any controls housed in a NEMA 4X control panel housing, and at a minimum, the following components:
1. Explosion-proof solenoid valves that will activate the air injection line. 2. A pressure regulator that regulates constant air flow. 3. Air flow meters to ensure that only 2.5% - 5% of the total flow rate is injected into the scrubber. 4. Stainless steel isolation valves.
I. Water Spray Wash System: The water spray system shall cycle water through the scrubbers as required, with water provided by the plant utility water system. Components shall include, but not be limited to:
1. Temperature switches and thermometers, as required, to continuously monitor the iron sponge bed temperature. 2. Explosion-proof solenoid valves as required. 3. Spray wash nozzles, suitable for water supply pressure of 40-50 psig, constructed of 316 stainless steel.
WRCRWA DIGESTER GAS H2S SCRUBBER SYSTEM PLANT EXPANSION PROJECT 437100 - 2 4. The water supply will automatically be activated if the temperature in the vessel reaches a point beyond the operating temperature of the media, as determined by the manufacturer.
J. Soda Ash Injection System:
1. The manufacturer shall supply any necessary pumps, piping, and valving as necessary for a complete injection system.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The biogas scrubber system shall be installed in accordance with the manufacturer’s written instructions.
B. Start-up: The manufacturer shall furnish his factory trained representative for a minimum of one (1) day, or as required for start-up and training labor. The representative will remain on site until start-up of the system has been completed.
C. Functional and Validation Tests: Upon completion of the installation, functional and validation tests shall be performed by the Contractor with the assistance of the manufacturer’s representative. The manufacturer’s representative will demonstrate compliant operation of the system to the Owner’s satisfaction. Should the system not perform to the requirements of this specification, the expense of any re-testing, if required, will be borne by the system manufacturer, unless failure to achieve successful operation is neither the fault or cause of the manufacturer.
3.2 WARRANTY
A. The manufacturer shall warranty that all equipment provided shall be free of defect and operate according to the requirements above for a minimum of 12 months from start-up or 18 months from delivery, whichever comes first.
END OF SECTION 437100
WRCRWA DIGESTER GAS H2S SCRUBBER SYSTEM PLANT EXPANSION PROJECT 437100 - 3 SECTION 437600 Ð DIGESTER GAS SAFETY EQUIPMENT
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall furnish and install gas handling equipment for the anaerobic sludge digesters and the sewage gas piping system and all appurtenant work, complete and operable, including condensate and sediment traps, drip traps, flame arresters, flame traps, flame check, pressure relief/flame trap, pressure and vacuum relief valves, foam separator, and waste gas burner in accordance with the requirements of the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Codes: All codes, as referenced herein, are specified in Section 014200 Ð Reference Standards.
1. ANSI/NFPA 70 - National Electric Code
B. Commercial Standards
1. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 123, 250, and 800 2. ANSI B16.5 - Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys
1.3 CONTRACTOR SUBMITTALS
A. Prior to ordering of equipment, the CONTRACTOR shall submit shop drawings of all sludge processing equipment in accordance with Section 013300 Ð Contractor Submittals.
PART 2 - PRODUCTS
2.1 DRIP TRAPS
A. The drip traps shall have a 1” NPT inlet and outlet connections and shall be of the ball float operated needle valve type. A plug shall be provided to permit manual draining of the bowl. Construction shall be low copper aluminum body and cover. Internal working parts and fasteners shall be stainless steel. Maximum working pressure shall be at least 5 psig. The drip trap shall be at least one (1) quart. All drip traps shall be piped to a drain, as shown on the Drawings.
WRCRWA DIGESTER GAS SAFETY EQUIPMENT PLANT EXPANSION PROJECT 437600 - 1
B. Acceptable Manufacturers: 1. Varec Biogas, 2. Groth Corporation, 3. Shand and Jurs, 4. Or equal
2.2 FLAME ARRESTERS
A. The flame arrester shall have an ANSI class 125 flange as shown on the drawings. Housing construction shall be cast aluminum. Flame arrester net free area through the bank assembly shall be not less than three times the corresponding size standard pipe. Entire bank assembly shall slide easily out of the arrester housing to facilitate inspection and cleaning. Removing or replacing the bank assembly shall not require support for alignment, jackscrew for extending the housing, and shall not place a strain on the connecting piping. Bank frame shall be extensible and shall be filled with corrugated rectangular shaped bank sheets. Alternating flat and crimped ribbon is not an acceptable substitute. Flame arrester shall be fitted with a ½” NPT drain plug at the low point. The Contractor shall supply a ½” stainless steel ball valve, in accordance with Section 220523m “Valves,” at the drain plug. Arrester housing construction shall be low copper cast aluminum. Bank assembly shall include a low copper aluminum frame and bank sheets with stainless steel hardware.
B. Acceptable Manufacturers: 1. Varec Biogas, 2. Groth Corporation, 3. Shand and Jurs, 4. Or equal
2.3 PRESSURE AND VACUUM RELIEF VALVE
A. Pressure and vacuum relief valve shall have flanged connections. Pressure relief shall be set at 15” WC. Capacity shall be not less than 4,000 SCFH digester gas of 0.8 s.g. at 4” WC overpressure. Vacuum relief shall be set at 2” w.c. Capacity shall not be less than 4,000 SCFH digester gas of 0.8 s.g. at 1” w.c. underpressure.
B. Valve pressure and vacuum ports shall be oversized to keep overpressure to a minimum. Pallets and seat rings shall be replaceable and interchangeable. Pallets shall be dead weight loaded, and both center and side guided for stability. They shall incorporate replaceable “air cushion” Teflon seat inserts. HDPE protective screens shall be provided at the pressure and vacuum ports, located external of the pallets.
C. The valve body and cover shall be low copper cast aluminum construction. Spun hood, seat rights, and pallet assemblies shall be low copper aluminum. Guideposts shall be 304 stainless steel. Flanges shall be drilled ANSI 125 FF Flanged dimensions.
D. Acceptable Manufacturers: 1. Varec Biogas, 2. Groth Corporation, 3. Shand and Jurs,
WRCRWA DIGESTER GAS SAFETY EQUIPMENT PLANT EXPANSION PROJECT 437600 - 2
4. Or equal
2.4 SAFETY SELECTOR VALVE
A. The valve design shall prevent the possibility of leaving the digester unprotected at any time during the switch-over of the operating Pressure and Vacuum Relief (PVR) Valve and Flame Arrester Assembly.
B. Valve shall have built in seat equalization. This is defined as the pressure being uniform and equalized across the SSV seat during changeover in order to facilitate the changeover process. During changeover pressure shall be applied to both sides of the seating surface. Valves in which pressure is applied to only one side of the seating surface during changeover shall not be allowed. No special tools shall be required to operate the unit. The SSV shall require no more than 80 foot-pounds of torque to equalize the seat. Units requiring more than 80 foot-pounds shall be supplied with explosion proof electric actuators.
C. There shall be means to accommodate a locking device shall be provided to prevent unwanted access to either of the Pressure and Vacuum Relief (PVR)Valve and Flame Arrester Assembly.
D. The SSV shall have a pressure drop through the active device of not greater than 3% of the flow with the pressure relief valve fully open. Valve design shall have Cv values which are verified in an ASME certified flow test facility. Testing shall have been witnessed by an ASME observer and test reports shall be supplied as part of the submittal process. Cv shall, at a minimum, be as defined in the following table:
Size Cv 2” 225 3” 612 4” 1061 6” 2713 8” 4512
E. Packing design shall be tested to ASTM E427, Method A Halogen Leak Test, to reduce the possibility of fugitive emissions.
F. The SSV shall come with threaded ports on both process sides. The threaded ports shall come with 1” manual hand valves constructed in stainless steel. This will allow pressure testing of each process side and subsequently allow field testing and calibration of the Pressure and Vacuum Relief Valve and Flame Arrester.
G. The Safety Selector Valve shall be rated for a minimum pressure of 15 psig at 100 degrees F and shall be rated for a maximum temperature of 400 degrees F. The unit shall come with ANSI 150 FF Flanged Connections.
H. Material shall be as follows: Body, Base: Aluminum; Rotor, Indicator and Seat: 316 SS; Isolation Disk, Index Shaft, Retraction Bushing: 1704 stainless steel; Body/Base Nut and Process Connection Nut: SA194-8M stainless steel; Body/Base Stud and Process Connection Stud: SA193-B8M stainless steel; Soft Goods: Teflon.
WRCRWA DIGESTER GAS SAFETY EQUIPMENT PLANT EXPANSION PROJECT 437600 - 3
2.5 ROOF MANWAY COVER
A. Roof manway cover shall have 36” inside diameter and shall include a flanged base for mounting. Cast wing nuts and a replaceable tallow flax insert shall be provided to provide non-sparking operation and ensure a positive seal. Construction shall be low copper cast aluminum base and cover, brass wing nuts and lugs, and stainless steel hinge pins. Maximum working pressure shall be 1 psig. Roof manway cover shall be Varec 220 series or equal.
2.6 SAMPLING HATCH
A. Sampling hatch shall have 8” size flanged connections. Hatch shall include inclined foot pedal to facilitate opening. Handwheel shall be provided to ensure a positive seal. Handwheel shall include locking capability. Construction shall be low copper aluminum. Replaceable BUNA-N cover insert shall be provided for non-sparking operation. Flange shall be drilled per ANSI 150 FF flanged dimensions. Maximum working pressure shall be 3 psig. Sampling hatch shall be Varec 42 series or equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: All gas handling equipment shall be installed in strict accordance with the manufacturer’s printed recommendations.
B. Upon completion of the installation, each piece of equipment and each system shall be tested for satisfactory operation without leakage, excessive noise, vibration, overheating, etc. All equipment must be adjusted and checked for misalignment, clearance, supports, and adherence to safety standards.
END OF SECTION 437600
WRCRWA DIGESTER GAS SAFETY EQUIPMENT PLANT EXPANSION PROJECT 437600 - 4
SECTION 437700 - DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM
PART 1 - GENERAL
1.1 SUMMARY
A. This section specifies equipment required to condition and pressurize raw, wet anaerobic digester gas for delivery to one of two digester gas boilers (specified elsewhere), or to a Waste Gas Burner to be wasted. The equipment specified herein shall be procured as a single complete system and installed by the Contractor.
B. In general, the digester gas conditioning systems shall process the digester gas through the following units in the sequence specified here:
1. Raw, water-saturated warm digester gas shall be piped from the anaerobic digesters into dual hydrogen sulfide removal vessels (specified elsewhere). The wet digester gas shall then be piped to a moisture removal unit. The moisture removal equipment shall include an air-cooled glycol chiller unit, a glycol circulation pump, and a gas-to-liquid heat exchanger to reduce the gas temperature for moisture condensation.
2. The digester gas shall then pass through a coalescing particulate filter to remove particles larger than 6 microns.
3. When a demand for digester gas is called for from the boilers, two gas blowers (one duty, one standby) shall pressurize the gas for delivery to the boilers. Alternately, when no demand for digester gas from the boilers is called for, a control valve shall direct the flow to an enclosed digester gas burner.
4. The liquid water condensate removed from the digester gas shall be piped via a gas-tight trap device directly to an equipment drain at each condensate removal point. Condensate shall not be collected and piped above ground to a common drain.
C. The systems and assemblies furnished under this section shall be designed, manufactured, and/or supplied by a single vendor. Submittals without all systems included in this specification will not be accepted.
1.2 DESIGN AND PERFORMANCE CRITERIA
A. Performance Requirements: The digester gas handling and waste gas burner system shall be capable of treating gas produced by anaerobic digesters to the quality identified in Part B of this section. The digester gas, after passing through the hydrogen sulfide removal vessels, has characteristics listed below:
1. Minimum Gas Flow: 45 scfm 2. Design Peak Flow: 180 scfm 3. Inlet gas pressure: 0 – 10” w.c. 4. Average Gas Temperature: 60-100 ¡F 5. Methane, percent by volume (dry): 50-60%
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 1 6. Maximum Hydrogen sulfide: 100 ppmv 7. Water Expressed as Relative Humidity: 100% 8. Minimum Allowable Pressure in Digesters: 6” w.c. 9. Maximum Allowable Pressure in Digesters: 13” w.c.
B. Design Requirements
1. Glycol Solution Chiller: The chiller shall be designed and selected for continuous duty and for the site elevation and temperatures to constantly supply a propylene glycol solution to the chilling heat exchanger. The digester gas chiller shall operate on 460 volt, 60 Hz, 3 phase power service. The chiller capacity shall be 33,800 Btu/hr as a minimum under the design conditions of this section. 2. Digester Gas Heat Exchanger: A heat exchanger shall utilize the chilled glycol solution in a gas-to-liquid section to reduce the gas temperature to a maximum of 40¡F for condensation. 3. Digester Gas Coalescing Particulate Filter: The filter shall be an in-line filter with removable elements. The filter shall remove 100% of all particles larger than 6 microns. The filter shall be rated for a minimum of 10 psig. The condensation of gas in the heat exchanger and the filtration of particulates and moisture in the coalescing particulate filter shall reduce the moisture content to a maximum of 2% by volume. 4. Digester Gas Blower: The digester gas blowers shall be designed to constantly operate under the conditions indicated in this section while meeting the following performance criteria: a. Blower capacity: 45-180 scfm b. Minimum Discharge Pressure: 2 psi c. Minimum Efficiency at Average Gas Flow: 60% d. Motor voltage/Phase: 460/3 5. Enclosed Waste Gas Burner (Flare): The waste gas burner shall be designed for intermittent operation, and shall meet all applicable SCAQMD emission requirements for all ranges of flows, including, but not limited to: a. Smokeless Capacity: 100% b. Operating Temperature: 1400-1800¡F c. Retention Time: 0.6 seconds minimum at 1500¡F d. Emissions: 1) NOx: 0.06 lbs/MM Btu 2) CO: 0.20 lbs/MM Btu e. Destruction Efficiency 1) Total Organic Compounds: 99% 2) Total Non-Methane Organic Compounds: 98% 6. Explosion Proof Requirements: The digester gas conditioning system control panel, the glycol circulation system’s chiller and pump shall be located more than 10 feet away from digester gas conditioning equipment such that they are outside the Class I, Division 2 classified envelope, as defined by NFPA 820. All other digester gas conditioning equipment shall conform to NFPA 70 for service in a Class I, Division 2, Group D space. Electrical cabling, conduit and control wiring from the remote equipment shall be as specified. 7. Control System: The Digester Gas Handling and waste gas burner System shall control and monitor the operation of all equipment included herein. The System shall monitor pressure levels in the digesters and relieve pressure in excess of the maximum allowable (as indicated in Section 1.2.A) by operating a flow control valve to the waste gas burner. The System shall continuously monitor gas flow to both the waste gas burner and to the WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 2 boilers. The control panel shall be powered by 480 V, 3-phase power supply as provided by the Contractor. The control panel shall include all required electrical controls, motor controls, annunciation devices, alarm systems, and logic devices required for a fully operable system as required by this specification.
1.3 RELATED WORK
A. Section 033000 – Cast-in-place Concrete
B. Section 221060 – Stainless Steel Pipe
C. Division 26 – Electrical
D. Division 40 – Process Integration
E. Section 432100 – Digester Gas Boilers
F. Section 437100 – Digester Gas H2S Scrubber System
G. Section 437600 – Digester Gas Safety Equipment
1.4 SUPPLIER QUALIFICATIONS
A. The equipment supplier shall have a minimum of 5 years of experience in supply similar equipment for digester gas purification with the specified treatment and conditioning units.
1.5 QUALITY ASSURANCE
A. Qualifications of installers: Use adequate numbers of skilled workmen who are thoroughly trained and experienced in the necessary crafts and who are completely familiar with the specified requirements and the methods needed for proper performance of the work of this section.
B. Factory Testing: Factory tests shall be performed according to the Supplier’s standard test procedures. Certified test results shall be provided as product data. Testing shall contain, at a minimum, the following:
1. Static tests of all control and protective circuits. 2. Not less than five (5) days of operation of the system at the Supplier’s factory with ambient air as the testing fluid. 3. The digester gas blower shall be factory tested to confirm performance.
C. Basis of acceptance: The manufacturer's recommended installation procedures, when approved by the Engineer, will become the basis for inspecting and accepting or rejecting actual installation procedures used on this work.
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 3 1.6 WARRANTY
A. The digester gas handling and waste gas burner system including all equipment, instrumentation, appurtenances, controls, and system performance, shall have a written Warranty for the lesser of 18 months from the receipt date of the complete system, or for 12 months of operating time unless otherwise specified. The warranty shall include parts and labor. Furthermore, the manufacturer shall provide a performance guarantee that the conditions specified in Section 1.2 will be met. The manufacturer shall provide instrumentation and monitoring systems sufficient to verify the performance of the system in accordance with the requirements of this section.
B. Where equipment or system does not perform as required above, the equipment shall be repaired or replaced by the manufacturer at no cost to the Owner until such conditions are met.
1.7 PIPING COORDINATION
A. The supplier shall coordinate with the Contractor for the design and installation of all interconnecting digester gas and drainage piping so that the digester gas handling system functions properly. The Contractor shall furnish the Supplier with piping layouts prior to fabrication. The Supplier shall review Contractor pipe layouts and notify both the Contractor and the Engineer of any changes required to make the digester gas handling system function properly.
1.8 ENVIRONMENTAL CONDITIONS
A. The equipment to be provided under this section shall be suitable for installation in weather exposed locations at the operating wastewater treatment plant in Riverside, California. The project site is approximately 600 feet above sea level. Outside ambient temperatures are expected to range between 40¡F and 100 ¡F.
B. The area within five (5) feet of the digester gas blowers, the hydrogen sulfide removal vessels, the gas particle filter and any digester gas valves is considered hazardous in accordance with NFPA 70 Class I, Division 1, Group D. The area beyond 5 feet and within 10 feet is considered hazardous in accordance with NFPA 70 Class I, Division 2, Group D.
1.9 SUBMITTALS
A. Compliance: A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements or those parts which are to be provided by the Contractor or others. Check marks shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number, referenced to a detailed written explanation of the reasons for requesting the deviation. The Engineer shall be the final authority for determining acceptability of requested deviations.
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 4 B. Shop Drawings: Before any of the materials of the Section are fabricated, the Contractor shall submit complete shop drawings to the Engineer in accordance with the provisions of Section 013300, “Contractor Submittals”. Shop drawings shall show all details of:
1. Certified general arrangement drawings showing all important details and materials of construction, dimensions, loads on supporting structures, and anchor bolt locations. 2. Equipment dimensions, component parts and list of materials. 3. Electrical wiring diagram and details. 4. Drawing and catalog information detailing all control devices in the control cabinets as well as overall panel layout interconnection diagrams and construction.
C. Materials list: Submit three (3) copies of a complete list of all materials and equipment proposed to be furnished and installed under this portion of the work, giving manufacturer's name, catalog number, and catalog cut for each item where applicable.
D. Foundation recommendations and anchor bolt sizing for the vessels, and seismic design calculations signed and sealed by a California registered structural P.E.
E. Supplier’s information confirming interface requirements between PLC and plant SCADA system.
F. Predicted performance curves for the specified blower operating requirements showing pressure-capacity, power-capacity and efficiency-capacity curves and surge points. Capacity shall be shown in cfm, corrected for the site elevation. All performance parameters are to reflect site conditions.
G. Predicted digester gas temperature rise from the blower at maximum and minimum inlet gas flows.
H. Installation requirements, showing clearances required for maintenance purposes and mounting details.
I. Following installation, the Contractor shall provide to the Engineer the equipment supplier's written report certifying that equipment:
1. Has been properly installed and connected. 2. Is in accurate alignment. 3. Is free from undue stress imposed by piping or mounting bolts.
1.10 PRODUCT HANDLING
A. Protection: The Contractor shall use all means necessary to protect the condition and integrity of the equipment provided under this section both during and after receipt of said equipment, and to protect the installed work and all other trades.
B. Replacements: In the event of damage during installation, Contractor shall immediately make all repairs and/or replacements necessary to the approval of the Engineer and at no additional cost to the Owner.
C. Deliver materials in manufacturer's original packaging with all tags and labels intact and legible.
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 5 D. Store and handle material in such a manner as to avoid damage; store at site under cover if required to meet the conditions of this section.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Proprietary products: References to specified proprietary products are used to establish minimum standards of utility and quality. Other materials may be considered by the Engineer in accordance with the provisions of Section.
B. Acceptable Manufacturers: 1. Varec Biogas, a division of Westech Industrial, Inc. (Basis-of-Design) 2. Martin Machinery, LLC 3. Perennial Energy, Inc. 4. John Zink Company, LLC 5. Or equal
2.2 DIGESTER GAS CHILLER
A. Construction: 1. General: The glycol chiller shall be of the air-cooled weather proof type using screw, reciprocating or scroll type compressors as the refrigerant motive force. The chiller shall be a completely packaged unit, factory assembled and tested. The chiller shall have a fan-cooled condenser refrigerant compressor unit, refrigeration circuit, evaporator, a power panel and a control panel, full factory refrigerant and oil charge, and accessories for field installation. The glycol chiller shall be powered from the digester control panel. 2. Materials of construction: a. Condenser tubes: Copper of aluminum b. Condenser fins: Aluminum c. Evaporator brazed plate: Stainless steel d. Evaporator shell and tube: Carbon steel e. Frame: Steel 3. Compressor and Motor: Refrigerant compressors shall be the direct drive, hermetically- sealed type easily accessible for service. The lubrication system shall be force fed. Compressor motor power factor shall be 0.9 or greater. Provide vibration isolation between motor compressor unit and frame. 4. Chilled Glycol Circulation Pump: The pump shall be a centrifugal type pump with a TEFC motor designed to circulate the specified flow of glycol solution. 5. Glycol Solution Expansion Tank: The expansion tank shall be the pressurized bladder or diaphragm type.
2.3 DIGESTER GAS HEAT EXCHANGER
A. Construction: 1. The digester gas heat exchanger shall be manufactured and tested in accordance with the ASME Pressure Vessel Code. All welding shall conform to the latest standards of the WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 6 American Welding Society. The heat exchanger shall be the stainless steel multi-finned- tube-core type in a stainless steel housing. Flanged connections shall be provided for connection to external piping systems. The heat exchanger housing shall have one or two removable cover plates that allow access to clean the fin-tube core. The heat exchanger housing shall be provided with NPT drain connections for gas condensate removal. The heat exchanger shall have an NPT port for installation of a level switch at the point of condensate accumulation. 2. Two (2) expansion joints shipped loose to be installed at the inlet and outlet of the exchanger.
B. Installation: 1. The heat exchanger shall have drain and vent connections and support for horizontal mounting and shall be installed per the manufacturer’s recommendations. The support shall be constructed of welded channel and angle steel.
2.4 DIGESTER GAS COALESCING FILTER
A. Construction: 1. The filter shall Class 150 flanges for in-line connections to piping. Filtration shall be achieved by stationary, interior filter units consisting of a metal basket and attached fins, covered by the polypropylene filter element with molded PVC ends. The filtration level shall be 100% removal of 6 mircron and larger particulates. The filter shall be designed for vertical mounting with a horizontal in-line flow direction. The filter shall be tapped and equipped with a 1-inch threaded drain opening. The filer shall be floor mounted. The unit shall provide access for servicing and easy, quick removal of the pleated filter element for inspection, cleaning or replacement as necessary. 2. Two (2) ½-inch connections, one upstream and one downstream of the filter shall be provided for the purpose of connecting a differential pressure monitoring device. The vessel shall be provided with a differential pressure gauge installed with valving for isolation and atmospheric calibration. 3. The filter system shall be equipped with an ultrasonic level switch for monitoring high condensate level in the base of the vessel. This system shall provide a signal which shall be indicated on the touch screen in units of inches of level, and shall further provide adjustable set-points for alarm and shutdown levels 4. At the design flow rates, temperatures and pressures, the filter shall not have a clean pressure drop greater than 2 in. W.C. The filter vessel shall be capable of withstanding no less than 5 PSIG pressure/vacuum.
