2. Upon completion of installation and after circuitry has been energized, demonstrate capability and compliance of transfer switches with requirements. Initial testing and re-testing, where necessary, shall be provided at no cost to OWNER.
M. Battery and UPS Systems:
1. Require factory-authorized technician to test and start up system.
N. Fire Alarm System:
1. Testing:
a. The ENGINEER and OWNER shall be present during the CONTRACTOR's pretest of the system, and subsequent fire department tests of the completed system. If the pretest of the system is unsuccessful, the CONTRACTOR shall compensate the ENGINEER and OWNER for witnessing all subsequent tests until the system is ready for acceptance testing by the Fire Department. The ENGINEER shall provide a written report of each test to the OWNER. These requirements shall be included in the specifications so that the CONTRACTOR will notify the ENGINEER of the times and dates of the tests, and will be aware that he will be responsible for reimbursing the ENGINEER should there be a need for subsequent tests.
b. The service of a competent, factory-trained engineer or technician (minimum NICET level 2) authorized by the vendor of the fire alarm equipment shall be provided to technically supervise and participate during all of the adjustments and tests for the system. All testing shall be in accordance with NFPA 72, Chapter 7, as amended in Part I, UFC Standard 10-2.
c. Before energizing the cables and wires, check for correct connections and test for short circuits, ground faults, continuity, and insulation.
d. Close each sprinkler system flow valve and verify proper supervisory alarm at the FACP. e. Verify activation of all water flow switches.
f. Open initiating device circuits and verify that the trouble signal actuates. g. Open and short signaling line circuits and verify that the trouble signal actuates. h. Open and short notification appliance circuits and verify that trouble signal actuates. i. Ground all circuits and verify response of trouble signals. j. Check presence and audibility of tone at all alarm notification devices. k. Check the digital communicator as follows: disconnect the primary phone line (a trouble signal shall be sent through the secondary phone line). Disconnect the secondary phone line (a trouble signal shall be sent through the primary phone line). If another telephone is on the same phone line as the fire alarm system, take the telephone off the hook to check for line seizure by the digital communicator.
l. Check installation, supervision, and operation of all intelligent smoke detectors using the walk test. Canned smoke (provided by CONTRACTOR and acceptable to the fire alarm equipment vendor) will be used at the final inspection to verify actuation of smoke detectors.
m. Each of the alarm conditions that the system is required to detect should be introduced on the system. Verify the proper receipt and the proper processing of the signal at the fire alarm panel and the correct activation of the control points. n. When the system is equipped with optional features, the vendor's manual shall be consulted to determine the proper testing procedures. This is intended to address such items as verifying controls performed by individually addressed or grouped devices, sensitivity monitoring, verification functionality and similar. 558
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2. Final Inspection:
a. At the final inspection, a factory-trained representative of the vendor of the major equipment shall demonstrate that the system functions properly in every respect. The CONTRACTOR is responsible for providing all tools and equipment necessary to demonstrate that the system functions as specified herein. Submit a request for a formal inspection at least five working days prior to the date the inspection is to take place. Any or all of the required tests shall be conducted by the CONTRACTOR at his own expense and additional tests required for the system to demonstrate compliance with all contract documents shall also be incurred by the CONTRACTOR. The CONTRACTOR shall furnish all appliances, equipment, instruments, connecting devices, two-way radios and personnel for the tests. Any costs incurred by OWNER for repeat tests, due to the failure of the CONTRACTOR to adequately demonstrate that the system complies with the contract requirements, shall be borne by the CONTRACTOR.
O. Kitchen Hood Fire Control Panel:
1. The completed system must be tested in the presence of the OWNER. The proper operation of the panel must be demonstrated.
2. Panel testing and demonstration will be in addition to tests and inspections required by Code Authorities having jurisdiction.
P. Telecommunications Systems:
1. Testing:
a. All cables and terminations shall be 100% tested for defects in installation and to verify cable performance under installed conditions. The CONTRACTOR, prior to system acceptance, shall verify all conductors of each installed cable. Any defect in the cabling system installation including but not limited to cable, connectors, feed-through couplers, patch panels, and connector blocks shall be repaired or replaced in order to ensure 100% useable conductors in all cables installed prior to final acceptance of the telecommunications system.
b. Testing results documentation must be provided on all installed cabling.
CONTRACTOR shall use a Fluke Model DSP4300 in-house for testing both fiber optic and copper media. CONTRACTOR to provide calibration certificate. c. Fiber testing shall be done using an approved tester as outlined above to achieve bidirectional testing for all links. Test results documentation shall be furnished to the ENGINEER upon completion of testing. Printed documentation is required and electronic documentation from the tester shall be included in the final submittal. Tests will be performed to the TIA/EIA – 568B.3 Standards. Terminated fibers shall not exceed
1.5-db loss from connector to connector.
d. Copper cable testing will require Permanent Link testing using the Fluke DSP4300 and PM-06 personality modules. Printed documentation is required and electronic documentation from the tester shall be included in the final submittal.
2. Inspection:
a. CONTRACTOR Project Manager shall inspect wiring installation after wire is installed and before closing the ceiling.
b. CONTRACTOR Project Manager shall inspect quality and workmanship of terminations on an on-going basis.
Q. Special Systems:
1. Test each PA/Intercom speaker to ensure that each one works at an acceptable sound level and without distortion.
2. Test each security device and ensure that each works and that the overall system is operational.
3. Test the clock system to ensure that the system and each device is operating correctly.
4. Test each voice enhancement system to ensure it is operational.
5. Test lightning protection systems per vendor’s instructions. 559
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3.4 ELECTRICAL SYSTEM STARTUP
A. Energize switchgear.
B. Check voltages at mechanical equipment
C. Check polarity for all receptacles.
D. Check lighting levels throughout building, within office spaces, on roof, and at parking and storage areas.
3.5 ACCEPTANCE FOR OPERATION
A. Each piece of equipment installed by this contract shall carry "Acceptance for Operation Checklist." Each checklist shall be signed by the CONTRACTOR's representative or OWNER's representative.
Each list shall have applicable blanks filled in and attached to items indicating that it is prepared for operation.
B. OWNER