B. Materials of Construction: 1. Vessel shell: 304 stainless steel 2. Filter support legs: 304 or 316 stainless steel 3. Gaskets: Non-asbestos synthetic fiber/nitrile binder 4. Filter elements: Polypropylene
C. Spares: One extra filter element shall be provided with the filter.
D. Experience: Filter assemblies shall be manufactured in the United States. Manufacturers shall have a minimum of 5 years’ experience in the design and manufacture of this type of equipment, and shall have a minimum of 10 units operating successfully on digester gas WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 7 installations in this country.
2.5 DIGESTER GAS BLOWERS
A. Construction: 1. The blowers shall be of the direct or magnetic electric motor driven VFD controlled regenerative type, designed to deliver digester gas at any volume within the capacity range of the blower, with a relatively constant pressure. The blowers shall be of non- sparking design. VFDs shall be provided to modulate digester gas flow, sized and selected for the intended service. The blowers shall be capable of exerting a minimum of 0" WC vacuum at the suction side, and shall deliver sufficient pressure to service the digester gas-fuelled-boiler discharge nozzle at a minimum of 2 psi and shall operate down to 45 scfm without surging. 2. The casing shall be cast aluminum. The impeller shall be aluminum and the shaft shall be 316 stainless steel. Process connections shall be ANSI flanged connections. The lowest part of the blower casing shall include a ½-inch NPT stainless steel drain connection with an isolation valve. 3. The blower shall be driven by a 460 Volt, 3 phase 60 Hz electric motor. The motor shall have a high temperature switch and shall be suitable for installation in a NFPA 70 Class I, Division 1, Group D area 4. The VFD shall be capable of controlling the blower motor by either a manually selected speed control or by a 4-20 mADC signal provided by the PLC. The operator shall be able to select a desired pressure at the operator interface console (Touch Screen), and the VFD will automatically control the blower speed to maintain the selected digester pressure. 5. The blower shall be furnished with a vibration sensor, mounted on or near the driven end bearing housing assembly of the blower, and shall develop an output of 4-20 maDC representative of in/sec vibrations from the blower. The PLC shall accept this signal, and shall process the signal for touch screen display as well as adjustable alarm and shutdown levels. 6. Suitable flexible connectors shall be furnished to isolate the blowers from the piping system. 7. Structural Skid: The blowers shall be supplied on a structural skid. The skid shall be manufactured from ASTM A-36 structural members. The sizes, weights and shapes of the structural members shall be engineered to support all assemblies and sub-assemblies in loading, transport and operation. Design criteria for the structure(s) shall be as required by CBC 2010 and ASCE 07. All welding shall be accomplished per AWS Section 1.1. Skid finishing shall be in compliance with the preparation, priming, and painting methods described in section 3.6 of this specification. 8. Protective Devices: Emergency stop buttons shall be provided and located on the digester gas compression system. The emergency stop button shall be provided with an enclosure suitable for installation in a NFPA 70 Class I, Division 1, Group D area 9. Experience: Manufacturers shall have a minimum of five (5) years’ experience in the design and manufacture of this type of equipment.
2.6 DIGESTER GAS ENCLOSED BURNER SYSTEM (FLARE)
A. The Digester Gas enclosed flare system shall be a unitized, modular system including all components for a complete and operational system.
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 8 B. The Digester gas enclosed flare system shall be pre-piped and pre-wired to the extent possible, requiring minimal field re-assembly. The flare assembly shall be designed to be installed remotely from the Digester Gas Handling System (refer to drawings for exact location). Installation of conduiting, piping, wiring, etc. between the systems is the responsibility of the installing contractor. The systems shall be designed with junction boxes at each sub-system such that the installing contractor will need only to attach interconnect wiring to numbered terminals. Interconnect wiring diagrams shall be provided by the system supplier.
C. The Digester gas enclosed flare system shall include, but not be limited to, the following components which shall meet as a minimum the listed specifications: 1. The main gas valve shall be a pneumatically (compressed air), or electrically actuated butterfly valve equipped with a stainless steel disk and viton or Teflon seat. The operator shall be provided as a spring fail close device and shall close when directed by the logic in less than 2 seconds. For electrically actuated valves, a backup battery shall be supplied. The manufacturer shall provide the regulator train and mounting facilities for plant compressed air at between 80 and 100 psig.
2. Flame arrester: A pressure relief and flame arrester assembly shall be installed at the inlet to the flare. The assembly shall have an integral thermal shut-off valve. The pressure drop it imposes on the system shall be a maximum of 2 inches w.c. The flame arrester shall be constructed of cast aluminum housing with aluminum flame element. The flame arrester shall be provided with pressure monitoring such that both flare back pressure and flare + flame arrester back pressure can be monitored. The assembly shall be Varec series 440 or equal. 3. Flare stack: The flare stack shell shall be constructed of 1/4" minimum thickness ASTM A36 carbon steel, and shall be a maximum of 35 ft. in height. Sections of the flare cylinder shall be attached via continuous welds conforming to AWS D1.1 standards. The flare stack shall have the following properties and accessories. a. Lifting lugs: Minimum two (2) lifting lugs shall be provided, each capable of carrying the entire weight of the unit. b. Maximum internal temperature rating: 2000¼ F. c. Maximum external skin temperature: 250¼ F. d. Concrete Pad Protection: Flare mounting shall be designed such that a minimum of 4" of passively ventilated air space is provided beneath the insulated flare floor and the concrete pad. e. Insulation: Three (3) layers of ceramic fiber insulation blanket (maximum 2,300OF) or 3” of castable refractory shall be provided as combustion cylinder protection. If blankets are used, two one inch layers of 8#/ft3 blanket shall be installed, using overlap outer face construction methods, over one (1) 2 inch layer of 4 lbs/ft3 density material. Insulation shall be attached to the flare wall and floor with Inconel 600 series studs and washers. f. Insulation coating for blankets: High temperature, sprayed on surface sealer/protectant. g. Manway: Min. 18" x 18" square, insulated, installed above burners. h. View ports: Minimum of two (2), each 2" NPT with removable tempered glass covers and cooling holes. Viewports shall be located to view the pilot flame, the base of the main flame and each thermocouple. i. Thermocouple ports: As required, 2" NPT with bushing and cooling holes. j. Source test ports: Minimum two 4" NPT with cooling holes. k. Main gas inlet nozzle: Stainless steel, raised faced slip on weld flange meeting the requirements of 150 # ANSI specifications, size is 4" ANSI to connect to the 4" WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 9 flame arrester. l. The external portion of the stack shall have a SSPC-SP-6 surface preparation and the manufacturer’s standard priming and top coating, with color by Owner. m. Natural gas fueled pilot gas inlet nozzle: 1/2" NPT. n. Where required to meet low flow, provide a low turndown (LTD) burner train inlet nozzle: Diameter as required. 4. Burner: The burner unit shall have the following properties and accessories: a. Anti-flashback: All burners furnished shall be anti-flashback type. b. Construction: 304L/316L Stainless Steel (<0.03% carbon content) with castable refractory venturi liners. c. The burner arrangement shall be designed such that a smooth main flame light off from the pilot burner will take place under all flow conditions. The pilot burner shall not be located more than 12 inches from the combustion chamber shell d. Burner Warranty: The Stainless Steel portions of the burner assembly shall be warranted by the manufacturer to perform for the purpose for which it is intended, and to be capable of maintaining compliant operation over the range of specified design pressures, flow rates and heat rates for a minimum period of two (2) years from date of delivery to site when operated continuously (>85% Duty Cycle) within the specified design flow rate and heat loading limits. Offers which do not address this burner warranty requirement may be considered non-responsive. e. Products of combustion temperature measurement shall be provided by a type K ceramic protection tube thermocouple located adjacent to a test port. The thermocouple shall be wired to a temperature controller which controls the modulating air dampers to maintain the specified operation temperature. The temperature controller shall be complete with a 4-20 mA current output and two alarms. 5. Flame safeguard controller: Honeywell or engineer approved equivalent, factory mutual reviewed. Device shall include an ultra violet signal amplifier module and shall display flame signal strength at the control panel. 6. Ultraviolet scanner: Honeywell or equal, Factory Mutual reviewed. Device shall be "self-checking" type. 7. Natural Gas pilot system: Removable pilot assembly rated at 40,000 Btu/hr, including pressure regulator, pressure indicator, solenoid valve, manual shutoff valve and pilot gas pressure manometer port. Plant natural gas pressure connection shall be a maximum of 2 psig. 8. Total combustion and quenching air control: Motor operated, 12 gauge galvanized steel damper(s) with 3/4" shaft at each inlet. 4-20 maDC actuator damper motor(s) shall be utilized at the louver(s). Actuators shall cause louver(s) to fail open on loss of signal. Actuators shall be housed in a NEMA 7 enclosure per NFPA 820. 9. Flare temperature controller: Flare temperature control shall be directed by the inherent analog control capabilities of the supervisory PLC system, with capabilities of proportional, integral and derivative control. Controller shall drive damper actuator motors via a 4-20 maDC signal, and shall include operator adjustable set-point control for both operational setpoint and low flare temperature. Logic in the PLC controller shall include auto start louver position signal and automatic switch over capabilities to control to an adjustable set-point flare temperature setting. Temperature control system shall be capable of controlling the flare temperature to within +/- 30o F of set-point. 10. Electronic spark ignition: 5000 V electronic igniter assembly removable from outside the flare without disconnecting conduit or wiring. 11. Flare anchor system: Flare mounting feet shall be provided such that appropriate anchorage can be provided using a HILTI HIT C-100 System using HFA or HAS inserts. WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 10 Embedment depth and spacing shall provide full overturn and seismic attachment to foundation. Flare shall be designed to withstand loads & stresses per the requirements of UBC100 mph wind loading and seismic zone 4 criteria. 12. Finish: The stack shall be internally coated with a 1.5 mil layer of bitumastic for corrosion protection. High temperature primer and finish coat over sand-blast prepared metal. Sand blasting shall be to SPC SP-10 guidelines. 13. Ignition transformer enclosure: The enclosure for the ignition transformer shall meet NEMA 7 to meet NFPA 820 criteria and shall receive the 120 VAC power and hi-tension conduits. 14. Flare junction enclosure/main control panel: The flare mounted junction box(s) / panel(s) shall meet NEMA 7 criteria, and shall house all of the flare mounted electrical gear required to meet the operational requirements of this specification.
D. Spare Parts: One each of the following devices, of the manufacturer, type and model installed in the system, shall be provided as a part of this scope of work and supply; 1. Thermocouple 2. Flame Safeguard module 3. Flame Signal Amplifier module 4. U.V. Flame monitoring sensor 5. Pilot gas igniter 6. Louver actuator motor 7. Pilot gas ignition transformer 8. Complete set of fuses applicable to system operation
2.7 CONTROLS AND ELECTRICAL
A. General: Controls and electrical devices and systems shall conform to the requirements of Divisions 26 and 40. All controls necessary for the manual and fully automatic operation shall be provided.
B. Instrumentation: All instruments provided by the manufacturer shall be in accordance with applicable Sections in Division 26, “Electrical,” and Division 40, “Process Integration.” In addition to instrumentation previously listed, the manufacturer shall supply, at a minimum, the following instruments:
1. Digester gas inlet and outlet temperature transmitters (at heat exchanger). 2. Glycol inlet and outlet temperature transmitters. 3. Chiller pump suction pressure indicator 4. Chiller pump discharge pressure indicator 5. Coalescing filter differential pressure indicator 6. Coalescing filter level indicator 7. Blower inlet and outlet pressure indicators 8. Blower inlet and outlet pressure transmitter 9. Blower inlet pressure switch 10. Blower temperature transmitter 11. Two (2) mass flow meters: One downstream of the blowers; one downstream of the control valve to the flare. 12. Two (2) flare pressure indicators, one upstream and one downstream of the flame trap.
C. Mass Flow Meters: Mass flow meters shall be supplied to meter flow to both the boilers and to the flare and shall meet the following requirements: WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 11 1. The mass flow meters shall be constructed of 316L stainless steel, all welded, with an S- style sensor and a maximum operating temperature of 350¡F. Meters shall be installed in a horizontal orientation. 2. Flow vanes shall be provided for installation upstream and downstream of the meters. 3. Mass flow meters shall be manufactured by Fluid Components International, or equal.
2.8 GAS HANDLING AND WASTE GAS BURNER (FLARE) CONTROL SYSTEM
A. General: The control panel for the Digester Gas Handling and Flare System shall be compliant with NEMA 12 specifications at a minimum, and shall be located in the Digester Control Building, located approximately 50 feet away from the heat exchanger, coalescing filter and blowers, and approximately 250 feet away from the enclosed flare. The control panel shall be mounted, installed and pre-wired to the extent possible by the system manufacturer. All conduiting and wiring shall be completed at the factory to the maximum extent possible. The complete control system shall be manufactured, wired and tested in a UL approved panel shop, and shall be specifically designed for the performance of the electrical and logical control requirements of this project. The control panel shall bear the official UL label confirming UL classification as an “Industrial Control Panel”. The panel shall include as a minimum, but not be limited to, the following components:
1. A load center for all the motors, fixtures, controls and devices included with the system. The electrical system shall include voltage transformer(s), disconnects, main and branch circuit protectors and any other protection and/or control devices required for complete operation of the system based on a single electrical service supply of 480 VAC, 3 Phase, 60 Hz. 2. A PLC based control center to receive all the signals from the various safeties, controls and monitoring equipment, and to automatically control all the various components of the system. An Ethernet module shall be incorporated in the PLC to accommodate connection to the plant SCADA system. One licensed copy of the appropriate software shall be provided to the Owner as a part of this scope of work and supply. 3. An operator interface panel to allow either manual or automatic selection for the control of the operational components of the system. Such operator interface shall be provided as a “Touch Screen”, and shall be fully compatible with the PLC and shall be designed for industrial duty applications. 4. Safeties: The system shall be equipped with the following safeties as a minimum:
a. Blower Motor overcurrent b. Blower motor undercurrent (surge) c. High Flare Temperature d. Low Flare Temperature e. Flame Failure f. Low Digester Pressure g. High Digester Pressure h. High coalescing filter condensate level
5. Control Panel Face Mounted Devices: The system shall be equipped with the following control panel face mounted devices as a minimum:
a. Auto Dialing Alarm System (ADAS) to accept a minimum of four inputs and shall be capable of being programmed to contact a minimum of 8 phone numbers. WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 12 b. Alarm and shutdown message annunciation (Touch Screen Display) c. Load center circuit breakers as required for full system operation. d. Test/Off/Auto Switch for the blower e. Test/Off/Auto Switch for the system f. Open/Closed/Auto switch for the flare shutdown valve g. Flame failure annunciation for the flare (Touch Screen) h. High flare temperature annunciation (Touch Screen) i. Low flare temperature annunciation (Touch Screen) j. Inlet Valve Failure annunciation (Touch Screen) k. Low DG Pressure annunciation (Touch Screen) l. High DG Pressure annunciation (Touch Screen) m. Test/Off/Auto Switch for the pilot ignition system n. Flame Failure Reset
B. Operation Logic and Control: The manufacturer shall provide control logic, at a minimum, of the following: 1. Upon receipt of signal from the boilers, the compressors will start up to provide the required pressure to the boilers. 2. When pressure at the digesters exceeds the preset upper pressure limit (as indicated in Section 1.2.A), the control valve to the flare shall operate open to a set stop that passes the minimum flow required by the flare. The control valve will continue to operate in the open position until the pressure in the digesters drops below the preset limit. At no time shall the control valve operate in a range that sends an insufficient flow of gas to the flare to meet emission requirements. 3. When pressure at the digesters exceeds the preset lower pressure limit (as indicated in Section 1.2.A), the system shall not operate the blowers or the control valve to the flare.
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: Install the work of this section in strict accordance with the manufacturer's recommendations as approved by the Engineer.
B. Installation shall proceed in compliance with the submitted installation schedule, as approved by the Engineer.
C. The work of this section shall be installed plumb and perpendicular to piping where required on Construction Drawings.
D. Painting: Marred or abraded surfaces shall be cleaned and refinished in accordance with the manufacturer’s recommendations.
3.2 START-UP & TESTING
A. Factory Test: The entire system, including all controls shall be tested at the manufacturer's plant before shipment. Complete test reports shall be made available which shall show all system controls operate correctly prior to shipment.
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 13 B. Start-up: The manufacturer shall furnish his factory trained representative for a minimum of three (3) days of start-up & training labor. The representative will remain on site until start-up of the system has been completed to the engineers’ satisfaction, unless failure to achieve a successful start-up is NOT the fault or cause of the manufacturer.
C. Functional and Validation Tests: Upon completion of the installation, functional and validation tests shall be performed by the Contractor with the assistance of the manufacturer's representative in accordance with Section 017500, “Commissioning”. The manufacturer’s representative will demonstrate compliant operation of the system to the engineer’s satisfaction. Should the system NOT perform to the requirements of this specification, the expense of any re- testing, if required, will be borne by the system manufacturer, unless failure to achieve successful operation is neither the fault or cause of the manufacturer.
3.3 TRAINING
A. When all required approvals of this portion of the work have been obtained, and at a time designated by the Owner and/or Engineer, the Contractor and/or the manufacturer’s representative in charge of start-up and testing shall thoroughly demonstrate to the Owners operation and maintenance personnel the operation and maintenance of all items installed under the work of this section.
B. The instructions shall be separate from the installation, start-up and equipment adjustment services.
3.4 CLEANING
A. Clean exposed surface of all grease, dirt and other foreign materials.
B. Touch up all marred or abraded surfaces as specified herein.
3.5 PAINTING
A. Surface Preparation
1. All surfaces of equipment shall be provided with the manufacturer’s standard shop priming and painting system. The installing Contractor shall be responsible for field touch up coating, in accordance with Specification Section 098000, “Protective Coatings” and the manufacturer’s recommendations.
END OF SECTION 437700
WRCRWA DIGESTER GAS CONDITIONING AND WASTE GAS BURNER SYSTEM PLANT EXPANSION PROJECT 437700 - 14 SECTION 441000 – BIOFILTRATION ODOR CONTROL SYSTEM
PART 1 - GENERAL
1.1 SUMMARY
A. Description of Work:
1. Furnish, install, and test a complete biofiltration odor control system contained in a concrete reactor. Odor control system shall be ready to operate and complete with all engineered media, fiberglass reinforced plastic blower(s), FRP ductwork, irrigation system, recirculation system, fluid controls, instrumentation, control panel accessories, and appurtenances including spare parts, to form a complete operating system in compliance with these specifications and as shown on the Drawings. 2. All components of the biofilter odor control system, including all accessories, shall be provided by a single manufacturer. The manufacturer shall have unitary responsibility for the performance and compatibility of the entire system in conformance with the Contract Documents. System components not provided by equipment manufacturer shall be rejected. Unitary responsibility includes all equipment listed herein, even if described in more detail in another specification section or on the Contract Drawings. 3. To assure proper interfacing and reliable operation of all system components, the manufacturer shall assume sole responsibility for the quantity and proper functioning of all components, including those not of his manufacture. 4. Contractor shall review all aspects of the equipment installation with the manufacturer to ensure systems that are capable of functioning as described and that are fully compliant with the manufacturer’s recommendations. 5. During bidding, the manufacturer shall provide general arrangement drawings, process and instrumentation diagrams (P&IDs), and any other information necessary for Contractor to adequately price materials and labor required for a fully functional system including system startup and testing requirements. Electrical and instrumentation wiring, cabling and conduit requirements, as well as plumbing and process piping, ancillary equipment, and temporary equipment required for startup and testing shall be determined by Contractor in coordination with the manufacturer and be provided by Contractor if not provided by the manufacturer.
B. Section Includes:
1. Biofilter reactor. 2. Media. 3. FRP Covers 4. Media support system. 5. Humidification systems. 6. Irrigation system. 7. Blower. 8. Accessories. 9. Motors and drives. 10. Controls.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 1
C. Related Documents:
1. Section 013300 – Contractor Submittals. 2. Section 014000 – Quality Requirements. 3. Section 016100 – Product Requirements. 4. Section 016600 – Equipment Testing and Plant Startup. 5. Section 017823 – Operation and Maintenance Data. 6. Section 098000 – Protective Coatings. 7. Section 233100 – Fiberglass Reinforced Duct. 8. Section 260000 – General Electrical Requirements. 9. All electrical equipment, control panels, and wiring shall be in full compliance with Division 26 Specifications.
1.2 REFERENCES
Reference Title ACMA American Composites Manufacturers Association AMCA 210 Air Movement and Control Association Test Code and Certified Ratings Program ANSI American National Standards Institute ASTM C582 Standard Specification for Contact-Molded Reinforced Thermosetting Plastic (RTP) Laminates for Corrosion-Resistant Equipment ASTM D790 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulation Materials ASTM D883 Definition of Terms Relating to Plastics ASTM D2563 Recommended Practice for Classifying Visual Defects in Glass Reinforced Plastic Laminate Parts ASTM D2583 Test for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor ASTM D3299 Standard Specification for Filament-Wound Glass Fiber Reinforced Thermoset Resin Corrosion-Resistant Tanks ASTM D4097 Standard Specifications for Contact Molded Glass Fiber Reinforced Thermoset Resin Chemical Resistant Tanks IEEE Institute of Electrical and Electronic Engineers NEC National Electrical Code NEMA ICS 2-88 Industrial Control Devices, Controllers and Assemblies NEMA ICS 6-88 Enclosures for Industrial Controls and Systems NEMA MG 1-87 Motors and Generators NFPA 820 Standard for Fire Protection in Wastewater Treatment and Collection Facilities UL 674-89 Motors and Generators, Electric, for Use in Hazardous Locations, Class I, Groups C and D, Class II, Groups E, F and G
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 2
1.3 DEFINITIONS
A. The terms “manufacturer” and “equipment manufacturer” listed herein are used to describe the manufacturer and supplier of the biofiltration odor control system.
B. The term “equipment” listed herein is used to describe the biofiltration odor control system and all accessories.
C. D/T: Detection to threshold. The odor concentration or dilution ratio which has a probability of 0.5 of being detected under the conditions of the specified test.
D. OU: Odor Unit. The quantity of any odor or mixture of odors that, when dispersed in one cubic foot of odor-free air, produces a median threshold odor detection response.
1.4 PERFORMANCE AND DESIGN CRITERIA
A. One (1) biofiltration odor control system shall be provided to treat foul air collected from the Primary Clarifiers and Equalization Basin.
B. System shall be suitable for outdoor installation in a Class I, Div 2, Group D area in accordance with NFPA 820.
C. Any electrical component located within 3 feet of a potential leak source shall be labeled for use in a Class I, Dive 1, Group D environment.
D. All components of the biofilter shall be compatible with the conditions and chemicals to which they will be subjected during normal operation. Compounds with which the materials must be compatible include, but are not limited to:
1. Hydrogen sulfide. 2. Sulfuric acid. 3. Other reduced-sulfur compounds. 4. Ammonia.
E. Biofiltration odor control system shall meet the following criteria:
1. Design criteria:
Biofiltration System Airflow Capacity, total 10,000 cfm
H2S Loading, peak 100 ppmv
H2S Loading, average 30 ppmv Total Reduced Sulfur Compounds Loading, 2 ppmv average Ambient Air Temperature 40 – 110 degrees F Make-up Water Supply Plant effluent Reactor Pressure Drop, maximum 2.0 inches w.c. (1)
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 3
Biofiltration System Empty Bed Residence Time, minimum 30 seconds Blower Motor Horsepower 25 HP Pump Motor Horsepower 3 HP Notes: (1) Maximum reactor pressure drop is taken from blower inlet to discharge at media surface. This pressure rating does not include collection system ductwork upstream of odor control blower. (2) Maximum ductwork pressure drop is taken from the odor source to the blower inlet. This pressure rating does not include blower or media losses.
2. Performance criteria:
Inlet Outlet
H2S (1-10 ppmv) 0.1 ppmv
H2S (>10 ppmv) >99 percent removal of inlet Total Odor Reduction >90 percent removal of inlet (1) Notes: (1) Removal percentage for average inlet conditions shall be >90% d/t or below 600 d/t, whichever is greater.
1.5 SUBMITTALS
A. Submittals shall be in accordance with the Contract Documents including Section 013300.
B. At a minimum, the submittals shall contain, but not be limited to, the following information to establish compliance with these specifications:
1. Shop Drawings in accordance with Section 013300. a. Additional shop drawing requirements: 1) Drawings showing plan, elevation, and appropriate cross sections of the equipment being provided. Detailed drawings showing irrigation piping, nozzles, electrical, instrumentation and structural connections. 2) Complete engineering data including, but not limited to, all pertinent engineering calculations including odor removal performance and pressure drop, descriptive data, material specifications, equipment weights, piping diagrams, instrumentation diagrams, and wiring diagrams, as appropriate, to support the design of the equipment being provided.
2. A test procedure for the performance testing specified in Part 3. Test procedure shall be in accordance with Section 016600 and as specified in Part 3. Procedure shall include: a. Test equipment and apparatus. b. Calibration and setup procedures. c. Specific testing methodology to be used. WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 4
d. Sampling and analysis procedures. e. Final report providing a narrative of the sampling activities, a copy of the original sampling log, photographs showing locations of velocity and pressure measurements, tabular summary of velocity, pressure, H2S and odor removal data, calculated results, and conclusions of these results. 3. Complete operation and maintenance data on equipment in accordance with Section 017823. 4. Manufacturer's certification that the equipment has been properly installed, aligned and tested, and meets all requirements for satisfactory performance under the conditions specified in accordance with Section 016100 and all related test results and associated forms. 5. Manufacturer's instruction certification that instructions to operators have been completed in accordance with Section 016100. 6. Whenever the manufacturer receives notice that components that are part of his system are to be discontinued from manufacture, manufacturer shall inform Engineer within seven (7) days of receiving that notice along with his recommendations on how to resolve this issue.
1.6 SOURCE QUALITY ASSURANCE
A. In order to maintain a standard of quality and compatibility, all equipment and accessories specified in this Section shall be provided by a single manufacturer who has been regularly engaged in the design and manufacture of the equipment for at least three (3) years and with no less than ten (10) similar units installed in the United States in similar applications using site constructed concrete structures.
B. Factory Performance and Shop Tests:
1. Factory performance tests will not be required. However, the manufacturer must be prepared to guarantee the performance requirements specified herein.
1.7 DELIVERY, HANDLING AND STORAGE
A. Packing, Shipping, Handling, and Unloading:
1. Equipment shall be shipped and handled in accordance with the requirements of Section 016100 of these specifications. 2. Avoid cross-contamination of foreign materials with media during handling and placement. All media shall be delivered in bulk bags or boxes.
B. Storage and Protection:
1. Equipment shall be stored and protected in accordance with the requirements of Section 016100 of these specifications. 2. Media shall be covered if stored longer than one week.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 5
1.8 WARRANTIES
A. The biofilter media shall be warranted not to compact, degrade or decompose for a period of 10 years from the date of Substantial Completion.
B. Mechanical equipment shall be warrantied for the standard manufacturer’s warranty, for no less than 1 year from the date of start-up.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the specifications given herein, the following manufacturers are acceptable:
1. BIOREM Environmental, Inc. (Basis-of-Design) 2. Or equal.
B. Dimensions and locations shown on Drawings for equipment and accessories are based on equipment provided by BIOREM Environmental, Inc. Any change in the dimensions or location of equipment or accessories or type of accessories required to accommodate alternate manufacturers and models shall be at Contractor’s expense.
C. All costs associated with modifying the design and construction of the building, structural, piping, electrical, mechanical, plumbing and instrumentation systems required to accommodate alternate manufacturers and models shall be responsibility of Contractor.
D. In the case of an “or-equal”, Contractor shall demonstrate in writing, to the satisfaction of the Owner and Engineer at the time of the shop drawing submittal that the manufacturer has produced the specified type and size of equipment for sanitary wastewater service that has been in successful operation in at least 20 different locations for a minimum period of 5 years prior to the bid date.
2.2 BIOFILTER REACTOR
A. The biofilter reactor shall be constructed of reinforced concrete and finished as specified herein and in Section 098000.
B. The reactor shall be operated in the up-flow configuration.
C. Interior reactor floor shall be continuous and maintain a 1-percent slope towards the reactor plenum for leachate collection and drainage.
D. Access hatches shall be provided as shown on the Drawings.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 6
2.3 EQUIPMENT DESIGN
A. Media: Media shall be made up of a porous, acid resistant base designed to facilitate biological growth. The substrate materials shall be capable of being handled or driven over by machinery. Lava rock is not acceptable as a substrate. Base media shall be processed and enhanced by permanently affixing an engineered coating comprised of buffering agents, nutrients and other minerals to control pH and propagate biological growth. Uncoated or untreated media is not acceptable. Organic components in the media bed are not acceptable. Media that requires on- site treatment for enhancement is not acceptable. Media that requires nutrient addition or other means of on-site treatment to facilitate or accelerate acclimation are not acceptable. Additives shall be suspended in a time release engineered coating. The following, at a minimum, shall be provided as part of the submittal:
1. General non-proprietary details on the coating system including buffering and nutrient content. A random sample taken by the client of the delivered media may be sent to an independent testing lab for analysis to confirm content. 2. Location of media processing facility. Engineer shall be given full access to visit this facility and confirm the media is being coated with the submitted content. 3. pH control plan utilizing buffering agents, and anticipated bed pH graduation based on specified process treatment airstream. 4. Media life calculations based on a minimum of ten (10) previous installations. At least one installation shall have been in operation for a minimum of five (5) years. Supplier shall provide documentation and photographic evidence that media in the 5-year installation was the same product being submitted – manufactured using the same material and process. Owner/Engineer may, at their discretion require additional proof if submitted information does not satisfy their requirements. 5. Know engineered media products that are acceptable to the engineer are Biosorbens by Biorem and BioPure by ECS. Alternate products must be pre-approved 20 days prior to bid tender. To achieve pre-approval a full submittal package satisfying all requirements of this specification section should be submitted.
B. Media Support System.
1. The biofilter media shall be supported by a corrosion resistant FRP grating, reinforced with FRP angle beams. 2. Angle beams shall be supported on both sides of the treatment cell. 3. Grating/beam system shall support a minimum loading of 100 pounds per square foot. 4. A mesh polypropylene screen shall be placed on the FRP grating to prevent the biofilter media from falling through the grating openings.
C. Humidification System.
1. The humidification recirculation system shall designed such that it meets the design requirements as listed in Section 1.4 of this specification. The system shall include a PVC spray nozzle assembly above the packing media and a centrifugal recirculation pump. 2. Water piping shall be Schedule 80 PVC.
D. Water Cabinet.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 7
1. A water cabinet, which houses components necessary for water recirculation shall be provided. 2. Water cabinet to be a NEMA 4X enclosure of either FRP or Type 304 stainless steel with mounting feet if required. 3. Water cabinet shall be mounted a minimum of 3 feet from any potential leak point to comply with NFPA 820. 4. Water cabinet shall contain the following: a. Ball valves and plumbing required for media irrigation. b. Field connection (1-inch) to make-up water supply. c. Fuse block and terminals for all field connections. d. One (1) flow indicator/switch, to display re-circulated water flow rate, signal alarm and shut-off recirculation pump in case of reduced water flow. e. One (1) flow indicator to display blow down water flow rate. f. One (1) flow totalizer on make-up water supply line. g. One (1) pressure indicator for recirculated water flow.
5. One (1) solenoid valve for irrigation control.
E. Irrigation system.
1. The irrigation system shall consist of a spray irrigation assembly above each biofilter media cell. 2. The biofilter media bed shall be irrigated intermittently.
F. Blower.
1. Blower shall be designed for continuous service. 2. Blowers shall be FRP, backward inclined or radial-bladed centrifugal type. 3. Blower shall be statically and dynamically balanced. 4. Blower shall be equipped with a slip inlet connection, outlet flange, drain connection at bottom of blower scroll and inspection panel. 5. Blowers shall have a Type 316 stainless steel shaft. 6. Blower shall have self-aligned grease-packed bearings with minimum 100,000 hour B-10 life, neoprene shaft seals and OSHA approved weatherproof motor/drive cover. 7. The blower shall be manufactured by New York Blower, Hartzell, Universal Fan and Blower or approved equal.
G. Accessories.
1. Fluid Control Systems: a. One (1) lot fluid control valves and 1.8 mm (1800 micron) strainers as required. b. One (1) lot 0.25-inch tubing for differential pressure gauges. c. One (1) lot drip legs for differential pressure gauges.
2. Field instrumentation external to Water Cabinet: a. Two (2) differential pressure gauges to measure pressure drop across media. b. One (1) inlet air temperature indicator. c. Pressure indicators at outlet of each recirculation pump.
3. Piping
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 8
a. The supplier shall provide all piping between the fan and the humidification tower, and from the tower to the biofilter reactor. The supplier shall also provide the drain piping from the humidification tower into the reactor. b. The supplier shall provide all necessary flexible connections for the fan and the humidification tower.
2.4 MOTORS AND DRIVES
A. Recirculation pump motor.
1. Conform to Section 220513 and the following: 2. Suitable for Class 1, Division 2, Group D classification. 3. Horsepower: As listed in Design Criteria. 4. Electrical: 460-V, 3-phase, 60 Hz. 5. Service Factor: 1.15. 6. Duty: Continuous.
B. Blower.
1. Drive: Constant V-belt drive. 2. Motor: a. HP: As listed in Design Criteria. b. Suitable for Class 1, Division 2, Group D classification. c. Electrical: 460-V, 3-phase, 60Hz. d. Enclosure: TEFC. e. Speed: 1800 rpm. f. Service factor: 1.15. g. Duty: Continuous.
2.5 CONTROLS
A. All control panels shall comply fully with Division 26 and shall be located as shown on Contract Drawings. Interface with the plant-wide SCADA system shall be coordinated with the system integrator.
B. General Requirements.
1. Manufacturer shall provide all necessary controls including all sub-systems as specified herein and as recommended and required for a complete and operational system. Instances of Hand-Off-Auto selector switches herein shall refer to physical switches mounted in the control panel. Contractor shall be responsible for installation of all controls supplied by manufacturer including all related wiring and conduit and connections to plant SCADA system, in coordination with manufacturer. Contractor shall also be responsible for providing any additional components required or recommended by manufacturer. 2. All control panels shall be NEMA 4X rated and fabricated of Type 304 stainless steel.
C. Local Control Panel.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 9
1. Provide a single control panel to service the biofilter system. Provide all items which are required to implement the specified functions and the functions required for proper system operation. a. Panel shall contain the local control and monitoring for the odor control system components, including: 1) Mounting pedestal, if required. 2) Door-mounted fused disconnect. 3) Motor starter and Hand/Off/Auto switch for blower. 4) Motor starter and Hand/Off/Auto switch for recirculation pumps. 5) Status light (on when running) for blower and recirculation pumps. 6) Recirculation low flow alarm. 7) General alarm indicating light. 8) Alarm reset push button. 9) Space heater. 10) Controls transformer. 11) Timer relay for control of irrigation water. 12) Dry contacts for transmitting signals to remote location. 2. The power feed to the control panel shall be 480-volt, 60 Hz, 3-phase. 3. Panel shall be UL certified and shall be mounted a minimum of 3 feet from any potential leak point to comply with NFPA 820. 4. Panel shall be equipped with SCADA signals (dry contacts) for the following signals that shall be wired to terminals located inside master control panel:
D. Functional Control Description.
1. The solenoid valves shall be controlled on a timer with field-adjustable set points. The open status indication for the solenoid valves shall be derived by flow switches located downstream of the valve to verify the valve is open and flow is present.
2.6 FABRICATION
A. Anchorage:
1. All bolts, nuts, washers, and other fasteners shall be Type 316 stainless steel unless otherwise noted and shall be provided by Contractor unless otherwise supplied by equipment manufacturer. Inform Engineer any time Type 316 stainless steel parts will not be used prior to using alternative materials. 2. Anchor bolts shall be Type 316 SS HILTI-style epoxy anchors and shall be provided by Contractor unless otherwise required by odor control system manufacturer. Inform Engineer any time Type 316 stainless steel parts will not be used prior to using alternative materials. 3. Contractor shall provide lock nuts and/or lock washers when recommended or required by equipment manufacturer or as necessary for Work to prevent nuts from disengaging from their seated positions due to vibration or other factors associated with equipment operation.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 10
2.7 FINISHES
A. Surface preparation, shop painting and field painting and other pertinent detailed painting specifications shall be in accordance with Section 098000 and manufacturer’s standards. Manufacturer shall coordinate fully with the Contractor the system and application of paints used. Machined and polished surfaces, stainless steel, non-ferrous, and galvanized metals shall not be primed or painted. All surfaces not specified to be factory-primed shall be protected from corrosion by applying a rust inhibitor or other acceptable means of protection. Surfaces to be painted shall include metal surfaces of motors, speed reducers, bases, and accessories unless otherwise exempted.
1. Unless otherwise specified below, all system components shall be received at the project site with full factory-applied finishing in accordance with Section 098000. 2. For those components to be painted at the project site by Contractor, manufacturer shall supply all components with factory-applied prime coat in accordance with Section 098000. Contractor shall be responsible for providing all other coats, including any necessary touchups to the prime coat, in accordance with Section 098000. 3. Manufacturer shall provide Contractor with correct paint and/or prime coat materials in the correct color and any other special materials required by Contractor to make any necessary field repairs to the factory applied finish should said finish be marred or damaged. 4. The following system components shall be field painted by Contractor: a. All internal walls of the humidification filter stage shall be coated in accordance with Section 098000. b. All internal walls of the biofilter stage shall be coated accordance with Section 098000.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Coordinate any required interruptions with operation of Owner’s facilities with Owner and Engineer.
B. Contractor shall furnish and install all equipment, accessories, and appurtenances according to the Contract Documents, including Section 016100, and equipment manufacturer’s written instructions. Conflicts of information shall be called to the attention of the Engineer before proceeding with work.
C. Contractor shall field verify all dimensions and elevations and shall notify Engineer of any specific differences.
D. Contractor shall provide all necessary equipment (including temporary equipment, measuring devices, etc.), materials (including temporary materials, lubricants, chemicals, etc.) and labor necessary for initial system startup, testing, and operation. Grades of oil and grease for all equipment shall be in accordance with the recommendations of the equipment manufacturer. Contractor shall account for fact that many of the other plant systems may or may not be online when the equipment is started up and tested.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 11
E. Contractor shall be responsible for ensuring that all equipment is rigidly and accurately anchored into position. Contractor shall be responsible for providing all necessary foundation bolts, plates, nuts, washers, and other fasteners not provided by equipment manufacturer.
F. Equipment manufacturer shall provide Contractor with engineering and technical support related to the specified equipment, and participate in the commissioning, startup, testing, and training of the Owner’s personnel as required by the Contract Documents and as necessary to allow Contractor to provide a complete and operable system.
3.2 FIELD QUALITY ASSURANCE AND INITIAL OPERATION
A. Field Acceptance Testing:
1. Preliminary tests, field tests, start-up and initial operation shall be performed in accordance with the Contract Documents, including Sections 016100, 016600, 017500 and this specification section. 2. All testing shall be done in the presence of the Engineer and the equipment manufacturer or their approved representative. All testing shall be conducted by an independent testing lab at the Contractor’s expense. 3. Three week acclimation period will be deemed as equivalent to the equipment start-up period. 4. Performance Testing of Odor Control System. a. Verify conformance to specified parameters using actual inlet conditions of the site. Testing to be completed no sooner than a 3-week acclimation period, but not later than 10 weeks, after system startup and shall include: 1) Verification of proper airflow. 2) Measurement of inlet and outlet H2S concentrations. 3) Test will be conducted for a period of not less than 8 continuous hours with H2S readings being logged continuously with a data logger. 4) Record pressure drop readings across media lift. 5) Bag samples will be collected at two different times, on the inlet and outlet of the biofilter, for odor panel analysis. 6) A report of the test results shall be provided.
B. Final acceptance of the equipment shall be made after the equipment has been demonstrated in the field to meet the performance requirements stated in this specification under all normal operating conditions and verification that the motors are not overloaded in normal operating conditions.
C. Adjust, repair, modify, or replace any components of the system, which fail to meet all specified requirements. Retest entire system after repairs, adjustments, and modifications have been made and until all issues are resolved and system operates in full compliance with the Contract Documents and manufacturer’s specifications and requirements. All such work shall be at Contractor’s expense. Owner and Engineer shall review and approve of any modifications proposed by Contractor necessary to correct any issues prior to work commencing.
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 12
3.3 MANUFACTURER’S SERVICE
A. Provide services of the equipment manufacturer or their approved representative in accordance with Sections 014000, 016100, and 016600. Representative for the specified equipment shall be present at the job-site for the following services:
1. Installation assistance: 1 man-day(s). 2. Final acceptance: 2 man-day(s). 3. Job-site training: 1 man-day(s).
B. Provide jointly to the Owner and the Engineer an installation certificate from the equipment manufacturer or their approved representative stating that the equipment has been properly installed, tested to their satisfaction, that all final adjustments required have been made and equipment will be warranted as required by the specifications.
C. All test results, forms, and certifications shall be included in O&M manual.
D. In addition to the site visits specified herein above, the equipment manufacturer shall provide one person for a 2-day site visit (time represents time at the project site and does not include travel time) 6 months after Substantial Completion to:
1. Verify conformance to specified parameters, to be conducted using actual inlet conditions of the site. Testing shall include: a. Verification of proper airflow. b. Measurement of inlet and outlet H2S concentrations. c. Test will be conducted for a period of not less than 8 continuous hours with H2S readings being collected every 30 minutes. d. Record pressure drop readings across media lift. e. Bag samples will be collected at two different times, on the inlet and outlet of the biofilter, for odor panel analysis. f. A report of the test results shall be provided.
2. Provide additional training as required.
END OF SECTION 441000
WRCRWA BIOFILTRATION ODOR CONTROL SYSTEM PLANT EXPANSION PROJECT 441000 - 13
SECTION 460100 – GENERAL MECHANICAL REQUIREMENTS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Special Conditions and Division-1 Specification sections, apply to work of this section.
B. Sections of other Divisions which relate to mechanical work apply to the work of this section and others. See various Sections on sitework, underfloor work, structural work, finish materials, etc.
C. Related Sections:
Refer to "Electrical Requirements for Mechanical Equipment Section in Division 26 for basic electrical requirements for all mechanical equipment. Special and specific electrical requirements are specified within each respective equipment specification section.
1.2 SUMMARY:
A. This Section specifies the basic requirements for mechanical installations and includes requirements common to more than one section of Division 22, 23, 35, and 46. It expands and supplements the requirements of Division 1.
B. This Division does not define, nor is it limited by, trade jurisdictions. All work described herein is a part of the General Contract and is required of the Contractor regardless.
1.3 DESCRIPTION OF PROJECT:
The mechanical work described in these mechanical specifications is for a project located in Eastvale, California. Design weather conditions are: summer 110° F (max), and winter 25°F (min). Altitude readings, unless otherwise noted, are approximately 600 ft above sea level and adjustment to manufacturer's performance data shall be made accordingly.
1.4 CODES AND PERMITS, AUTHORITIES HAVING JURISDICTION
A. The mechanical work shall be performed in strict accordance with the applicable provisions of the various codes, ordinances and adoptions pertaining to the project location in effect on the date of invitation for bids. All materials and labor necessary to comply with rules, regulations and ordinances shall be provided. Where the drawings and/or specifications indicate materials or construction in excess of code requirements, the drawings and/or specifications shall govern.
B. The Contractor shall hold and save the Owner and Architect/Engineer free and harmless from liability of any nature or kind arising from his failure to comply with codes and ordinances.
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-1 C. Permits necessary for the prosecution of the work under this contract shall be secured and paid for by the contractor(s).
D. Reference Standards:
American Welding Society International Mechanical Code/State Code International Building Code/State Code SMACNA Duct Design Standards Local/State Plumbing Code Locally enforced NFPA Codes Local Fuel Utility Regulations Local Power Utility Regulations American Gas Association ASME Codes for Pressure Vessels and Piping ANSI B31.1 Piping
E. Final inspection by the Engineer will not be made nor Certificate of Substantial Completion issued until certificates of acceptability from the Authorities having jurisdiction are delivered.
1.5 DEFINITION OF PLANS AND SPECIFICATIONS:
A. The mechanical drawings show the general arrangement of piping, ductwork, equipment, etc., and shall be followed as closely as the actual building construction and the work of other trades will permit. The architectural and structural drawings shall be considered as part of the work insofar as these drawings furnish the Contractor with information relating to design and construction of the building. Architectural drawings shall take precedence over mechanical drawings. Request clarification and participate in resolution in the event of conflict.
B. Because of the small scale of the mechanical drawings, it is not possible to indicate all offsets, fittings and accessories which may be required. Investigate the structural and finish conditions affecting the work and arrange the work accordingly, providing such extensions, fittings, valves and accessories to meet the conditions as may be required.
C. Examine the actual construction site prior to bidding and obtain an understanding of the conditions under which the work will be performed. No allowances will be made for failure to make such examination.
D. During construction, verify the dimensions governing the mechanical work at the building. No extra compensation shall be claimed nor allowed because of differences between actual dimensions and those indicated on the drawings. Examine adjoining work on which mechanical work is dependent for perfect efficiency, and report any work of other trades which must be corrected. No waiver of responsibility for defective work shall be claimed nor allowed due to failure to report unfavorable conditions affecting the mechanical work.
1.6 ROUGH-IN
A. Verify final locations for rough-ins with field measurements and with the requirements of the actual equipment to be connected.
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-2
B. Refer to equipment specifications in Divisions 1 through 46 and the contract drawings for rough-in requirements.
1.7 MECHANICAL INSTALLATIONS
A. Coordinate mechanical equipment and materials installation with other building components.
B. Verify all dimensions by field measurements.
C. Arrange for chases, slots, and openings in other building components to allow for mechanical installations.
D. Coordinate the installation of required supporting devices and sleeves to be set in poured in place concrete and other structural components, as they are constructed.
E. Sequence, coordinate, and integrate installations of mechanical materials and equipment for efficient flow of the Work. Give particular attention to large equipment requiring positioning prior to closing-in the building.
F. Coordinate the cutting and patching of building components to accommodate installation of mechanical equipment and materials.
G. Where mounting heights are not detailed or dimensioned, install mechanical services and overhead equipment to provide the maximum headroom possible.
H. Install mechanical equipment to facilitate maintenance and repair or replacement of equipment components. As much as practical, connect equipment for ease of disconnecting, with minimum of interference with other installations.
I. Coordinate the installation of mechanical materials and equipment above ceilings with suspension system, light fixtures, and other installations.
J. Coordinate connection of mechanical systems with exterior underground and overhead utilities and services. Comply with requirements of governing regulations, franchised service companies, and controlling agencies. Provide required connection for each service.
1.8 ACCESSIBILITY
A. Install equipment and materials to provide required access for servicing and maintenance. Coordinate the final location of concealed equipment and devices requiring access with final location of required access panels and doors. Allow ample space for removal of all parts that require replacement or servicing.
B. Extend all grease fittings to an accessible location.
C. Establish required clearance to all installation features involving operation and maintenance. Respect manufacturer’s recommendations for access and clearance.
D. Access Doors - General:
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-3
All items of mechanical equipment which may require adjustment, maintenance, replacement or which control a system function shall be made readily accessible to personnel operating the building.
1. Provide access doors in all ductwork or plenums as required to maintain fire dampers, equipment, controls or other elements of the system. Doors shall conform to SMACNA standards unless otherwise detailed or specified.
2. Provide access doors in floors, walls, ceiling and partitions to valves, cleanouts, chases, dampers, etc., and to access doors in ductwork requiring the same. Access doors shall be all-steel construction equivalent to "Milcor" by Inland Ryerson in a style approved by the Owner's Representative. Doors shall be 24" x 24", or as needed, with screwdriver latches.
1.9 CHANGE ORDERS (See General Conditions)
1.10 ALTERNATIVE CONSTRUCTION/SUBSTITUTION:
A. These documents outline a way in which the Owner may be delivered a functional and reliable facility. Drawings and specifications describe reasonable engineering practice for the Contractor to follow.
B. Coordination between trades may result in periodic needs to adjust the installation from that indicated, but in no case shall the intended function be compromised.
C. The Contractor may perceive some work methods which differ from those specified which could save time and effort. These may be presented to the Engineer with a breakdown of possible cost savings for review. Implement only with authorization and in accordance with General Conditions.
D. Materials substitutions will generally be covered in a review process prior to bidding. After bidding, substitutions shall be proposed only on the basis of definitive cost accounting and implemented only with authorization and in accordance with General Conditions.
1.11 CUTTING AND PATCHING
A. Layout the project ahead of time, providing sleeves and blockouts and have work specifically formed, poured and framed to accommodate mechanical installations. Cut and patch only as needed.
B. CUTTING AND PATCHING:
Refer to the Division 1 Section for general requirements for cutting and patching.
C. Record Drawings:
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-4 During the course of construction, maintain a set of drawings, specifications, change orders, shop drawings, addenda, etc., for reference and upon which all deviations from the original layout are recorded. These marked-up documents shall be turned over to the Engineer at the conclusion of the work so that the original tracings can be revised. If the Contractor fails to mark up the prints, he shall reimburse the Engineer for time required to do so.
1.12 BASIC ELECTRICAL REQUIREMENTS:
A. Refer to Division 26 for requirements for cutting and patching electrical equipment, components, and materials.
B. Do not endanger or damage installed Work through procedures and processes of cutting and patching.
C. Arrange for repairs required to restore other and any work damaged as a result of mechanical installations.
D. No additional compensation will be authorized for cutting and patching Work that is necessitated by ill-timed, defective, or non-conforming installations.
E. Perform cutting, fitting, and patching of mechanical equipment and materials required to:
1.Uncover Work to provide for installation of ill-timed Work;
2.Remove and replace defective Work;
3.Remove and replace Work not conforming to requirements of the Contract Documents;
4.Remove samples of installed Work as specified for testing:
5.Install equipment and materials in existing structures.
F. Upon written instructions from the Engineer, uncover and restore Work to provide for Engineer observation of concealed Work.
G. Cut, remove and legally dispose of selected mechanical equipment, components, and materials as indicated, including, but not limited to removal of mechanical piping and other mechanical items made obsolete by the new Work.
H. Protect the structure, furnishings, finishes, and adjacent materials not indicated or scheduled to be removed.
I. Provide and maintain temporary partitions or dust barriers adequate to prevent the spread of dust and dirt to adjacent areas.
1.123 SUBMITTALS:
Submittal of shop drawings, product data, and samples will be accepted only from the Contractor to the Engineer. Data submitted from subcontractors and material suppliers directly
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-5 to the Engineer will not be processed. The Contractor shall document each transmittal and shall sign and stamp the submittal indicating that it has been reviewed and is in compliance with the criteria of the project, any exceptions being clearly noted.
A. Shop Drawings:
As soon as possible after the contract is awarded, submit to the Engineer, seven (7) copies of the descriptive literature covering all equipment and materials to be used in the installation of mechanical systems for this project. Written confirmation of acceptable review by the Owner's Representative shall be obtained before ordering, purchasing, acquiring or installing any such equipment or materials for the project.
The submittals shall be prepared in an orderly manner after the order of this specification, contained in a three-ring looseleaf binder(s) with identification tabs for each item or group of related items. Submitted literature shall clearly indicate performance, quality, utility requirements, dimensions of size, connection points and other information pertinent to effective review.
Equipment must fit into the available space with allowance for operation, maintenance, etc. The Contractor shall take full responsibility for space and utility requirements for equipment installed.
Factory-wired equipment shall include shop drawings of all internal wiring to be furnished with unit.
Review of the Engineer is for general conformance of the submitted equipment of the project specification; in no way does such approval relieve Contractor of his obligation to furnish equipment and materials that comply in detail to the specification, nor does it relieve the Contractor of his obligation to determine actual field dimensions and conditions which may affect his work.
1.134 OPERATION AND MAINTENANCE TRAINING
A. Instruction Of Owner's Personnel:
At a time prior to Owner making use of a device or system, and in general after testing and balance work for a building or major system is complete, prepare, schedule and conduct a series of training sessions for Owner's operating and supervisory personnel. Instructions shall cover each device and system with emphasis on understanding of the purpose and function, the maintenance requirements and the proper adjustment and operating technique.
B. Instruct building operating staff in operation and maintenance of mechanical systems utilizing Operation and Maintenance Manual when so doing.
C. Minimum instruction periods shall be as follows:
1. HVAC - four hours.
2. Temperature Control - four hours. Programming help as needed.
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-6 D. Initial instruction periods shall occur after pre-final observation when systems are properly working and before final payment is made. Subsequent visits scheduled with Owner throughout the first year.
E. None of these instructional periods shall overlap another.
F. Vendors for each piece of equipment controls, etc., shall participate along with the Contractor(s).
1.15 GUARANTEE/WARRANTY:
A. The following guarantee is a part of this specification and shall be binding on the part of the Contractor and his assigns:
"Contractor guarantees that this installation is in accordance with the terms of the Contract and is free from mechanical defects. He agrees to replace or repair, to the satisfaction of the Owner's Representative, any part of this installation which may fail or be determined unacceptable within a period of one (1) year after final acceptance. See also the General Conditions of these specifications. Failed equipment in the repair or replacement shall be guaranteed for one full year from the date of recommission.
B. Compile and assemble the warranties required by Divisions 22, 23, 26, 35, 40, 43, 44 and 46 into a separated set of vinyl covered, insert sheets, tabulated and indexed for each reference, included in the O & M Manual.
C. Provide complete warranty information for each item to include product or equipment to include data of beginning of warranty or bond; duration of warranty or bond; and names, addresses, and telephone numbers and procedures for filing a claim and obtaining warranty services.
D. Mechanical systems and equipment shall not be considered for substantial completion and initiation of warranty until they have performed in service continuously as specified in the Comissioning section.
1.146 TESTS AND CERTIFICATIONS:
Make all tests required by code or specification in the presence of a representative of the Owner, recorded and certified by the Contractor and Representative. Involve local authorities where required.
1.17 PERMITS, FEES, LICENSES:
Pay for all permits, fees and licenses required for the conduct of the specified work and be responsible for all criteria associated with the same. Comply with requirements for inspection, certifications, etc.
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-7 1.18 CEILING SPACE COORDINATION:
Carefully coordinate ceiling cavity space with all trades; however, installation of mechanical equipment within the ceiling cavity space allocation, in the event of conflict, shall be in the following order: plumbing waste lines; supply, return and exhaust ductwork; domestic hot and cold water; control conduit.
PART 2 - GENERAL MECHANICAL MATERIALS AND METHODS
2.1 QUALITY OF MATERIALS AND EQUIPMENT
A. All equipment and materials shall be new, and shall be the standard products of manufacturers regularly engaged in the production of piping, plumbing, heating, ventilating and air conditioning equipment, and shall be the manufacturer's latest design. Specific equipment shown in schedules on drawings and specified herein is to be the basis for the Contractor's bid. Provisions for substitute equipment are outlined in the General Conditions. All materials shall be produced by manufacturing plants located in the United States of America.
B. Furnish and install all major items of equipment specified in the equipment schedules on the drawings complete with all accessories normally supplied with catalog items listed, and all other accessories necessary for a complete and satisfactory installation.
2.2 PROTECTION OF MATERIALS AND EQUIPMENT
A. Close pipe and duct openings with caps or plugs to prevent lodgement of dirt or trash during the course of installation. Cover equipment tightly and protect against dirt, water and chemical or mechanical injury. Plumbing fixtures intended for the final installation shall not be used by the construction forces. At the completion of the work, clean fixtures, equipment and materials and polish thoroughly and deliver in a factory dock condition for the Owner's acceptance. Make damage and defects developing before acceptance of the work good at Contractor's expense.
B. Do not make temporary use of project equipment during construction without the consent of the Owner. Such use often represents a substantial percentage of the life expectancy of the device or system. DO NOT USE SYSTEM FOR TEMPORARY HEAT!!
2.3 QUALIFICATIONS OF WORKMEN
A. All mechanics shall be capable journeymen, skilled in the work assigned to them. Apprentices may be used with appropriate direction.
B. Employ no unskilled persons in the work which he is given to do; execute all work in a skillful and workmanlike manner. All persons employed upon this work shall be competent, faithful, orderly and satisfactory to the Owner. Should the Owner's Representative deem anyone employed on the work incompetent or unfit for his duties, and so certify, Contractor shall dismiss him and he shall not be again employed upon the work without permission of the Owner's Representative.
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-8 C. All welders involved in welding of pressure piping systems shall be certified in accordance with Section IX of the ASME Boiler and Pressure Vessel Code. Written verification of successful test completion shall be submitted to Engineer prior to initiating work.
2.4 FOREMAN:
Designate a general mechanical foreman to the Owner's Representative to be consistently available on site for consultation. Do not replace this individual without prior approval from the Owner's Representative.
2.5 USE OF COMMON VENDORS:
Regardless of subcontract delegations, coordinate purchasing between trades so that equipment and materials of similar nature come from a single vendor, i.e., all package HVAC units shall be common source. Base mounted pumps, valves, etc., the same. Do not burden the Owner with multiple brands of similar equipment unless so directed.
2.6 ROOF/WALL/FLOOR PENETRATIONS - FLASHINGS
A. Sleeves:
1. Sleeves through the floor into dry rooms shall be flush with the floor, caulked and sealed.
2. Sleeves through the floor into wet rooms shall be 2" above the floor, caulked and sealed.
3. Wet rooms shall include any room with the possibility of wetness, including any wash down areas.
B. Pipe sleeves shall allow for movement of the pipe due to expansion and contraction, yet to include seismic restraint.
C. Refer to Section for fire stopping requirements.
D. Flashings:
1. Flash all pipes and ducts penetrating the roof. Vent pipes terminating within 24" of the roof shall have a seamless flashing of 6-pound lead clamped to the pipe, and with a flashing shield extended horizontally not less than 12" all around. For single ply membrane roof, follow manufacturer's directions, provide required flashing components.
2. For built-up and gravel roof, clamp roof drains to a 6-pound lead flashing extending 18" all around. For single ply membrane roof, follow manufacturer's directions.
3. Other piping penetrating the roof shall be flashed and counterflashed. See drawings or Engineer for additional detail.
4. Make all ductwork penetrating the roof watertight with flashings, counterflashing and sealant. Provide curbs for all such openings.
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-9 2.7 EXCAVATING AND BACKFILLING (GENERAL)
A. Provide all excavation, trenching and backfilling for Divisions 22, 23, and 46 underground piping work. Excavation and backfilling shall comply with applicable paragraphs of Division 31. Tamp bottoms of trenches hard and, for soil and waste piping, grade to secure uniform fall of 1/4" per foot, or as noted. Excavate bell holes for hub and spigot pipes so that pipe rests on solid ground for its entire length. Lay sewer and water pipe in separate trenches, except where otherwise noted, as detailed.
B. After work has been tested, inspected and approved by the Owner's Representative and/or State/Local Inspector, and prior to backfilling, clean the excavation of all rubbish, and clean backfill materials free of trash. Backfill shall be placed in horizontal layers not exceeding 12" in thickness, properly moistened. Mechanically compact each layer with suitable equipment to a dry density of not less than 95 percent as determined by the Modified AASHO Test T-18O. See Division 31 for additional requirements.
1. Provide adequate shoring to safeguard workers from cave-ins for all excavations.
2. In areas where General Contractor has finish grade work to do, Mechanical Contractor shall backfill and compact to 8" below finish grade. Where no finish surface work is to be done, Mechanical Contractor shall backfill and compact to and match adjacent undisturbed surface with allowance for settling, etc.
3. Protect from damage all existing underground utilities indicated on the contract drawings (or field located for the Contractor by the Owner prior to excavation operations). Any damage to identified existing utilities shall be repaired by the Contractor.
2.8 HANGERS AND SUPPORTS (GENERAL)
A. Provide hangers and/or supports for all equipment, piping and ductwork. Primary information is contained in these specifications and on the drawings.
B. Provide hangers and supports to correlate with seismic restraint and vibration isolation.
2.9 MANUFACTURER'S DIRECTIONS:
Install all equipment in strict accordance with all directions and recommendations furnished by the manufacturer. Where such directions are in conflict with the plans and specifications, report such conflicts to the Engineer, who shall direct adjustments as he deems necessary and desirable.
2.10 LUBRICATION:
Lubricate equipment at startup. Then, provide all lubricants for the operation of all equipment until acceptance by the Owner. The Contractor is held responsible for all damage to bearings while the equipment is being operated by him.
2.11 ELECTRICAL WIRING AND CONTROL:
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-10
A. Motor starters, related motor starter equipment and power wiring indicated on the electrical drawings and control diagrams shall be furnished and installed under Division 26 and 27. Items of electrical control equipment specifically mentioned to be furnished by Divisions 22, 23, 35, and 46 either in these specifications or on the electrical or mechanical drawings, shall be furnished and mounted by this Contractor and shall be connected under and as required by the respected Divisions and Specifications.
B. Refer to the control equipment and wiring shown on the diagrams. Any changes or additions required by specific equipment furnished shall be the complete responsibility of the contractor.
C. Divisions 22, 23, 35, and 46 must be fully coordinated with Division 26 to insure that all required components of the work are included and fully understood. No additional cost shall accrue to the Owner as a result of lack of coordination.
D. Where the detailed electrical work is not shown on the electrical drawings, the Mechanical Contractor shall furnish, install and wire or have prewired all specified and necessary controls for package equipment and other equipment specified for this project. The objective of this paragraph is to make sure a complete operating system is obtained at no additional cost to the Owner for field wiring required related to the equipment.
2.12 FLUSHING AND DRAINING OF SYSTEMS/CLEANING OF PIPING AND DUCTS:
Fill, clean and flush and sterilize where appropriate, all water piping systems with water and drain these systems before they are placed in operation. Blow out all other piping systems with compressed air or nitrogen to remove foreign materials that may have been left or deposited in the piping system during its erection. Duct systems shall have all debris removed and fans shall be run to blow out all dust and foreign matter before grilles or outlets are installed and connected.
2.13 JOBSITE CLEANUP
A. Keep site clean during progress of work.
B. At the conclusion of work, clean all installation thoroughly.
1. Equipment shall be kept clean and in a new condition, free from damage or wear. The Contractor shall correct any damage and touch up or repaint if necessary at his own expense.
2. Remove all debris from site.
END OF SECTION 460100
WRCRWA GENERAL MECHANICAL REQUIREMENTS PLANT EXPANSION PROJECT 460100-11 SECTION 461000 – PRIMARY CLARIFIER EQUIPMENT
PART 1 – GENERAL
1.1 DESCRIPTION
A. The Contractor shall furnish and install two (2) circular spiral scraper cage drive clarifiers. The equipment shall include a center drive unit and torque control, platform, stationary center influent column, dual gate energy dissipating inlet (DG-EDI), center feedwell, rotating drive cage, rake arms with spiral blades, anchor bolts, scum skimmers, scum box, effluent weir, scum baffle, and all other appurtenances required or shown on the drawings.
B. An aluminum cover, not supplied by the clarifier manufacturer, shall be installed above the clarifier mechanism. The cover will not be supported off of the center column of the clarifier. It is the responsibility of the Contractor to ensure that the clarifier manufacturer coordinates with the cover manufacturer to ensure a complete and operable system.
C. All the equipment specified under this Section shall be furnished by a single, reputable Manufacturer who meets the experience requirement, as specified in herein.
1.2 SUBMITTALS
A. Submit for review the following:
1. Certified general arrangement drawings showing all important details and materials of construction, dimensions, loads on supporting structures and anchorage location. 2. Descriptive literature, bulletins, and/or catalogs of the equipment. 3. Complete data on motors and speed reducers. 4. Electrical schematics for all control equipment to be furnished. 5. Calculations documenting the AGMA rating of the drive unit and life of the main bearing, prepared and signed by a registered professional engineer. 6. Complete descriptive information and electrical schematic for torque overload device. 7. Complete sludge transport calculations substantiating the rake blade design, rake tip speed, and floor slope. 8. Complete process calculations substantiating the sizing of the center column and ports, EDI and outlets, and outer feedwell. These calculations shall be based on parameters from the manufacturers operating experience. These parameters shall be verified by data presented from successful operating installations. Side by side comparison testing of EDI and feedwell design from existing operating clarifiers that have spiral rake blades and are products of the manufacturer shall be presented with the calculations. 9. The submittal shall include data from a minimum of five (5) successfully operating installations that verify the experience of the manufacturer. Data shall include performance verification of influent flow rate (Q), hydraulic loading (OFR), effluent suspended solids (ESS), return sludge solids concentration (RSS), return activated sludge flow rate (RAS) for secondary clarifiers, and waste sludge flow rate (WAS).
WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 1
1.3 DESIGN CRITERIA
A. Clarifier design shall conform to the following:
1. Design Average Daily Flow: 7.0 MGD (Each) 2. Design Peak Flow: 17.5 MGD (Each) 3. Tank diameter (ft.): 95’-0” 4. Side water depth (ft.): 12’-6” 5. Freeboard (ft.): 2.5 6. Bottom slope (in./ft.): 1 7. Influent column outside diameter (in.): 36 8. Scum box width (ft.): 5 9. Motor HP: 1/2
1.4 QUALITY ASSURANCE
A. The equipment supplier shall have at least 15 years experience in the design, application, and supply of circular clarifiers in water or wastewater treatment plants, and shall submit a list of not less than 25 operating installations of clarifiers with spiral rake blades and EDI as evidence of meeting the experience requirement. This experience shall be evidenced by process performance data that is submitted showing actual data on a minimum of five existing installations that are operating successfully as required in the submittal section.
1.5 WARRANTY
A. Warranty: A written supplier’s warranty shall be provided for the equipment specified in this section. The warranty shall be for a minimum period of five (5) years from start-up or 66 months from time of equipment shipment, whichever comes first. Such warranty shall cover all defects or failures of materials or workmanship which occur as the result of normal operation and service except for normal wear parts (i.e. squeegees, skimmer wipers, etc.).
PART 2 – PRODUCTS
2.1 MANUFACTURER
A. The clarifier equipment shall be as manufactured by the following:
1. WesTech Engineering, Inc. (Basis-of-Design) 2. Ovivo Technologies 3. Or equal.
2.2 GENERAL DESIGN
A. Description: The clarifier mechanism shall be of the center drive type, supported on a stationary influent column, with the flow entering at the bottom of the influent column and flowing upward into the energy dissipating inlet. The flow shall then proceed into the feedwell through tangential gates near the water level for further energy dissipation and settling. The WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 2
clarifier shall be designed to remove settled sludge from the bottom of the tank and floating scum from around the periphery of the tank.
B. The clarifier shall perform the following integrated functions:
1. Dissipate energy and control localized currents. 2. Separate solids from the clear liquid. 3. Evenly withdraw the clear liquid. 4. Transport and thicken settled sludge. 5. Remove scum from the clarifier surface.
C. Materials: All structural steel shall conform to the requirements of ASTM A36. Steel pipe used for structural members shall conform to ASTM A53. Steel members in contact with liquids, either continuously or intermittently, shall have a minimum thickness of 1/4" unless otherwise noted. All aluminum shall be type 5052, 6061, 6063, or 2014 alloy unless noted.
D. Fabrication: Shop fabrication and welding of structural members shall be in accordance with the latest edition of the “Structural Welding Code”, AWS D1.1, of the American Welding Society. All welded connections shall develop the full strength of the connected elements and all joined or lapped surfaces shall be completely seal welded with a minimum 3/16" fillet weld. Intermittent welding shall not be allowed.
E. Edge Grinding: Sharp projections of cut or sheared edges of ferrous metals shall be ground to a radius by multiple passes of a power grinder as required to ensure satisfactory coating adhesion.
F. Shop Surface Preparation/Coating: All non-submerged and submerged steel shall receive a surface preparation per specification SSPC SP 8 and shall be hot dip galvanized. The drive unit shall be coated with the supplier’s standard priming and enamel paint system. All other non- steel metals shall be coated with manufacturer’s standard system.
G. Structural Design: The ratio of un-braced length to least radius of gyration (slenderness ratio) shall not exceed the values listed in the AISC manual. For angles, the radius of gyration shall be taken about the Z-Z axis. In addition, all structural members and connections shall be designed so that the unit stresses will not exceed AISC allowable stresses by more than one-third when subject to loading of the previously listed peak torque. All steel design shall be in accordance with the AISC Manual of Steel Construction, latest edition, and the California Building Code (CBC), latest edition.
2.3 DRIVE UNIT
A. Design Parameters: The drive unit shall be designed and manufactured by the clarifier equipment supplier to ensure unit responsibility. The drive unit shall be designed to produce and withstand the designed momentary average and peak torque. The drive main bearing shall be designed for the total rotating mechanism loads with a minimum L-10 life of 100 years or 876,000 hours. The drive main gear shall be designed to a minimum AGMA 6 rating when rated in accordance with the latest AGMA standard. Gear teeth shall be designed for proper load distribution and sharing. Stub tooth design and surface hardening of the main gear shall not be allowed.
WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 3
All spur gearing shall be designed to the latest AGMA spur gear standard for strength and surface durability, based on a life of 175,000 hours. The design running torque rating of the drive gearing shall be based on the smaller of the strength and durability values determined from the above AGMA standard. To ensure safety and ease of maintenance, all components of the drive shall be direct coupled.
No overhung pinions shall be allowed on the speed reducing unit. The lower pinion bearing shall not be located below the turntable base.
B. Physical Characteristics: The drive unit shall consist of a solid internal main spur gear, bearing turntable, pinion, secondary speed reducer, support base, and drive unit bearing. The drive shall be mounted on the center column and support the entire rotating load of the mechanism. The main internal gear shall be forged of alloy hardened steel. The pinion shall be heat treated alloy steel. All speed reducers shall be fully enclosed and running in oil or grease. Support base for the drive shall be of welded steel to assure rigidity. Cast iron main drive housings are not acceptable due to their potential for cracks and leakage. Lubricant and dust shields shall be provided. The drive bearing shall include a forged steel precision gear/bearing set, with fully contoured raceways hardened to a minimum 58-60 Rc and protected by a neoprene seal. Strip liners designed for periodic maintenance and replacement shall not be acceptable. The drive shall be designed so that the balls and nylon spacers can be replaced without removing the access walkway. The main gear to pinion gear mesh shall be run in an oil bath. An oil sight glass, fill pipe, and drain line shall be provided for the reservoir.
C. Overload Protection: An overload device shall be provided in a stainless steel, weatherproof enclosure. The device shall be actuated by torque generated from the main drive, which shall operate two independently adjustable switches (the alarm switch at 100 percent of design running torque and the motor cutout switch at 120 percent of design running torque). Devices that require the worm to float and measure the thrust of the worm gear shall not be acceptable. These two switches shall be factory adjusted to accurately calibrate the alarm torque value and the overload position. A visual torque indicator shall be provided and oriented so that it may be read from the walkway. It shall be calibrated from 0 to 160 percent of design running torque.
D. Turntable: The turntable base shall have an annular bearing raceway upon which the rotating assembly rests. It shall have a maximum allowable deflection in accordance with the bearing specifications. The allowable modulus of elasticity shall be a minimum of 29 x 106 psi. The center cage shall be fastened to and supported from the gear casing. Ball bearings shall be of high carbon chrome alloy 52100 steel running in fully contoured races, as part of a precision gear/bearing set. The balls shall be grease lubricated and protected by elastomer seals. Felt seals that allow the entrance of moisture from outside the drive (i.e. rain water, condensate, etc.) will not be allowed.
E. Speed Reducing Unit: The speed reducing unit shall consist of cycloidal speed reducers directly connected to a motor without the use of chains or v-belts, and shall be keyed to the pinion.
The main ring gear of cycloidal drives shall be made of high carbon chromium bearing steel and be fixed to the drive casing. An eccentric bearing on the high speed shaft shall roll cycloidal discs of the same material around the internal circumference of this main ring gear. The lobes of the cycloid disc shall engage successively with pins in the fixed ring gear. The movement of the cycloid discs shall be transmitted then by pins to the low speed shaft. Speed reducer efficiency shall be a minimum of 92.5% per reduction stage.
WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 4
The speed reducer shall have a minimum service factor of 1.33 based on the output torque rating of the drive. The speed reducer shall be capable of withstanding a 500% shock load.
The reducers shall be fitted with radial and thrust bearings of proper size for all mechanism loads and are grease lubricated. As a safety feature, the speed reducer shall be back drive able to release any stored energy as the result of an over torque condition.
F. Motor: The motor shall be a squirrel cage, induction type, TEFC, ball bearing heavy duty unit of ample power for starting and operating the mechanism without overload, with a minimum service factor of 1.15.
Power supply to the equipment shall be 240/480 volt, 60 hertz, 3 phase.
2.4 PLATFORM
A. Center Drive Platform: A center drive platform shall be provided. It shall consist of ¼” aluminum checkered plate with necessary stiffeners and supports, resting on the drive unit and center column. The platform shall be provided with a smooth outer surface to accommodate the seal supplied by the cover manufacturer.
2.5 INFLUENT AND SLUDGE REMOVAL
A. Stationary Center Influent Column: A stationary cylindrical steel influent column of 1/4" minimum wall thickness shall be provided. One end shall have a support flange for bolting to the tank floor over the influent line, with a similar flange at the top for supporting the drive unit and walkway. The structure and anchor bolts shall provide adequate support for the entire mechanism dead load plus live loads and torque with an adequate factor of safety to eliminate excessive deflection or vibration. Suitable openings shall be provided in the upper portion of the column to allow unrestricted passage of the flow into the energy dissipating inlet.
Prior to the center column being grouted in place, the drive unit shall be installed, positioned, and leveled.
B. Dual Gate Energy Dissipating Inlet (DG-EDI): A rotating circular energy dissipating inlet with bottom shall be supported by the cage and be designed to diffuse the liquid into the flocculation well without excessive disturbance or formation of vertical velocity currents. The DG-EDI shall be designed to positively prevent sludge from depositing within the EDI and shall include bottom drain holes.
Complete process calculations shall be included with the submittal substantiating the sizing of the DG-EDI and outlets, and outer feedwell. The diameter, depth, and detention time of the DG- EDI shall be included with the design calculations, and shall show proper process application as evidenced by the required successful operating installations. These parameters shall be verified by data presented from successful operating installations. Data from side by side comparison testing of the DG-EDI and feedwell design from existing operating clarifiers that are products of the manufacturer shall be presented with the calculations.
The submittal shall include data from a minimum of two (2) successfully operating installations that verify the experience of the manufacturer.
WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 5
The rotating DG-EDI shall be designed with a full bottom extending to within 1" of the center column. It shall include an upper rim angle for stiffness. Multiple dual diffuser gate assemblies shall be provided to gently mix and diffuse influent flow between the DG-EDI and flocculation well and specifically preclude any vertical currents. The outlet assemblies shall include baffled openings with dual fully adjustable gates designed to cause incoming flow to impinge upon itself. The gates shall extend past the outlet openings at least the same distance as the opening width. The outlet assemblies shall have a fixed bottom to prevent vertical currents as the flow exits the DG-EDI.
The EDI shall be made of not less than 3/16" thick steel plate with necessary stiffening angles. All gate adjustment hardware, including hinges, pins, and chains, shall be type 304 stainless steel.
The configuration and operation of the Dual Gate EDI as employed in these specifications are covered under U.S. Patent and Trademark Office Number 6800209. The owner will require proof of a fully paid license to operate the Dual Gate EDI within 90 days of award of the prime contract. WesTech Engineering of Salt Lake City, Utah is the exclusive licensee of the patents with rights to sub-license. The clarifier manufacturer shall include the Patent License fee in their bid.
C. High performance EDIs of differing design of equal performance to that of the EDI listed above shall be considered. The burden of proof of equal performance shall be the responsibility of the supplier.
D. Feedwell: The flocculating feedwell shall be located outside of the EDI to diffuse the liquid into the tank without disturbance or formation of velocity currents. Baffled openings shall be provided near the water surface to allow scum to exit the feedwell.
The supports for the feedwell shall be located either above the liquid extending from the cage or bridge, or on the rake arms. Submerged supports from the rake arms shall be designed so as to minimize horizontal flow disruption.
No feedwell support or feedwell spliced connection shall be contained within the annular space formed between the feedwell and EDI. The depth of the feedwell shall be such as to provide proper detention time and an exit velocity at maximum flow that will not scour the settled sludge. The diameter, depth, detention time, and exit velocities shall match the process application calculations as evidenced by the required successful operating installations.
The feedwell shall be made of not less than 3/16" thick steel plate with necessary stiffening angles.
E. Center Cage: The center cage shall be of steel box truss construction. It shall be provided with connections for the two sludge rake arms and feedwell supports if required. The cage top shall be bolted to the main gear which shall rotate the cage with the attached arms and feedwell. The cage and each arm shall be designed to withstand 150 percent of the design running torque of the drive without over stressing the members. Loading to develop the torque shall be considered as uniform loads applied to each arm individually.
F. Sludge Rake Arms: The mechanism shall include two long sludge rake arms of steel truss construction with spiral-shaped steel scraper blades and adjustable stainless steel squeegees. Squeegees shall be fastened to the rake blades with stainless steel fasteners. WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 6
Scraper blades shall be designed for sufficient sludge transport capacity to handle the design solids loading rate, with the depth of the blade varying from a minimum at the tank periphery to a maximum at the tank center.
Blades shall properly convey settled sludge to the sludge hopper. Blades which move sludge away from the center column to the sludge hopper shall also be provided.
The arms shall be adjustable at the cage to assure an even grout thickness over the tank bottom.
The rake speed shall be sufficient to transport the necessary volume of sludge to the sludge outlet, but shall not re-suspend settled sludge.
2.6 SCUM REMOVAL
A. General: The clarifier manufacturer shall furnish two (2) skimming devices as part of each clarifier mechanism. Each skimming mechanism shall be arranged to sweep the surface of the sedimentation compartment, automatically removing scum and floating material to a scum box at the periphery of the tank.
B. Skimmer Construction: The rotating scum skimmer shall include a horizontal steel plate skimmer blade supported by vertical steel members extending up from the rake arms. The blade shall extend tangentially from a point 6" away from the influent feedwell to the hinged scum skimmer assembly at the tank periphery.
C. Scum Skimmer Assembly: A hinged scum skimmer assembly shall be mounted on the outer end of the skimmer blade. The hinged scum skimmer assembly shall be designed to form a pocket for trapping the scum. The hinged arrangement shall insure continual contact and proper alignment between wiper blade, scum baffle, and ramp as the blade travels up the scum box ramp. The wiper blade shall have a wearing strip on its outer end, which contacts the scum baffle and a neoprene strip on its lower and inner edge. The neoprene wipers shall be a minimum 1/4" thickness. The scum is trapped as the wiper blade meets the ramp and is raised up the ramp to be deposited into the scum trough for disposal.
D. Scum Box: The scum box shall be of the size specified, supported from the tank wall and connected to the scum withdrawal piping. It shall be made of 1/4" thick welded steel plate. The box shall have a scum trough, vertical steel sides, and a sloping approach ramp that extends from 1-1/2" above water level to 5-1/2" below. A similar ramp shall be provided at the opposite end to allow the skimmer blade to lower back to the operating position. A flexible connector shall be provided for connection to the contractor supplied scum withdrawal piping in the tank wall.
E. Scum Flushing Valve: A valve shall be attached to the scum box which automatically opens and allows clarified liquid into the scum box to flush out solids. The valve shall actuate at every pass of the scum skimmer over the scum box, allowing sufficient delay after deposit of the solids before flushing begins. Delay and flush duration shall be adjustable. The valve shall be constructed of oil impregnated UHMW-PE disks with stainless steel rods and stainless steel hardware. The opening and closing of the scum flushing valve shall be one smooth continuous movement. The valve shall provide 2 to 5 gallons of flush water per each pass of the skimmer assembly.
WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 7
F. Scum Baffle: The baffle shall consist of 1/4" thick x 12" deep fiberglass sections. The baffle sections shall be curved and fastened to the launder wall with adjustable FRP support brackets, stainless steel fasteners, and anchor bolts.
2.7 EFFLUENT REMOVAL
A. Launder: A rectangular effluent launder shall be provided around the perimeter of the tank. The launder shall be formed as part of the concrete wall. A drop-out box shall be provided in the bottom of the launder at one point for collection and discharge of the clarified effluent.
B. Weir: An adjustable weir shall be provided around the periphery of the tank at the water surface for removal of clarified effluent.
The weir shall consist of 1/4" thick x 9" deep fiberglass sections with 2-1/2” deep 90 degree v-notches at 6” intervals. The weir sections shall be curved and fastened to the launder wall with special large washers, anchor bolts, and hex nuts to allow vertical adjustment.
2.8 ELECTRICAL
A. The equipment supplier shall furnish all electrical items specifically called for in this specification section. The contractor shall supply and install all other electrical items required to place the equipment into service.
The contractor shall supply and install all field wiring required including but not limited to proper size wire, conduit, fittings, and supports.
2.9 ANCHORAGE AND FASTENERS
A. Anchor Bolts: All anchor bolts shall be a minimum of 1/2” diameter and made of type 304 stainless steel. The equipment supplier shall furnish all anchor bolts, nuts, and washers required for the equipment. The supplier shall provide all anchor bolt calculations, signed and sealed by a professional engineer registered in the State of California.
B. Fasteners: All structural fasteners shall be a minimum of 1/2” diameter and made of type 304 stainless steel. The equipment supplier shall furnish all fasteners required for the assembly of the equipment.
PART 3 - EXECUTION
3.1 SITE STORAGE AND HANDLING OF EQUIPMENT
A. The Contractor shall store the supplied equipment in accordance with the manufacturer’s recommendations and instructions. Gear reducers and motors shall be stored in buildings or trailers which have concrete or wooden floor, a roof and fully enclosed walls, and will protect the equipment from dust, dirt, and moisture. Equipment provided with space heaters shall be connected to a temporary power source to provide continuous operation of the heaters until the site is ready for installation. Rotate all shafts with bearings on a monthly basis. The Contractor WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 8
shall be responsible for work, equipment, and materials until inspected, tested and finally accepted.
3.2 INSTALLATION
A. The equipment shall be installed properly to provide a complete working system. Installation shall follow the supplier’s recommendations.
B. The floor of the clarifier shall use a sweep-in grout, in accordance with the manufacturer’s recommendations.
C. Shop Assembly and Inspection: The equipment specified herein shall be factory assembled as far as practical to verify that all mating parts can be field assembled. All mating parts shall be trial fit and match-marked. The manufacturer shall submit certification of shop trial assembly and photographs of assembly before shipment. The customer and installing contractor shall be given the opportunity to witness the shop assembly.
D. Shop inspection shall be performed by a qualified inspector and certified by the manufacturer. The inspection shall be documented and all deficiencies noted, corrected, re-inspected and final completion formally authorized. Final shipment authorization shall be by the manufacturer to ensure completion of all fabrication, assembly, and inspection requirements. Inspection records and evidence of inspector qualification shall be submitted to the owner upon request.
E. Field Service: The equipment supplier shall provide the service of a qualified representative for two trip(s) and two day(s) to inspect the mechanism installation, lubrication, torque test, assist in start-up, and instruct plant personnel in the proper operation and maintenance of the mechanism.
F. Field Testing:
1. Torque Tests: The entire sludge collector mechanism shall be statically load tested by individually loading each rake arm with 150 percent of the specified design running torque. The test shall verify the torque overload control device settings for alarm and motor cutout. Each arm shall be individually anchored and the load measured to demonstrate the rake arms, cages, and drive unites ability to withstand the specified torque. Sketches and calculations shall be submitted illustrating how the torque will be applied prior to the test taking place.
G. Operation Tests: The mechanism shall be operated in a dry tank for a minimum of 4 continuous hours before flow is allowed to enter the system. There shall be no binding, jerky, or unusual motion exhibited during this run in period. Motor amperage shall be checked at least hourly for any unusual or higher than normal figures. After the unit has successfully passed this initial test, flow shall be introduced into the tank and the same 4 hour observation test run. If the unit should fail under any of these conditions, the test shall be halted and the problem corrected. If, after several attempts, the unit does not successfully pass the field test, the faulty portion of the equipment shall be repaired or replaced and the test re-run.
END OF SECTION 461000
WRCRWA PRIMARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461000 - 9
SECTION 461100-SECONDARY CLARIFIER EQUIPMENT
PART 1 - GENERAL
1.1 DESCRIPTION
A. There shall be furnished one (1) clarifier mechanism, each suitable for installation in a concrete basin as shown on the contract drawings.
B. Each mechanism shall be a center column supported center feed unit with peripheral effluent collection. A center drive mechanism shall be provided for rotation of the two rake arms with spiral type rake blades.
C. The equipment shall be designed to effectively settle mixed liquor suspended solids and scrape the settled solids from the basin floor to the sludge withdrawal drum as shown on the drawings. The clarified effluent shall be collected uniformly by the peripheral launder. Surface scum shall be collected by the scum skimming equipment and discharged through the scum withdrawal pipe.
D. The equipment furnished for each clarifier mechanism shall include but not be limited to: walkway with handrails, center drive assembly, center drive platform, center support column with inlet openings, flocculating feedwell, inner dispersion inlet well (EDI), center cage, sludge collection arms with spiral rake blades, rotating sludge collection drum, surface scum skimming equipment, effluent weir plates and scum baffle, peripheral density wall baffles, anchor bolts and assembly fasteners.
E. Except where specifically indicated otherwise, all plates and structural members designated for submerged service shall have a minimum thickness of 1/4 inch. All structural steel will conform to ASTM A-36 requirements and steel plate will conform to ASTM A283C requirements. All anchor bolts used to secure the mechanism to the tank shall be stainless steel. All fasteners shall be stainless steel. Handrail, skimmer, and rake blade squeegee fasteners shall be stainless steel.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Section 033000 Ð Cast-in-Place Concrete
B. Section 051400 Ð Structural Aluminum
C. Section 055100 Ð Metal Stairs
D. Section 055213 Ð Pipe and Tube Railings
E. Section 055300 Ð Metal Gratings
F. Section 098000 Ð Protective Coatings
G. Section 260000 Ð General Electrical Requirements
H. Section 409000 Ð Instrumentation Control for Process Systems WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 1
1.3 PROCESS REQUIREMENTS
A. The equipment shall be designed according to the following process requirements:
1. Design average flow 4.67 MGD 2. Design Peak flow 11.67 MGD 3. Design average recycle flow 4.67 MGD 4. Design maximum recycle flow 4.67 MGD 5. Design average loading rate 352 GPD/sqft 6. Drive continuous torque 30,000 ft-lb @ 0.023 rpm 7. Drive 100% design torque 70,000 ft-lb 8. Drive momentary peak torque 96,976 ft-lb 9. Mechanism rotation Clockwise 10. Rake arm tip speed, 8-12 ft/min
1.4 DESIGN REQUIREMENTS
A. The following design requirements shall be met:
1. Basin diameter 130'-0" 2. Side water depth 16'-0" 3. Tank freeboard 24" minimum 4. Floor slope 1:12 5. Center column diameter 36 6. Feedwell diameter 32’-0” 7. Feedwell submerged depth 5’-0” 8. Energy dissipating inlet (EDI) diameter 10’ 9. EDI submerged depth 42” 10. Number of baffled EDI openings Multiple vanes 11. Cage minimum size 4’-0” square 12. Rake arm minimum size 4’-0” square 13. Spiral blade height at tank wall 10" 14. Spiral blade height near tank center 30" 15. Rotating sludge drum diameter 9’-6” 16. Scum box width 10’-0”
1.5 FIELD SERVICE REQUIREMENTS
A. Number of eight-hour days 2
B. Number of trips to jobsite 2
1.6 REFERENCES
A. American Society of Testing Materials (ASTM):
1. A-36 Structural Steel Specifications 2. 304 Bolt Specifications 3. A-123 Hot-Dip Galvanized Coatings
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 2
4. A-153 Hot-Dip Galvanized Bolts 5. A-48 Cast Iron Specifications 6. A-536 Ductile Iron Specifications 7. A-283C Steel Plate Specifications
B. American Iron and Steel Institute (AISI), Heat Treated Steel Specifications
C. American Gear Manufacturers' Association (AGMA), Gear Ratings
D. American Welding Society (AWS), Current Standards
E. Anti-friction Bearing Manufacturers' Association (AFBMA), Bearing Life Specifications
F. National Electrical Manufacturer's Association (NEMA), Motor Design Standards and Standards for Control Enclosures
1.7 QUALITY ASSURANCE
A. The clarifier equipment manufacturer shall modify his standard equipment to meet the minimum values specified for dimensions, design, and the intent of this specification.
B. The clarifier equipment shall be as manufactured by:
1. Ovivo C4D Secondary Clarifier (Basis-of-Design) 2. WesTech Inc. 3. Or equal
C. Manufacturers regularly engaged in the manufacture of the clarifier equipment as specified herein and who can demonstrate equipment of this specified design, in actual service for a period of not less than 5 years will be considered as acceptable manufacturers.
D. Manufacturers shall show evidence of quality assurance in manufacturing and supplying equipment essential in details to the equipment herein specified.
E. The equipment supplier shall have at least 15 years’ experience in the design, application, and supply of circular clarifiers in water or wastewater treatment plants, and shall submit a list of not less than 25 operating installations of clarifiers with spiral rake blades and EDI as evidence of meeting the experience requirement. This experience shall be evidenced by process performance data that is submitted showing actual data on a minimum of five existing installations that are operating successfully as required in the submittal section.
1.8 CONTRACTOR'S SUBMITTALS
A. The contractor shall submit complete shop drawings of all equipment furnished for this project as covered by these specifications. The contractor's submittal must include a certification that the submitted material describes exactly the equipment to be provided. Substitutions of equipment subsequent to submittal approval will not be accepted.
B. The clarifier equipment manufacturer shall furnish as a minimum the following design and description information to establish compliance with these specifications: WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 3
1. Certified general arrangement and tank dimensional drawings. 2. Structural calculations including anchoring calculations stamped by a Registered Professional Engineer. 3. Certificate of design stamped by a Registered Professional Engineer stating that the equipment to be provided for this project meets or exceeds all design requirements of these specifications. The certificate shall state the respective loads and design criteria. 4. Drive mechanism rating calculations, stamped by a Registered Professional Engineer, verifying the compliance of the drive gears and bearings with the specified continuous torque rating and bearing life rating. 5. Calculations to demonstrate that the scraper design has adequate capacity to transport the maximum day sludge loadings per Section 1.03. 6. Motor data and catalog information. Electrical drawings are as applicable to the supply of the clarifier equipment manufacturer. 7. Catalog cut sheets for purchased sub-components.
1.9 OPERATION AND MAINTENANCE MANUALS
A. Operation and maintenance manuals will be provided by the clarifier manufacturer at least two weeks prior to shipment of all major equipment components. Each manual shall be a bound, indexed binder with drawings and parts lists prepared specifically for this project rather than general instructions that are not designed for this project.
B. As a minimum the manual shall contain:
1. Certified drawings (general arrangement and general arrangement detail drawings). 2. Erection drawings. 3. A complete bill of materials for the equipment including the weights of all structural steel components. 4. Installation and maintenance instructions for the specific equipment including the erection sequence, maintenance and trouble-shooting check points, and complete lubrication procedures with recommended grades of lubricants. 5. Cut sheets for all equipment items purchased from sub-vendors. 6. A list of the clarifier manufacturer's recommended spare parts specifically denoting wear items, long delivery items, and all items convenient for stocking as optional replacement items.
1.10 DELIVERY
A. Fabricated assemblies shall be shipped in the largest sections permitted by carrier regulations, properly match marked for ease of field erection.
B. All components shall be erected immediately upon receipt from the clarifier manufacturer or stored in strict conformance with storage recommendations provided by the clarifier manufacturer in the operations and maintenance manual.
C. The mechanism shall be lubricated in strict accordance with the instructions of the clarifier manufacturer's field service representative. The required lubricants shall be provided by the contractor.
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 4
PART 2 - PRODUCTS
2.1 GENERAL
A. Each clarifier mechanism shall be of the center drive type, supported on a stationary influent column, with the flow entering at the bottom of the influent column and flowing upward to the inlet openings and dispersed into the tank through the EDI and flocculating feedwell. The clarifier shall be designed to remove sludge uniformly from the bottom of the tank.
2.2 CENTER DRIVE ASSEMBLY
A. The center drive assembly shall consist of an integral motor and primary speed reducer coupled through roller chain and sprockets to a secondary worm/worm gear reducer driving the main gear through a pinion and shall have an integral overload protection system.
B. All gears and bearings shall be oil bath lubricated with the main bearing totally submerged in oil and the teeth of the main spur gear submerged at least 70 per cent in the oil bath. Oil pumps for lubrication or grease lubricated bearings are not considered appropriate for this application and will not be allowed. The oil reservoir for the main bearing and gear shall have a section of minimum depth 5 inches below the main bearing to positively prevent contamination of the main bearing and gears with condensate or other contaminants. Gear and bearing housings must also be fitted with oil level sight glasses and condensate drains. Condensate must be allowed to drain from a low point of the housing. Condensate and contaminants will not be allowed to drain through the lower pinion bearing. Oil pump or grease for lubrication is not considered appropriate for this application and shall not be allowed.
C. Drive components will be located via a machined, registered fit to preserve the alignment of key drive components under all load conditions. Inspection of the completed drive unit shall be accomplished at the clarifier manufacturer's shop, with reports of all tests and certifications of material hardness being made available for review at the Engineer's request prior to shipment to the job site.
D. Major drive components, main gears and bearings must be designed to allow for separate and individual replacement by plant personnel to facilitate quick and economical repairs.
E. The complete center drive assembly, including the overload protection device, shall be a regularly manufactured in-house product of the clarifier manufacturer. The center drive assembly is a key element in a successful clarifier installation, therefore drive assemblies purchased from third party vendors will not be accepted.
F. The drive motor shall be minimum 3/4 horsepower and shall be totally enclosed, fan cooled, with a 1.15 service factor, and have bearings with a minimum B10 rating of 50,000 hours. Operating electric current will be 230/460 volt, 3 phase, and 60 hertz. Each motor will be NEMA Design B employing Class F insulation designed for an ambient temperature of 40 degree. C.
G. The gearmotor primary speed reducer shall drive a secondary worm gear reducer through a #60 roller chain and steel sprockets enclosed in a galvanized 22 gauge steel guard. A constant speed motor shall drive the speed reducer. Sprockets and chain shall be designed for the connected
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 5
horsepower of the drive with a minimum service factor of 4.0. Provision shall be made for adjustment of chain tension.
H. The main drive unit shall consist of a worm gear secondary reduction unit, pinion and main spur gear assembly. The secondary reducer shall be a worm/worm gear reducer specifically designed for this application. The worm gear shall be centrifugally cast high strength manganese bronze. The worm shall be hardened alloy steel. A single piece pinion shall be keyed to the worm gear to transmit power from the worm gear to the spur gear. In order to maintain proper alignment between the pinion and the spur gear, the pinion will be supported by bearings both above and below the spur gear. The bearings shall be fitted into precision machined bearing pilots to positively insure bearing and gear alignment.
I. The main spur gear material shall be cast iron per ASTM A536 grade 100-70-03 or equal. The main gear shall be made of a solid piece. Split gear design is not acceptable due to potential misalignment of the mating parts and higher deflection under heavy loads. If a split gear design is used, the manufacturer shall provide a spare pinion to compensate the shorter life of the pinion due to excessive wearing. The solid gear shall have a nominal pitch diameter of 40 inches with a 6 inch face width or the equivalent nominal spur gear surface area of 754 square inches. Spur gear surface area is defined as the spur gear pitch diameter multiplied by the spur gear face width multiplied by 3.14.
J. The main gear shall rotate and be supported on a ball bearing assembly provided with four replaceable liner strips fitted into the main gear and turntable base. Liner strips shall be special vacuum degassed carbon corrected alloy steel hardened to a Rockwell hardness of at least 43 to 46 RC. The turntable base shall be a minimum 1 inch thick to insure adequate structural rigidity to properly support the drive bearing and gear.
K. The main gear and bearing shall be completely enclosed in an ASTM A-48 Class 40A cast iron housing provided with neoprene dust seals. In order to ensure the maximum possible base rigidity and vibration dampening, the gear housing shall be of full sidewall construction, integral with the base. The turntable base walls shall be 1 inch thick minimum to insure adequate structural rigidity to properly support the drive bearing and gear. Prior to assembly, the base shall be thoroughly inspected for seep holes or inclusions and given a hydrostatic test to insure no leaks are in the oil containment area. Shop inspection reports must be made available for review. Fabricated base made with welded steel plates are not acceptable due to potential warping during fabrication. If fabricated steel are provided, material shall be in 316 stainless steel for a better corrosion resistance.
L. The drive unit shall be equipped with an electro-mechanical overload control device actuated by thrust from the worm shaft. The pointer shall provide a visual reading of the relative main gear output torque on a 0 to 100 percent graduated scale. The 100 percent reading shall equal the 100 percent drive rating as specified in section 1.03. The control device shall also activate an alarm switch for warning of impending overload, a motor cutout switch for overload protection and a back-up safety motor cutout switch for back up overload protection. In lieu of a back-up safety motor cutout switch a slip clutch assembly will be acceptable upon review by the Engineer. The respective switches in the overload control device shall be factory calibrated and set to the following settings:
1. Alarm - 40% of scale 2. Motor cutout - 85% of scale 3. Back-up motor cutout or slip clutch - 100% of scale.
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 6
M. All drive control components shall be mounted in a weatherproof enclosure of either epoxy coated aluminum construction or stainless steel with a gasket-sealed, removable cover. The pointer shall be covered with a clear plastic enclosure and shall be above the walkway surface for visibility from the walkway. Amperage sensing devices are not acceptable for torque overload protection due to their inability to react quickly enough to prevent damage to the drive. Overload devices with exposed linkage connections will not be accepted due to possible corrosion problems. Devices which react to rotational movement of the secondary reduction unit will not be allowed due to possible misalignment of gearing created by the movement of the reduction unit.
N. The center drive unit shall be designed for the continuous torque rating as specified in section 1.03. The continuous torque shall be defined as the minimum torque at which the drive mechanism may operate continuously 24 hours per day, 365 days per year, for 20 years, at the specified sludge collector arm speed. Main gear and pinion calculations shall be based upon ANSI/AGMA 2001-D04 standards for rating the pitting resistance and bending strength of involute spur and helical gear teeth. Calculations shall clearly present the values used for the following design parameters:
1. Number of pinions 2. Actual face width 3. Tooth geometry (I and J factors) 4. Load distribution factor 5. Allowable contact stress 6. Allowable bending stress 7. Pinion pitch diameter 8. Hardness ratio factor 9. Elastic coefficient 10. Life factor
O. The load distribution factor shall be determined by the empirical method. For parameters which are material dependent, such as allowable contact stress, the calculations shall include a complete description of material and heat treatment used.
P. Worm gearing shall be designed and rated to equal or exceed the specified continuous torque and life. The basis for rating shall be ANSI/AGMA 6034-B92 standards for durability rating and design of worm gear reducers.
Q. The continuous torque rating for the drive unit shall be the lowest value determined for the gearing.
2.3 WALKWAY ACCESS BRIDGE
A. The clarifier shall be provided with a 36 inch clear open width walkway extending from the tank wall to the center drive platform. The walkway shall be supported at the center by the drive unit and supported on the opposite end by the tank wall. As a minimum the walkway shall be designed to safely withstand all dead loads plus a live load of 50 pounds per square foot with a maximum deflection of l/360, over the entire span. The walkway shall consist of beams or a structural steel truss, with either sufficiently braced to resist the specified design loads. The walkway decking shall be 1-1/4 inch aluminum I-Bar grating. The walkway design shall be such to allow connection to access stairs (not provided by clarifier manufacturer) in accordance with the drawing and details included in the contract documents. WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 7
B. A center drive operations platform shall be provided. It shall be a minimum of 8 feet square to provide clearance around the center assembly and drive control for maintenance and service. The drive platform shall be decked with 1/4 inch aluminum checkered floorplate and have sufficient structural steel supports to meet the specified design load conditions.
C. Provide handrails with toe plate along both sides of the walkway and around the center drive platform. The handrailing shall be in conformance with the handrail specifications, found within this set of bid documents, and shall be as shown on the drawings.
2.4 CENTER CAGE AND RAKE ARMS
A. The center cage shall be of steel box truss construction, with connections for the two (2) sludge removal arms, rotating sludge collection drum and feedwell supports. The top of the cage shall be bolted to the main gear which shall rotate the cage with the attached arms and feedwell. The minimum angle size used for construction of the cage and rake arms shall be 2 inch x 2 inch x 1/4 inch members.
B. The clarifier mechanism shall include two (2) sludge removal arms of steel truss construction, with steel spiral rake blades and adjustable 20 gauge 304 stainless steel squeegees. The rake blades shall provide complete raking of the basin floor twice per revolution.
C. The rake blades shall consist of a minimum 3/16 inch thick steel plate. The blades shall be constructed to a logarithmic spiral curve with a constant 30 degree angle of attack. Blade depth shall vary as noted in Article 1.04. Each rake truss support arm shall be provided with the necessary outrigger bracing and other blade support structures, to ensure that the complete blade can be properly located and adjusted in the field.
D. The rake blades shall terminate in the center to within 1 inch of the rotating sludge collection drum. The 1 inch space shall be sealed with a neoprene seal.
E. The structural calculations for the rake arm shall include an analysis of the torsional loads from the spiral curve blade.
F. The cage and rake arms shall be designed such that calculated stresses do not exceed the AISC allowable stress at twice the drive 100% rating.
2.5 ROTATING SLUDGE COLLECTION DRUM
A. A rotating sludge collection drum shall be provided to collect settled solids raked to the center by the rotating spiral blades. The collected sludge shall be discharged from the tank by way of the RAS sludge pipe as shown on the contract drawings.
B. The sludge collection drum shall rotate with the center cage and shall be provided with sludge collection ports located directly in front of each rotating spiral rake blade. The ports shall be sized to collect thickened sludge from the bottom most dense sludge layer to maximize underflow solids concentration. The ports shall be 10” high by 24” wide minimum to avoid plugging. Similar devices using smaller ports shall be prohibited to avoid any plugging or shall be equipped with air blowers to clean clogged ports.
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C. The rotating sludge drum shall be constructed of ¼ inch steel plate. A neoprene seal shall be provided to seal against the center column. A stainless steel seal shall be provided to seal against the tank floor.
2.6 CENTER COLUMN
A. A stationary center column shall be provided which shall serve as the influent pipe. One end shall have a 1-1/4 inch support flange for bolting to the foundation with a minimum of eight (8) 1-1/4 inch diameter anchor bolts as shown on the plans. A similar flange shall be provided at the top of the column for supporting and securing the center drive assembly. Minimum center column thickness shall be 1/4".
B. Influent openings shall be provided in the upper portion of the column to allow unrestricted passage of the flow into the energy dissipating feedwell. Influent velocity shall be reduced by providing a total inlet port area a minimum of 135 percent of the center column cross sectional area.
2.7 ENERGY DISSIPATING INLET (EDI)
A. The clarifier shall be equipped with an energy dispersion inlet (EDI) located inside the rotating flocculation feedwell. The dispersion well shall be designed to dissipate the energy of the incoming flow by way of evenly spaced tangentially oriented vanes along the entire 360 degrees of the EDI circumference.
B. The influent column discharge ports will be set below the EDI vanes, providing immediate containment and baffling of the influent via the EDI floor and cylindrical shell.
C. The lower rim of the vane support ring extends back towards the column, forming a lip that provides additional flow baffling and energy dispersion.
D. The energy dissipating inlet shall have a bottom plate extending to within one inch of the center column. The bottom plate of the EDI shall be provided with properly sized drain holes.
E. The well shall be constructed of 3/16 inch plate.
F. The configuration and operation of this inlet dispersion well as employed in this specification are covered under U.S. Patent number 20050252868. The owner will require proof of fully paid license to operate the inlet dispersion well within 90 days of award of the prime contract. Ovivo USA is the primary licensee of the patents with right to sub-license. The clarifier manufacturer shall include the Patent License fee in their bid.
G. High performance EDIs of differing design of equal performance to that of the EDI listed above shall be considered. The burden of proof of equal performance shall be the responsibility of the supplier.
2.8 FLOCCULATING FEEDWELL
A. The flocculating feedwell shall be supported by structural members attached to the rotating center cage. The feedwell shall be fabricated out of 3/16 inch steel plate with upper and lower
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 9
reinforcing rim angles and stiffeners as required. Properly sized scum ports shall be equally spaced around the feedwell periphery to allow scum to exit from the feedwell at water level.
2.9 SURFACE SCUM SKIMMING EQUIPMENT
A. Surface scum skimming equipment shall be furnished with the clarifier mechanism. It shall be arranged to have the surface scum swept along an angled skimmer blade to the skimmer assembly, attached at the end of the blade, for discharge to the scum box as shown on the plans. The surface of the clarifier shall be swept once per revolution. The skimmer blade shall be tangential to the rotating feedwell and be supported by vertical supports from the rake arm.
B. The skimmer assembly shall be furnished for mounting to a 2” diameter pipe support arm located off of each rake arm. Skimmer assembly components shall mount to the support pipe utilizing clamping collars. No welding, drilling or field modifications to the support arm will be required for mounting any components.
C. An aluminum wiper blade shall be supplied in that skimmer assembly with replaceable neoprene wipers and aluminum backing bars at both ends and the bottom edge. A UHMW-PE wear block shall be furnished at the baffle end to prevent wear on the outer neoprene wiper as the skimmer travels around the mechanism in contact with the peripheral scum retention baffle. The wiper blade shall be attached utilizing machined aluminum castings which allow the blade to pivot freely both vertically and horizontally. An adjustable stop collar shall permit adjustment of the wiper blade to travel at the desired elevation around the tank and over the ramped scum box. A stainless steel spring acting on a pivoting steel baffle plate shall provide adjustable tension to contain scum and maintain constant contact of the wiper blade with the peripheral scum retention baffle during rotation. The pivoting baffle plate and wiper blade shall function to form a pocket in conjunction with the peripheral scum retention baffle to constrain scum and deliver it into the scum box.
D. The skimmer shall include a fail safe release to minimize damage to the skimmer and support steel should the skimmer come in contact with the scum box due to any accumulation of ice or scum on the peripheral scum retention baffle surface causing displacement of the skimmer. Assembly fasteners shall be supplied as 316 stainless steel for corrosion resistance.
E. The scum box shall be 10 feet wide, shall be supported from the tank wall and connected to a six (6) inch scum line, all as shown on the contract drawings.
F. The clarifier equipment manufacturer shall furnish a flush valve assembly for automatic flushing of the scum box and scum pipe. The flush valve assembly shall allow approximately 2 to 5 gallons of clarified effluent to enter the box as the skimmer assembly passes over the scum box. It shall consist of an actuator bar and a pivoting assembly that will allow a sealing plate to open the valve. A counterweight shall return the sealing plate to its closed position after the flush cycle. All parts of the flush valve shall be structural steel except for the sealing plate and the pivoting bearing assembly.
2.10 EFFLUENT WEIR AND SCUM BAFFLE
A. Effluent weir plates shall consist of 9 inch deep x 1/4 inch thick FRP sections with 2-1/2 inch deep 90 degree V notches at 6 inch intervals. The weir sections shall be fastened to the tank wall using 304 stainless steel cinch anchor bolts hex nuts and 5 inch diameter FRP washers,
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 10
allowing for vertical adjustment. To prevent leakage all surfaces between the launder walls and weir plates shall be given a seal coat of suitable mastic by the erection contractor.
B. The scum baffle plates shall consist of 12 inch deep x 1/4 inch thick FRP sections supported from the tank wall by FRP angle brackets secured with 304 stainless steel cinch anchor bolts and hex nuts, allowing for vertical and radial adjustment.
2.11 SURFACE PREPARATION AND PAINTING
A. All non submerged and submerged steel shall receive a surface preparation per specification SSPC SP 3 and shall be hot dip galvanized.
B. Prior to assembly of the drive unit, the castings shall have been sandblasted and thoroughly cleaned to remove any foreign particles in the drive base. After assembly, the drive mechanism shall be solvent cleaned and power wire brushed as needed prior to application of manufacturer's standard primer.
C. The drive unit will receive prime paint and finish paint per the following paint system: 1. The drive unit shall receive a surface preparation of SSPC-SP-06 and will be coated with two (2) coats of Tnemec N69 and one (1) coat of Tnemec Endura-shield series 73.
2.12 SPARE PARTS
A. The following spare parts shall be provided. 1. One (1) sight glass or dip stick for each main drive housing containing oil. 2. One (1) set of neoprene skimmer wipers for each mechanism.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The equipment shall be erected in strict accordance with the manufacturer's recommendations. A 2" layer of grout shall be applied to the tank floor in strict accordance with the manufacturer's recommendations. Screed boards shall be supplied by the erecting contractor.
3.2 SERVICE
A. The equipment manufacturer shall provide a service representative properly trained in inspection and operation of the mechanism to approve the installation, certify that the torque settings of the drive overload protection device are correct, perform the torque test and instruct the owner's personnel on maintenance and operation. If additional service is required due to the mechanisms not being fully operational, at the time of service requested by the contractor, the additional service days will be at the contractor's expense.
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 11
3.3 TORQUE TEST
A. The clarifier mechanism shall be field torque tested. The purpose of the torque test is to verify the structural integrity of the mechanism structural steel design and center drive unit. The testing shall be carried out under the supervision of the equipment manufacturer's representative and as approved by the Engineer before the mechanisms are accepted and placed into operation.
B. The torque test shall consist of securing the rake arms by cables to anchor bolts installed by the contractor in the tank floor at locations specified by the equipment manufacturer. A load shall be applied gradually to the scraper arm by means of a ratchet lever and cylinder connected to the cable assembly.
C. The magnitude of the applied load shall be measured by calculating the torque from the distance of the line of action of each cable to the center line of the mechanism. A reading shall be taken at the 100% value of the drive design torque.
D. The manufacturer's service representative shall verify that the alarm, motor cut out, and back up safety motor cut-out switches are properly set and are in proper operation to protect the clarifier mechanism as specified.
END OF SECTION 461100
WRCRWA SECONDARY CLARIFIER EQUIPMENT PLANT EXPANSION PROJECT 461100- 12
SECTION 461500 – ALUMINUM BASIN COVERS
PART 1 - GENERAL
1.1 SUMMARY
A. This specification is for a fully engineered, substantially airtight, aluminum cover structure comprised of panels, and beams.
1.2 SCOPE OF WORK
A. Furnish all labor, materials, and equipment to provide a complete, installed system of fixed and removable, custom fit, flat aluminum covers. The Tank Cover system includes cover panels, structural supports, and attaching hardware.
B. The following shall be covered with an aluminum cover as outlined in this specification:
1. Two (2) Primary Clarifiers – Overall diameter: 104’-0”. The covers shall free span the entire clarifier and shall not be supported off the center platform of the clarifier mechanism. 2. One (1) Equalization Basin – 180’-0” x 130’-0”. The cover shall free span the entire basin. The use of intermediate support columns will not be allowed.
1.3 APPROVED MANUFACTURERS
A. Basis-of-Design Product: Subject to compliance with requirements, provide aluminum basin covers as manufactured by:
1. Hallsten Corporation (Basis-of-Design) 2. Or equal
1.4 ENGINEERING
A. A submittal shall be provided to the engineer prior to the beginning of fabrication. The submittal shall include:
1. Complete structural calculations showing the governing stresses in all members and connections, and detailed shop drawings. Preliminary drawings shall be stamped by the cover manufacturer’s Professional Engineer. Final Drawings and calculations shall bear the stamp of local state Professional Engineer if required. 2. Manufacturer's standard guarantee. 3. A letter of certification signed and sealed by a registered Professional Civil Engineer confirming that the aluminum cover is in full compliance with the plans and specifications including any testing provisions included therein.
WRCRWA ALUMINUM BASIN COVERS PLANT EXPANSION PROJECT 461500 - 1 1.5 QUALIFICATIONS
A. Manufacturer: Shall be a company specialized in providing engineered aluminum covers for wastewater treatment tanks/troughs for at least ten (10) years. When requested by the Engineer, submit written evidence to show experience qualifications and adequacy of plant capability and facilities for performance of contract requirements.
B. Erector: Regularly engaged for at least ten (10) years in the erection of aluminum covers for wastewater treatment tanks.
C. Welders: Qualified within the past two (2) years in accordance with AWS.
1.6 PERFORMANCE
A. Span: The clear span length of the cover shall be as noted in the scope of work.
B. Width: The inside width of the cover shall be as noted in the scope of work.
C. Distributed Design Live Load and Deflection: All structural components shall be designed to support the dead weight of the structure, plus a live load of 50 pounds per square foot of surface. The maximum deflection of any component under this load shall not exceed L/240 of the span of that component. In no event shall the dead load deflection exceed the rise of any component in order to avoid surface ponding.
D. Concentrated Live Load: The structural components shall be designed to support a 400-pound load on a 6" X 6" area located anywhere on the surface of the structure without permanently deforming the tested area.
E. Design Stresses: All allowable design stresses in structural aluminum shall be in accordance with the "Specifications for Aluminum Structures" for building-type structures by the Aluminum Association.
F. Skid Resistance: The cover shall possess an integral non-skid surface and no exposed area of cover system wider than one inch shall be without ribs/non-skid surface. The aluminum- decking surface of the structure shall be Hallsten's Deck Slat, which is ribbed to provide an aggressively non-skid surface. The edges of adjacent deck slats shall double interlock so that the slats shall act together. The decking surface shall be manufactured form 6061-T6 alloy. The Manufacturer of the non-skid surface shall demonstrate in writing satisfactory performance for a minimum period of 10 years in the wastewater industry for the intended purpose. This surface shall not be achieved by the use of paint, adhesive tapes, sand blasting or any other means other than an extruded process.
G. Chemical Resistance: Panels shall be fabricated entirely of 6061-T6 corrosion resistant aluminum extrusions. Every panel to beam connection shall be chemical resistant and will not weaken or corrode and will interlock. A mechanical and replaceable Santoprene seal shall isolate the cover perimeter from the concrete wall. No foam tape or caulk shall be allowed.
H. Configuration: The aluminum cover shall be composed of panels and beams. All panels shall interlock with the adjoining beam and panels without the use of threaded fasteners. Uplift of
WRCRWA ALUMINUM BASIN COVERS PLANT EXPANSION PROJECT 461500 - 2 each panel will be resisted with the use of an integral latch system. The weight of an individual panel shall not exceed 150 pounds. Each removable panel shall be easy to remove without disruption of adjacent panels and the lifting force required shall not exceed the dead weight of the panel.
1.7 MATERIALS
A. Aluminum: All aluminum used in the fabrication of the cover shall be alloy 6061-T6. All plate shall be alloy 6061-T6. Material shall be new and of top quality.
B. Welding Electrodes: Welding shall be with electrodes of an alloy, which shall produce welds with strength and corrosion resistant characteristics compatible to the base metal.
C. Fasteners: All fasteners between aluminum components shall be stainless steel or structural plastic. Aluminum shall be isolated from dissimilar materials by means of a stainless steel spacer or an elastomeric isolator. Beams and panels shall be fastened to concrete using stainless steel drill in place anchor bolts.
D. Steel Accessories: No carbon steel components shall be used.
E. Seals: A mechanical and replaceable Santoprene seal shall isolate the cover perimeter from dissimilar materials such as concrete and steel. No foam tape or caulk shall be allowed for isolation of cover system.
F. Access Hatch Panels: Access to any location under the cover shall be gained through integral gear hinged access hatches. The Access Hatch Panels shall have the identical properties as the rest of the aluminum cover including loads, deflection and slip resistance specifications. The access-hinged panels shall be the full panel width. The length of the access panel shall be clearly indicated on drawings. Hinged panel components including hinges, decking and lifting handles shall be extruded 6061-T6. While in the closed position the hatches will be completely flush therefore posing no tripping hazard. In the open position the panel shall lie flat on the cover and will not need a hold open device.
G. Handles: Handles shall be an integral flush mounted aluminum and incorporated into the non-skid deck slat.
1.8 FABRICATION AND WORKMANSHIP
A. Workmanship: The quality of workmanship shall be equal to the best general practice in modern structural fabrication shops. Workmanship, fabrication, and shop connections shall be in accordance with the latest edition of ANSI/AWS D1.2 "Structural Welding Code - Aluminum".
B. Experience: The manufacturer must furnish adequate evidence of a minimum of ten (10) years of ongoing experience in the manufacture of similar structures.
C. Preparation for Welding: All components to be welded shall be free of dirt, grease, and other contaminants and shall fit up properly for sound welding. Surfaces to be welded may not be cut with oxygen. Sawing, shearing, or machining may be used. WRCRWA ALUMINUM BASIN COVERS PLANT EXPANSION PROJECT 461500 - 3 D. Welding Procedures: All welding shall be with an inert gas shield arc process. Machine settings shall be developed with test welds of the same material, alloy and geometry as the work pieces and samples will be tested destructively.
1.9 TESTING
A. Loads: After installation the cover structure will be tested for conformance with the deflection limits. A load of 400 pounds will be placed as directed by the Engineer and the maximum deflection created by the load will be measured.
B. Prequalified Shop Testing: MANUFACTURER shall perform a prequalified shop air tightness test and certification for the cover components proposed. This test shall be performed in accordance with the “Procedural Standards for Testing, Adjusting and Balancing of Environment System” as published by the National Environmental Balancing Bureau (NEBB) on cover components of not less than 80 square feet. Said test shall be conducted and witnessed by a NEBB certified technician. The method of testing, test apparatus and proposed contents of the test report shall be submitted to the Engineer for approval. Subsequent to the receipt of Engineer’s approval, the Manufacturer shall set up testing protocol and schedule the test. A report of the test shall be prepared by the certified technician and shall be sealed with the NEBB seal. The report shall include a description and illustration of the test components, a description and illustration of the test apparatus and a report of the results. The cover shall maintain an air intrusion leakage rate not to exceed 0.2 cfm per square foot at an applied negative pressure of 0.2 inches of water column for a five minute duration.
1.10 DELIVERY AND INSTALLATION
A. Delivery: Delivery of the components of the structure shall be made to a location nearest the site that is accessible to over the road trucks, unless otherwise specified.
B. Storage: The manufacturer shall be responsible for jobsite storage of the delivered components. The components shall be stored off the ground on level surface in such a manner as to prevent damage.
C. Installation: The manufacturer shall furnish such personnel, tools, equipment, and materials as required to install the cover using the recommended procedure. The manufacturer shall also provide a written certification to the Engineer that the cover has been installed according to the manufacturer’s requirements.
D. Contractor Installation: The cover manufacturer can provide installation instructions, on site supervision, and inspection if desired. The manufacturer shall also provide a written certification to the Engineer that the cover has been installed according to the manufacturer’s requirements.
END SECTION 461500
WRCRWA ALUMINUM BASIN COVERS PLANT EXPANSION PROJECT 461500 - 4 SECTION 462000 – FLOATING BALL BLANKET
PART 1 - GENERAL
1.1 SUMMARY
A. This section covers furnishing floating ball blankets consisting of hollow plastic balls as shown on the drawings.
1.2 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the requirements of this specification, the following manufacturers are acceptable:
1. Environmental Controls Company (ECC) 2. Costal Netting Systems 3. Or equal
1.3 QUALITY ASSURANCE
A. Floating ball blanket manufacturer shall have a minimum of (10) years’ experience in the design and manufacture of hollow plastic balls.
B. The manufacturer shall be ISO certified.
1.4 SUBMITTALS
A. In accordance with Section 013300, “Contractor Submittals,” submit part drawing and manufacturer’s data covering installation instructions, dimensions, weight, materials, and any and all information required to verify compliance with these specifications.
1.5 WARRANTY A. The manufacturer shall provide a minimum of a 10 year warranty against cracking or degrading due to natural causes, including snow, ice or UV radiation.
PART 2 - PRODUCTS
2.1 GENERAL
A. Each ball shall have a diameter of 4” plus or minus two percent. The balls shall be manufactured form High Density Polyethylene (HDPE) in black color with UV stabilizers to minimize the degrading effects of sunlight.
WRCRWA FLOATING BALL BLANKET PLANT EXPANSION PROJECT 462000 - 1
B. The manufacturer shall provide sufficient quantity of floating balls such that the surface of the tank is completely covered and no spaces larger than the diameter of the ball exist.
PART 3 - EXECUTION
3.1 DELIVERY, STORAGE, AND HANDLING
A. Deliver ball blankets to the site in an undamaged condition. The balls shall be packaged in such a way to facilitate handling.
3.2 INSTALLATION
A. The ball blanket shall be installed as shown on the Plans and installed in conformance with the manufacturer's instructions and as specified herein.
END OF SECTION 462000
WRCRWA FLOATING BALL BLANKET PLANT EXPANSION PROJECT 462000 - 2
463000 – GRIT CLASSIFIER
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. There shall be furnished and installed equipment for one (1) grit classifier mechanism. Each unit shall include a dewatering screw conveyor with drive unit, trough, support frame, bearings, adjustable weir, one (1) hydrocyclones, and all other appurtenances required or shown on the drawings.
B. Design Criteria:
1. Pumped Flow to Cyclone: 220 gpm 2. Cyclones required per unit: One (1) 3. Required Cyclone Inlet Pressure: 8 psi 4. Cyclone Inlet Connection: 4 inch flanged 5. Cyclone Overflow Outlet Connection: 6 inch flanged 6. Grit Removal Efficiency with Cyclone in Service: 95% of 150 Mesh Grit with 2.65 sg 7. Screw Diameter: 12 inch 8. Screw Pitch: 1:2 9. Trough Slope: 3.5 inches/ft 10. Solids Handling Capacity: 54 ft / hr. 11. Minimum Pool Area: 8.3 ft 12. Classifier Overflow Outlet Connection: 4 inch flanged 13. Classifier Tank Drain Connection: 1.5 inch NPT
C. Warranty: A written supplier’s warranty shall be provided for the equipment specified in this section. The warranty shall be for a minimum period of one (1) year from start-up or 30 months from time of equipment shipment, whichever comes first. Such warranty shall cover all defects or failures of materials or workmanship which occur as the result of normal operation and service.
D. Submittals: Four (4) copies of all materials required to establish compliance with these specifications shall be submitted for review. Submittals shall include at least the following:
1. Certified general arrangement drawings showing all important details and materials of construction, dimensions, loads on supporting structures, and anchor bolt locations. 2. Descriptive literature, bulletins, and/or catalogs of the equipment. 3. Complete data on motors and speed reducers. 4. Wiring diagrams and electrical schematics for all control equipment to be furnished. 5. Complete descriptive data on the grit cyclone including performance curves.
E. Experience: The equipment supplier shall have at least 10 years experience in the design, application, and supply of grit classifier equipment in water or wastewater treatment plants, and shall submit a list of not less than 15 operating installations as evidence of meeting the experience requirement.
F. To show evidence of being able to provide the quality of equipment and services described in this specification, the equipment supplier shall submit their ANAB-accredited ISO 9001 quality system
WRCRWA GRIT CLASSIFIER PLANT EXPANSION PROJECT 463000 - 1
certification. AIAO-BAR accredited systems are not a recognized equivalent and are therefore specifically prohibited. The quality procedures shall provide for a means of qualifying all sub- vendors and shall specify that the fabrication facility is a critical vendor and shall require inspection. The quality system shall be audited on-site by a third-party independent registrar at least annually. Certification shall remain in effect throughout the project start-up.
PART 2 - PRODUCTS
2.1 GENERAL DESIGN
A. Description: The influent shall be pumped into the classifier through a cyclone positioned over the settling pool. The inclined grit screw conveyor shall wash and dewater the grit while lifting it from the hopper to a higher point of discharge.
B. Materials: All wetted parts shall be constructed from stainless steel except for the shafted screw. The shafted screw is constructed from a high strength alloy steel and supplied with a protective primer coating. Bearings, electrical devices, motor and gear reducer shall be of the manufacturer’s standard materials. Steel members in contact with liquids, either continuously or intermittently, shall have a minimum thickness of 1/4".
C. Fabrication: Shop fabrication and welding of structural members shall be in accordance with the latest edition of the "Structural Welding Code", AWS D1.1, of the American Welding Society. All welded connections shall develop the full strength of the connected elements and all joined or lapped surfaces shall be completely seal welded with a minimum 3/16" fillet weld. Intermittent welding shall not be allowed.
D. Edge Grinding: Sharp projections of cut or sheared edges of ferrous metals shall be ground to a radius by multiple passes of a power grinder as required to ensure satisfactory coating adherence.
E. Shop Surface Preparation/Coating: Shafted screw shall be sand blasted per SSPC-SP10 near white blast and shop primed with one (1) coat of Tnemec 66-1211 Epoxoline primer to a DFT of 3.0-5.0 mils. The drive unit shall be coated with the supplier’s standard enamel paint system.
F. Structural Design: All steel design shall be in accordance with the AISC Manual of Steel Construction, latest edition, and the Uniform Building Code (UBC), latest edition.
2.2 EQUIPMENT
A. Screw Conveyor: The grit classifier shall be composed of a screw conveyor operated in a 304 stainless steel trough fabricated of 1/4" steel plate. The flights on the screw shall be sectional type hi-tensile steel and shall be of not less than 1/4" base section welded to a steel pipe with solid steel stub shaft. There shall be 1/2" clearance between the screw and trough so that a build-up of sand or grit will provide a bed for the screw. Screw shall be fitted with replaceable abrasion resistant wear shoes from AR400 or similar metal with minimum Brinell hardness of 400 mounted to the screw with stainless steel hardware.
1. Grit will be conveyed on this bed to eliminate tank wear. The speed of the screw shall be as previously listed.
WRCRWA GRIT CLASSIFIER PLANT EXPANSION PROJECT 463000 - 2
B. Screw Trough: The trough shall have a settling compartment where grit separation can take place. The settling compartment shall provide a minimum water depth and a minimum pool area as listed. An adjustable effluent weir shall be provided allowing the effluent to overflow into a launder box.
C. Bearings: The submerged bearing shall be enclosed in cast iron housing. The bearing assembly shall also include a mechanical seal and will be designed to prevent the entry of grit. The bearing assembly shall consist of two (2) ball bearings, each with a calculated L10 life of 20 years under a load equal to half the screw weight. The thrust load of the conveyor shall be taken by a flange type tapered roller bearing through the drive shaft mounted to the upper trough end plate. The upper trough end plate shall be hinged to allow the lower bearing assembly to be lifted above the liquid level for service without removing the drive unit or draining the trough. It shall be lifted by means of a manually operated worm gear winch of steel with copper bronze powder coating mounted on top of the trough fitted with stainless steel aircraft cable which is factory connected to the lower bearing housing/screw.
D. Drive Unit: The classifier drive unit shall consist of a helical speed reducer and motor. The speed reducer shall be directly coupled to the motor and flange-mounted directly to the screw conveyor shaft. The drive shall rotate the conveyor at the specified speed and shall be designed for 24 hour a day operation under normal moderate shock loadings.
1. Speed reducers shall be manufactured to AGMA standards. The speed reducer shall have a service factor of 1.25. 2. The reducer includes an internal tapered roller bearing of proper size for all mechanism loads and runs in a totally submerged oil bath. 3. The motor shall be an 1800 RPM, squirrel cage, induction type, TEFC, ball bearing heavy duty unit of ample power for starting and operating the mechanism without overload, with a service factor of 1.15. Refer to Section 220513 for additional motor requirements. 4. Power supply to the equipment shall be 460/230 volt, 60 hertz, 3 phase. The motor shall be suitable for an outdoor installation.
E. Grit Cyclone: There shall be furnished one (1) grit cyclone. The cyclone shall be capable of degritting the slurry influent at a pressure drop as listed. Each unit shall be a Krebs model D15LB Cyclone and provided with the following features:
1. The cyclone shall have an involuted feed entry with a flanged inlet and a flanged overflow connection. The housing shall be constructed from carbon steel with pure gum rubber liners and Ni-Hard vortex finder and fixed apex shall be sized for the required separation. 2. The wear liners shall be easily replaceable without the use of special tools or adhesives. The liners shall be made of pure gum rubber pressure molded to assure tight tolerances. The inlet pressure gauge shall have a dial indicator with a range from 0-30 psig, and shall be filled with oil. It shall be protected by a diaphragm assembly. The gauge assembly shall be mounted at the inlet of the cyclone. 3. The discharge end of the cyclone shall be fitted with a 1/4" thick neoprene elbow to direct the grit discharge to the grit classifier. The elbow shall be attached to the cyclone with stainless steel bolts. The apex assembly shall be fitted with quick-connect clamps for easy removal. 4. Support stand from type 304 stainless steel.
F. Discharge Bagging Device: The end of the discharge section will be equipped with a type 304 stainless steel transition piece and continuous bagging device to capture the dewatered grit. The bagging device shall be supplied with a replaceable magazine of continuous plastic hose.
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G. Other equipment: The system shall be supplied loose with one (1) pressure gauge (meeting the requirements of Section 220519 of the specifications), and one (1) 1 ½” stainless steel ball valve (meeting the requirements of Section 220523 of the specifications).
2.3 ELECTRICAL
A. In addition to the drive motor, the equipment supplier shall furnish all electrical items specifically called for in this specification section. The contractor shall supply all other electrical items, control panels, and interconnecting wiring of proper size, including all conduit and supports required to place the equipment into service. Each classifier shall be provided with the following:
B. NEMA 4X Local Control Station containing, at a minimum:
1. Emergency Stop Pushbutton: 2. Classifier HOA switch.
2.4 SEQUENCE OF OPERATION
A. Classifier Hand Operation: When the classifier selector switch is in the Hand position, the classifier spiral will run continuously. Turning the selector switch to Off will stop the unit.
B. Classifier Automatic Operation: When the classifier selector switch is in the Auto position, the classifier will be activated by the operation of the grit pump. While the pump is operating, the classifier shall cycle on and off by the settings of a repeat cycle timer. Once the pump completes operation, the classifier shall run for an adjustable off delay time.
C. Fault Conditions:
1. Excessive motor current will trip the starter overload relays, immediately stop the drive motor, and illuminate the alarm indicating light. This fault must be reset by depressing the motor starter overload reset internal to the control panel. 2. Momentary motor over current will trip the current monitor, immediately stop the drive motor, and illuminate the alarm indicating light. Pushing the reset pushbutton will reset this fault.
2.5 ANCHORAGE AND FASTENERS
A. Anchor Bolts: All anchor bolts shall be a minimum of 1/2" diameter and made of type 304 stainless steel. The equipment supplier shall furnish all anchor bolts, nuts, and washers required for the equipment.
B. Fasteners: All structural fasteners shall be a minimum of 1/2" diameter and made of type 304 stainless steel. The equipment supplier shall furnish all fasteners required for the assembly of the equipment.
WRCRWA GRIT CLASSIFIER PLANT EXPANSION PROJECT 463000 - 4
PART 3 - INSTALLATION
3.1 GENERAL
A. The equipment shall be installed properly to provide a complete working system. Installation shall follow the supplier’s recommendations.
3.2 MANUALS
A. The equipment supplier shall furnish four (4) copies of operation and maintenance manuals which will be retained at the installation site to assist plant operators. The manual shall include the supplier’s erection and assembly recommendations, a complete parts list, and a list of recommended spare parts.
3.3 SHOP ASSEMBLY
A. The equipment specified herein shall be completely factory assembled as one unit.
3.4 FIELD SERVICE
A. The equipment supplier shall provide the service of a qualified representative for one (1) trip and one (1) day to inspect the equipment installation, assist in start-up, and instruct plant personnel in the proper operation and maintenance of the equipment.
END OF SECTION 463000
WRCRWA GRIT CLASSIFIER PLANT EXPANSION PROJECT 463000 - 5
SECTION 466115 – AUTOMATED BRUSH SYSTEM
PART 1 - GENERAL
1.1 SUMMARY
A. The Automated Brush System shall be custom designed, field built and constructed for the individual Clarifier it is to be installed. Because of custom designed application of the automated brush units, variations in poured concrete, differences in the various clarifier providers and variances in the height of the skimmer as travels around the tank and the out of round of each Clarifier/ Thickener, it is required that the Manufacturer of the Brush Weir Cleaning system construct the device on site by Factory trained employees.
B. The Automated Brush System for algae and debris control shall be designed for a brush to make contact with each of the following surfaces:
1. Inner Baffle 2. Outer Baffle 3. Inner Weir (s) 4. Outer Weir (s) 5. Top Spillway Surface 6. Angled Spillway Surface 7. Inner Launder Wall 8. Launder Bottom 9. Outer Launder Wall
C. The Automated Brush System shall be designed to work off the power of the existing clarifier drive motor. The system shall be constructed to avoid any noticeable torque increases. The unit shall be capable of encountering an indefinite stall without incurring damage.
D. The Brush system shall weigh no more than 150 lbs in total for a single Skimmer installation and split Brush systems shall weigh no more than 100 lbs that will be installed on each Skimmer.
E. The unit shall be designed with an engaged position for cleaning, and a disengaged position allowing the system to ride idle around the tank.
F. Brush system must be approved by the Clarifier Manufacturer on which it is to be installed to address and prevent any warranty issues.
G. The system shall be installed in the following clarifiers:
1. Existing Secondary Clarifiers #1, #2, and New Secondary Clarifier #3
1.2 SPECIAL REQUIREMENTS
A. The Automated Brush System requires the clarifiers to have the following:
WRCRWA AUTOMATED BRUSH SYSTEM PLANT EXPANSION PROJECT 466115- 1
1. Clarifiers shall be circular in design and be completely free of obstructions around the entire periphery of the tank and compatible with automated brush cleaning devices.
B. Specific problem areas must be avoided:
1. Walkway support - Walkway should extend freely to the outer effluent launder wall or beyond and not be supported on the spillway surfaces. 2. Water Supply Lines - The area must be kept free of all supply lines. 3. Baffle Brackets - Brackets with webbing gussets must not be used to attach the baffle. An L-shaped bracket must be used to allow the free passage of the brush system and to promote more efficient cleaning. 4. Bolt Protrusions - Bolt protrusions should be minimized. Bolts/studs, which attach the weir and baffle, should protrude no more than 1/4 inch past the nuts. 5. Skimmer arm shall be of a standard design (no "ducking" or submersible skimmers). Skimmer arm must remain at consistent elevation (plus or minus 1") around the entire periphery of the tank. Skimmer arm must be able to support addition of approximately 100 lbs. without inducing metal fatigue. 6. Distance between baffle and weir shall be at least eight inches. If launder has tangential weir (i.e. multisided launder) then the distance between weir and baffle ideally should be 8” at the closest and 12” at the farthest. 7. A clearance of at least 18" shall be provided between the top of baffle and the lowest point of the walkway. If weir/baffle or launder has radial variance greater than 4" (i.e. multi- sided inboard launder) this clearance must be a minimum of 24". 8. Performance of automated brush system is greatly enhanced if top spillway surface is 6" wide. 9. Interior Concrete surfaces of the launder should be finished as smoothly as possible. This will allow for maximum brush life and also increase the effectiveness of algae removal. 10. Performance of automated brush system weir cleaning is greatly enhanced when the weirs are anchored in such a way as to allow for at least 5" of the weir surface above the horizontal concrete spillway.
PART 2 - PRODUCTS
The automated brush system shall be the “Weir Wolf System” as manufactured by Ford Hall Company, or equal.
2.1 ATTACHMENT ASSEMBLY
A. The Attachment Assembly shall provide a means of attaching the Automated Brush System to the skimmer arm and or rake truss so as not to interfere with any other operations of the skimmer arm (such as the effective skimming of floatable solids or the operation of the skimmer blade assembly at the scum box).
B. The Attachment Assembly shall be custom designed for each specific clarifier. It shall be constructed of 304 stainless steel.
WRCRWA AUTOMATED BRUSH SYSTEM PLANT EXPANSION PROJECT 466115 - 2
2.2 MAINFRAME
A. The Automated Brush System Mainframe shall be constructed of Type 304 stainless steel and designed to slip easily into the Attachment Assembly and be tightened in position with the use of set screws. The Mainframe shall be designed so that the Brush Arms can be positioned at any point on the Mainframe.
2.3 BRUSH ARMS
A. Brush Arms shall be of Type 316 stainless steel and custom designed and installed for individual applications. Factory service technician will be on site to observe and advise the installation of the Brush Arms to allow for cleaning all aforementioned surfaces and allow for the following:
1. SPRINGS ASSEMBLIES Flexibility to clean effluent surfaces within a plus or minus 4- inch radial variance (specifically: Clarifier walls, both sides of weirs & baffle). 2. To have opposite the Mainframe end, a Brush Holder component allowing for the insertion of a brush. 3. To allow Brush Holder to be adjusted telescopically so that a maximum number of Brush Arm adjustments are possible. 4. To have a means of biasing the arm to the Mainframe so as to provide sufficient force to remove algae and debris. 5. Include a component that allows for each brush arm to be “locked out” or disengaged. This will allow operators to customize cleaning schedule and extend life of the brushes.
2.4 SPRING ASSEMBLIES
A. Each Brush Arm requires spring tension to bias the Brush Arm with the Brush Holder and Brushes into tight engagement with the appropriate effluent surface to be cleaned. The Spring Assemblies require the following.
1. A minimum of one Spring Assembly of 316 stainless steel is required for each Brush Arm. 2. Spring Assemblies consist of two stainless steel springs & one stainless steel guide. 3. Each spring will be composed of 316 stainless steel wire with a minimum diameter of 0.95 inch and a minimum of 260 active coils per spring length. 4. Spring coils will have a mean diameter of 0.655 inches. A minimum inner coil diameter of 0.56 inch and an outer diameter of 0.75 inch are required of each stainless steel spring. 5. Springs to have a minimum initial spring tension of 6.68 lbf and a maximum of 10.02 lbf with a minimum load tolerance of 18.44 lbf.
2.5 BRUSH HOLDER
A. At the end of each Brush Arm, there will be a 316 stainless steel Brush Holder to allow the insertion of a Cleaning Brush.
B. A Brush Holder shall be aligned with each of the following surfaces: both sides of the baffle, both sides of the weir and each of the effluent launder surfaces. Each Brush Holder will:
WRCRWA AUTOMATED BRUSH SYSTEM PLANT EXPANSION PROJECT 466115 - 3
1. Consist of a “bolted clamp design” to allow for the easy insertion and removal of Brushes. 2. Include a factory-supplied brush suitable for prolonged exposure to wastewater environment. 3. Contain a Shear Safety Component.
2.6 SHEAR SAFETY COMPONENT
A. Each Brush holder will contain a Shear Safety Component having a frangible point designed to break when subjected to a force with in each Brush holder.
B. The stress value on each Shear Safety Component will be low enough to release the Brush Holder to forgo any damage to Brush Cleaning unit and/or Skimmer equipment but be high enough to allow standard operation of Brush cleaning system.
2.7 BRUSHES
A. Each Brush Holder shall contain one (1) Cleaning Brush. Brushes shall be provided that slip easily into the Brush Holder and provide the cleaning means necessary to remove algae and debris from their respective surfaces. A brush shall be aligned to make contact with both sides of the baffle, both sides of the weir and all the effluent launder surfaces.
B. Brush construction shall be as follows:
1. Brush backing shall be of durable plastic able to with stand continuous exposure to sunlight, seasonal temperature changes and the corrosive elements found in wastewater. 2. Brush bristles shall be polypropylene with adequate trim length, density, and stiffness for extended continuous use. 3. Brushes shall be cut and shaped appropriately so as to clean their respective surfaces without binding.
C. Replacement Brushes shall be stocked by the manufacturer to the exact dimensions and will be available for purchase. Brushes provided by the Automated Brush system manufacturer should average approximately one (1) year.
2.8 LOCK IN / LOCK OUT DESIGN
A. Each Automated Brush System shall be designed with an engaged or locked in position for cleaning and a disengaged or locked out position for riding idle around the tank.
B. Each Brush Arm will have permanently mounted to the Brush Arm a Lock Out Hook that corresponds to a Lock Out Ring, which allows disengagement of the individual Brushes. The Lock Out Ring is mounted to a Lock Out Boss that is attached parallel to the Mainframe.
C. Each Automated Brush System shall be designed so that the entire Brush system can be disengaged or individual Brush Arms can be disengaged allowing for customized cleaning of weir and effluent surfaces.
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2.9 BRUSH BRIDGES
A. Provides the automated brush system Launder Brush Assembly a "Bridge" over the effluent hole on which to travel.
B. Brush Bridge will also need to be provided over the Scum Box. An incline and a decline guide ramps of 304 stainless steel will need to be provided for each Scum Box in the Clarifier.
C. The Brush Bridge shall be constructed entirely out of Type 304 Stainless Steel.
2.10 BRUSH SYSTEM WEIGHT AND COUNTERBALANCES
A. Weight of the Automated Brush system will not exceed 150 lbs total for all Brush systems attachments, brush arms, components and parts. This is based on a Single skimmer arm design.
B. Automated Brush system will require a counterbalance to be installed on the opposite rake Mechanism to offset the weight of the Brush system that has been added to the skimmer. Manufacturer of the Automated Brush systems will need to provide additional counterbalances totaling the weight of the installed Brush system, attachment sleeve and mainframe and be responsible for the correct placement and installation. (This is an additional counterweight beyond the counterbalances provided by the Clarifier manufacturers.)
2.11 SPARE PARTS/TOOLS
A. The manufacturer shall supply one (1) full set of spare brushes for each clarifier on which the cleaning system is installed.
B. The manufacturer shall supply one (1) lock-out pole as necessary for adjustment of the cleaning systems.
PART 3 - QUALITY ASSURANCE, WARRANTY, EXPERIENCE QUALIFICATIONS
3.1 GENERAL
A. Use of factory trained workmen, who are completely familiar with the specified requirements of automated brush cleaning devices and the methods needed for proper performance of equipment will be required. Factory workmen will be responsible for calculating bridge clearances, calculating skimmer strengths, instruction in building ramps over effluent discharge/ scum box areas and adapting brush system for radial variances of the clarifier walls and weir surfaces. It will be the responsibility of the Manufacturer of the Automated Brush System to ensure the brush system is cleaning all effluent surfaces called out in the specifications with the proper force and contact at the time of installation as part of the Brush system start up.
WRCRWA AUTOMATED BRUSH SYSTEM PLANT EXPANSION PROJECT 466115 - 5
3.2 QUALIFICATIONS OF MANUFACTURER
A. The Manufacturer of Automated Cleaning Brush Systems shall regularly engage in the manufacture of Weir Cleaning systems with a minimum of five (5) years experience in the manufacture and shall have a minimum of seventy-five (75) units (of their own units) in operation. A history of successful installations (with contact names and phone numbers) must be included and contacted for confirmation before approval.
3.3 BASIS OF ACCEPTANCE
A. The manufacturer's recommended installation procedures, when approved by the Engineer, will become the basis for inspecting and accepting or rejecting actual installation procedures used on this work. Clarifier Manufacturers must sign off on Automated Weir Cleaning system which is to be installed on their clarifier mechanisms to ensure Clarifier performance, drive functions, compatibility issues and to validate warranties.
3.4 WARRANTY
A. Automated Brush System will include a 5 year parts warranty and 1 year labor warranty provided by the Manufacturer of the Automated Brush System. The Manufacturer of the Automated Weir Cleaning Brush System is the sole responsible party for the performance, adjustments and modifications of the Automated Brush System.
END SECTION 466115
WRCRWA AUTOMATED BRUSH SYSTEM PLANT EXPANSION PROJECT 466115 - 6
SECTION 466200 – EDUCTOR TUBE MIXERS
PART 1 - GENERAL
1.1 SUMMARY
A. This section covers furnishing biosolids mixing systems and appurtenances complete, for Anoxic Basins.
1.2 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the requirements of this specification, the following manufacturers are acceptable:
1. JDV Equipment Corp. 2. WesTech, Inc. 3. Or equal
1.3 WARRANTY
A. Supply manufacturer's warranty for all of the Mixing System except for motor and compressor units for continuous, 24 hour per day operation for a period of one (1) year after shipment. This warranty will cover defects in workmanship and materials as long as the equipment is properly installed and properly operated in accordance with the manufacturer's instructions. Defective parts will be replaced by the manufacturer at no charge under this warranty.
PART 2 - PRODUCTS
2.1 GENERAL
A. Equipment furnished in this specification shall be fabricated and assembled in full conformity with this specification and as shown on the contract drawings. Each mixing system shall be furnished complete with all mechanical equipment required for proper operation, including complete all steel, iron, and other metal construction specified herein; and all additional materials or fabrication as required by the supplier's design.
B. The Supplier shall acknowledge that he is familiar with all the requirements of the contract documents relevant to the equipment supplied herein and agrees to perform and observe all obligations under the contract documents which relates to the portion of the work covered by this section and related sections.
C. The Supplier of the material and/or products included in this section undertakes and agrees to defend, at Supplier's own expense, all suits, action or proceeding brought against the municipality or it's Contractor(s) for actual and alleged infringement on any United States
WRCRWA EDUCTOR TUBE MIXERS PLANT EXPANSION PROJECT 466200 - 1
patent or foreign letters patent because or on account of the employment of sales of such material or products, and further agrees to pay and discharge any and all judgments or decrees which may be rendered in any such suit, action or proceeding against the defendants herein.
D. All equipment included in this section shall be furnished by a single supplier who shall be responsible for the design, coordination, and the satisfactory operation of the system. The system shall be the Turbomixer "Piston Bubble" type as manufactured by JDV Equipment, or equal.
2.2 FABRICATIONS
A. All welds shall be continuous unless otherwise specified. Facing surfaces of bolted joints shall be shop primed. Facing surfaces of field welded components shall be beveled and match marked.
B. Edge Grinding. Sharp corners of all cut and sheared edges shall be made smooth by a power grinder.
C. Fasteners. All bolts, nuts, washers, and other fasteners shall be 316 stainless steel.
D. Surface Preparation. All iron and mild steel surfaces to be painted shall be dry abrasive grit blasted to "near white metal" in accordance with SSPC-SP6 or SSPC-SP10, and in accordance with the painting section of these specifications. Grit blasted surfaces shall be painted within 24 hours to prevent rusting and surface discoloration.
E. Painting. After surface preparation, metal surfaces shall receive a minimum of one coat of Tnemec "66-1211 Epoxoline primer" or equal, and one coat of "46H-413 Hi-Build Tnemec-tar" coal tar epoxy or equal, to provide a total minimum dry film thickness of 15 mils prior to shipment to jobsite. Stainless steel components shall be furnished unpainted.
2.3 SLUDGE MIXER
A. Each mix assembly shall consist of a long tubular barrel with a nominal outside diameter of 18 inches, operating as submerged "expendable piston" pumps by generating an intermittent 18 inch piston bubble at a frequency controlled so that at least one large bubble is in the barrel at all times. Design shall be such that the intermittent bubble produces an induced flow of anoxic basin mixed liquid which is essentially continuous through the entire length of the barrel.
B. The installed geometry and flow through the barrel shall be such that a special form of secondary turbulent stream is generated outside the barrel at its muzzle, thus introducing a large secondary flow pattern with strong horizontal velocities.
C. Each mix assembly shall be designed to provide a scouring velocity along the floor of the digester to prevent the deposition of heavy solids and inorganic material. To achieve these high floor velocities, each entrance to the mix assembly shall be no greater than 30" above the floor of the digester, and shall be a full 360 degrees.
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D. The piston bubble generator shall be specifically designed for operation on sewage sludge and shall be designed with a minimum 5 inches opening, with smooth surfaces through the entire passage of the bubble and liquid. There must be provided a hydraulic break between the discharge of the piston bubble generator and the entrance port to the barrel to produce discrete piston bubbles of definite and appropriate size and at regular intervals of time.
E. In order to avoid catching rags and debris, and the clogging or partial clogging of the mix/heat assemblies, there shall be an unobstructed, smooth passage through the entire length of the unit from the floor of the digester to the liquid surface. The units shall be designed so that there are no internal appurtenances within the vertical tube, no appurtenance immediately below the entry into the draft tube, nor any moving mechanical components within the digester. There will be no elastomers or flexible hose in contact with the sludge.
F. Each mix assembly shall be floor mounted. The Mixer construction shall be all AISI 304 stainless steel with a thickness of 1/8 inch for the barrel and supports, and a 1/8 inch AISI 304 stainless steel for the bubble generator.
PART 3 - EXECUTION
3.1 SHIPPING
A. The parts and assemblies specified herein that are of necessity shipped unassembled shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Generally, machined and unpainted parts shall be protected from damage by the elements of weather with the application of a strippable protective coating.
B. All items of equipment shall be cleaned at the point of origin and all openings plugged so that they arrive at the jobsite ready for assembly and operation.
3.2 INSTALLATION
A. The equipment shall be located as shown on the Plans and installed in conformance with the manufacturer's instructions and as specified herein.
B. Mixers shall be level within 1/8-inch.
3.3 FIELD SERVICE
A. The manufacturer of the mixing system shall provide the services of a fully qualified Service Engineer for a minimum of one (1) trip, one (1) day total, to inspect the installation, place the equipment in operation and to train personnel in its operation and maintenance.
B. Testing of Installed Equipment:
1. Prior to plant startup, the Contractor shall conduct field tests on all equipment, inspecting the proper alignment, noisy operation, proper connection and satisfactory performance. The manufacturer's Service Engineer shall inspect the completed installation and provide
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written certification to the Engineer that the equipment has been installed in accordance with the manufacturer's approved method and is ready for permanent operation. 2. In case of nonconforming equipment, the Engineer may, at his option, either withhold final payment or make final payment. If final payment is made with the equipment specified herein classed as nonconforming, the guarantee period of two (2) years on the nonconforming equipment shall not commence until the Contractor and Manufacturer have corrected and retested it as specified above and, in the opinion of the Engineer, the equipment is in conformance with these specifications.
END OF SECTION 466200
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SECTION 466250 – VERTICAL SHAFT TURBINE MIXERS
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. The Contractor shall furnish and install ready for use all heavy duty vertical shaft turbine rapid mixers, including all necessary appurtenances, for the complete assembly as indicated in the design drawings and as specified herein. The applications for this equipment are:
1) Mix treated, filtered wastewater with as 12.5% solution of sodium hypochlorite (NaClO) which is injected into the wastewater directly upstream from the mixer. Design concentrations of the solution at the injection and mixing point are anticipated to be between 5 and 25 ppm (mg/L). All components shall be suitable for 24-hour continuous exposure to these conditions and for an outdoor (non-covered) exposure.
2) Mix disinfected, filtered wastewater from the chlorine contact basin effluent that will contain 1.0 – 5.0 ppm (mg/L) residual chlorine and will mix a solution of 2 – 6 ppm of sodium bisulfite (NaHSO3) to dechlorinate the water All components shall be suitable for 24-hour continuous exposure to these conditions and for an outdoor (non-covered) exposure.
B. Mixers shall be complete assemblies including but not limited to the gear reducers, motors, shafting, impellers, couplings, pedestal mounting base and other appurtenant equipment necessary to be complete and operable in accordance with the requirements of the contract documents.
1.2 REFERNCE STANDARDS
A. AFBMA Anti-Friction Bearing Manufacturers Association
B. AGMA American Gear Manufacturers Association
1. AGMA 390.09 – Gear Handbook Volume 1: Gear Classification, Materials and Measuring Methods for Unassembled Gears. 2. AGMA 299.01 – Sound Manual. 3. AGMA 6010.E88 – Spur, Helical, Herringbone and Bevel Enclosed Drives.
C. ANSI American National Standards Institute
D. ASTM American Society for Testing and Materials
E. NEMA National Electrical Manufacturers Association
F. OSHA Occupational Safety and Health Administration, Code of Federal Regulations (CFR 29).
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1.3 QUALITY ASSURANCE
A. Each mixer shall be completely shop assembled and factory tested to assure proper fit-up and acceptable limits of vibration, shaft run out and motor power draw. The equipment shall then be packaged for shipment and jobsite storage to prevent damage or corrosion.
B. The equipment seller shall be solely and fully responsible for warranty and mechanical design adequacy of all the provided under this section of the specification.
1.4 SUBMITTALS
A. Copies of all materials to establish compliance with the specifications shall be submitted in accordance with the provisions as outlined in Section 013300 – Contractor Submittals. Submittals shall include a complete description of all materials, complete dimensioned drawings including opening/clearance requirements, dimensions of all mixer components including drive motor and complete outline dimensions, shaft and propeller dimensions and diameters, mounting requirements, and all assembly and mounting details.
B. Submittals shall include a complete bill of materials, the mixer’s weight (including call associated components), and a summary of all loads (weights, torques, moments) associated with installing and mounting the device. Submittal shall also include a complete list of spare parts and special tools as supplied and recommended by the manufacturer.
C. Submittal shall include detail of surface preparation, shop priming and finish painting of the mixer.
D. Submittal shall provide detailed calculations regarding mixing and process design.
E. Manufacturer shall supply operation and maintenance data in accordance with the requirements of Section 017823 – Operation and Maintenance Data.
1.5 DELIVERY, STORAGE AND HANDLING
A. All materials and equipment shall be shipped, unloaded, stored, handled and installed in such a manner as to not to degrade quality, serviceability or appearance. The equipment shall be stored in a clean, dry location free from construction dust, precipitation and excess moisture. If stored for more than two weeks, the equipment shall receive all maintenance considerations required by the manufacturer for proper storage of the equipment.
1.6 WARRANTY
A. Supply manufacturer's warranty for all of the Mixing System and all associated components for continuous, 24 hour per day operation for a period of twelve (12) months after successful startup and operation, not to exceed 24 months from the shipment date. This warranty will cover defects in workmanship and materials as long as the equipment is properly installed and properly operated in accordance with the manufacturer's instructions. Defective parts will be replaced by the manufacturer at no charge under this warranty.
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PART 2 - PRODUCTS
2.1 GENERAL
A. The equipment herein specified is intended to be standard mixing equipment of proven ability as manufactured by reputable concerns having experience in the production of such equipment. The equipment shall be designed, constructed and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed as shown on the drawings.
B. All parts shall be so designed and proportioned as to have liberal strength, stability and stiffness and to be especially adapted for the work to be done.
C. Contractor and supplier shall coordinate with Engineer regarding any additional base plates or supports required to install the mixer as indicated in the design drawings. The base plate shall completely cover the opening over which the device is installed and allow for mounting to the concrete support curb that surrounds the opening. The base plate shall be of sufficient thickness and strength to minimize deflection from the weight of the mixer (as recommended by the manufacturer) and to prevent vibrations or irregular diaphragm action (due to torque and moments) when the device is installed and operating. Mounting hardware shall be designed by the manufacturer for the installation application, including site-specific seismic and design conditions. Refer to the design drawings for details.
D. The mixer, including shaft, propeller, bolts, mounting hardware, and all components that are submerged in or exposed directly to the wastewater and sodium hypochlorite solution, shall be designed and intended for continuous exposure to these conditions. Anticipated concentrations of chlorine at the mixing/injection site are from 5 to 25 ppm (mg/L), with concentrations higher than 25 mg/L possible.
E. The mixer, including shaft, propeller, bolts, mounting hardware, and all components that are submerged in or exposed directly to the wastewater, sodium hypochlorite solution, and sodium bisulfite solution, shall be designed and intended for continuous exposure to these conditions. Anticipated concentrations of chlorine at the dechlorination/mixing site are from 1 to 5 ppm (mg/L) sodium hypochlorite, with concentrations higher than 10 mg/L possible; and from 1 to 6 ppm of sodium bisulfite, with concentrations higher than 10 mg/L possible.
F. Any re-design required to accommodate alternate bid equipment shall be borne by the contractor and equipment manufacturer. This includes redesign of the curb structure to support the mixer and base plate. Note that the entire device, including propellers, shall be able to be extracted from the basin without disassembly of the device (including propellers) or requiring the basin to be drained and offline.
2.2 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the requirements of this specification, the following manufacturers are acceptable:
1. ANCO Mixers as manufactured by Enviropax, Inc. (Basis-of-Design). 2. Or equal
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2.3 MATERIALS
A. All submerged parts including the mixer shaft and impeller shall be constructed of type 316 stainless steel. All fasteners required for assembly of submerged parts shall be type 316 stainless steel.
2.4 DESIGN CRITERIA
A. A summary of the installation and design criteria is provided here. Refer to the design drawings for additional details regarding the installation location and application associated with the mixer.
B. Chlorination Injection Mixing Basin Design Criteria:
1. Basin Width: 10’-0” 2. Basin Length: 6’-0” 3. Design Side Water Depth: 11’-0” 4. Opening in Lid for Mixer: 2’-10” square 5. Design Average Daily Flow: 14.0 MGD 6. Peak Hour Flow: 19.88 MGD 7. Peak Storm Event Flow: 35.0 MGD 8. Velocity Gradient (sec-1): 725 (minimum) 9. Flow Direction: Overflow from weir into top of mixing chamber, flow is from top to down.
10. Type: Axial-mix 11. Pumping/Mixing Direction: Upward 12. Number of Shafts: 1 13. Shaft Diameter: 3.5”* 14. Number of blades: 4 15. Diameter: 3’-2”* 16. Max Speed: 118 RPM** 17. Tip Speed: 20 ft/sec** 18. Refer to the design drawings for additional details on the installation location and configuration of the mixing box.
* Dimension for reference only, to be confirmed and coordinated with mixer supplier. ** Values given for reference only. To be confirmed with mixer supplier.
C. Dechlorination (Sodium Bisulfite) Mixing Basin Design Criteria
1. Basin Width: 6’-0” 2. Basin Length: 6’-0” 3. Design Side Water Depth: 4’-0” 4. Opening in Lid for Mixer: 2’-10” square 5. Design Average Daily Flow: 14.0 MGD 6. Peak Hour Flow: 19.88 MGD 7. Peak Storm Event Flow: 35.0 MGD 8. Velocity Gradient (sec-1): 675 (minimum)
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9. Flow Direction: Flow enters the mixing chamber from the bottom channel baffle opening, and flows up through the mixer and over the weir that represents the top of the mixing chamber.
10. Refer to the design drawings for additional details on the installation location and configuration of the mixing box.
11. Type: Axial-mix 12. Pumping/Mixing Direction: Downward – confirm with mixer supplier 13. Number of Shafts: 1 14. Shaft Diameter: 3.5”* 15. Number of blades: 2 or 4 as recommended by supplier 16. Diameter: 2’-4”* 17. Max Speed: 76 RPM** 18. Tip Speed: 9.3 ft/sec** 19. Refer to the design drawings for additional details on the installation location and configuration of the mixing box.
* Dimension for reference only, to be confirmed and coordinated with mixer supplier. ** Values given for reference only. To be confirmed with mixer supplier.
2.5 DRIVE ASSEMBLY
A. The mixer drive consisting of a speed reducer and motor shall be factory mounted to an open type extended pedestal base. It is intended that the extended pedestal base be manufactured in the same factory as the mixer assembly to insure the proper fitment of mixer components. The pedestal base shall elevate the oil drain on the speed reducer so that oil can be conveniently drained by maintenance staff without the use of pumps. The pedestal base shall also provide access to the low speed impeller shaft coupling above the mounting platform and shall be designed to allow removal of the drive assembly without lifting or removal of the impeller shaft assembly. The base shall be made from ASTM A36 carbon steel and shall be painted in accordance with the specifications. Mixer designs not incorporating a pedestal base with the features cited herein will not be approved.
B. The speed reducer shall be a parallel shaft, all helical gear design or right angle helical - spiral bevel gear design. Worm gear drives are not acceptable. The gearbox shall be suitable for AGMA class II 24-hour continuous service under moderate shock conditions in an outdoor environment. The reducer case is to be manufactured of high strength grey cast iron, SAE Class 30 (plastic housings or covers not allowed). The gears shall be carburized to a hardness of 58-62 Rockwell C, and finish ground to a minimum AGMA Class 10 quality level to assure minimum backlash, noise, heat and a minimum 95 percent gearbox efficiency.
C. The speed reducer shall be provided with a suitable lubrication system for all-weather starting and operation of the unit. A dipstick or sight glass shall be provided to observe oil levels. All fill and drain lines shall be sized for efficient functioning, and located for easy access. Oil changes following the initial run-in period, shall not be required at less than 8,000 hour intervals. The low speed shaft shall be provided with an internal synthetic, spring loaded double lip seal, Dual external spring loaded double lip seals and a dry cavity between the seals which
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shall contain the lower grease lubricated output shaft bearings. The speed reducer breather shall be located above possible oil foam level. Other forms of lubrication, such as greasing of certain working parts within the speed reducer, are permissible provided adequate separation is made of these parts from oil lubricated parts. General maintenance, specifically including motor changes, and oil system maintenance including oil changes, shall not require the removal of the speed reducer from its foundation. The speed reducer shall be provided with lifting lugs suitable for lifting the complete mixing unit.
D. Mixer drive main gearbox bearings shall be designed for a minimum rated L10 life of 100,000 hours, with the output bearings rated for 300,000 hours.
E. The thermal rating of the speed reducer shall exceed the mechanical rating to eliminate the need for external coolers.
F. The speed reducer shall have a minimum service factor of 4.5 based on the motor nameplate horsepower rating.
G. The full load operating noise level of the gear reducer shall meet the more stringent requirements of current OSHA occupational noise standards or AGMA 299.01, and shall not exceed 85 dBA at a distance of three feet from any part of the drive assembly.
2.6 MOTOR
A. The mixer drive motors shall be severe duty, high efficiency, totally enclosed fan cooled (TEFC), cast iron designed for operation with a variable frequency drive. The motor shall be designed for continuous operation in a 50¼C ambient temperature environment with the horsepower ratings and speeds specified. The motors shall have a 1.15 service factor on across the line starting and a service factor of 1.0 when operating on PWM power. The motors shall be nameplated for inverter duty and have a Class F insulation rating.
B. Motors and electrical components shall comply with all requirements as outlined in Division 26 (Electrical) of the technical specifications.
2.7 LOW SPEED COUPLING
A. A flanged coupling assembly shall be used for connecting the gearbox output shaft and the vertical impeller shaft. The upper coupling half shall keyed on the speed reducer output shaft and shall be held in place by a retainer washer and bolt in the end of the gearbox output shaft. The lower mixer shaft coupling half shall be welded to the mixer shaft.
B. The coupling halves shall be either cast or machined from solid round bar of the wetted material specified. The couplings shall be turned and faced to provide a precision machined register fit. The coupling assembly shall be designed to transmit 200 percent of the full torque and 150 percent of the axial load on the coupling.
C. The coupling halves shall be bolted together through the flanges with plated bolts. The Contractor shall submit with the shop drawings details of the coupling-shaft sleeve arrangement for the Engineers review and acceptance.
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2.8 IMPELLER SHAFT AND ASSEMBLY
A. The impeller shaft shall be solid bar sized so the maximum operating speed of the impeller and shaft assembly does not exceed 70% of the first natural critical speed. The weight of both the shaft and the impeller assembly shall be taken into account in calculating the critical speed. The shaft diameter shall be determined by an analysis of shaft stresses caused by torque and bending moments as well as critical speed but shall in no case be less than indicated herein. The combined shaft stress shall not exceed 8,000 psi. The mixer shaft shall be straightened to within ¼ inch for every ten feet of length.
B. The impellers shall be of the axial flow upward or downward pumping type as required for each installation location. The assembly shall be made up of an impeller hub with bolt on blades. Axial flow impellers shall have a hub the blades evenly spaced on the hub having a minimum outside diameter specified herein. All mill scale, rust, and contaminants shall be removed. Sharp corners, cuts or sheared edges shall by dulled by a power grinder or file.
C. The assembled impeller shall be attached to the shaft using a hook-key design to transmit the torque and support the weight of the impeller. The design of the hook-key feature shall be such that with the impeller hub set screw loosened, the impeller cannot slide down the impeller shaft during installation.
2.9 PROTECTIVE COATINGS
A. All non stainless steel components shall be provided with protective coatings that at a minimum comply with the requirements of section 098000 – “Protective Coatings.” Manufacturer standards that meet or exceed the requirements of this section are acceptable.
PART 3 - EXECUTION
3.1 FACTORY TESTING
A. The mixers shall be fully assembled at the factory to insure proper fit-up of all components, and then operated to check for noise and vibration.
3.2 INSTALLATION
A. Install in accordance with the manufacturers written instructions and as approved.
B. Equipment shall be furnished with all spare parts and special tools as recommended by the manufacturer.
3.3 FIELD SERVICE
A. After completion of installation, the equipment shall be tested by the contractor under actual operating conditions. The tests shall demonstrate that the system and individual equipment items operate properly and in all other respects fulfills its function properly and meets all
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requirements of the specifications. Contractor shall furnish a manufacturer representative to conduct startup and training services in compliance with Section 017900 – Demonstration and Training.
END OF SECTION 466250
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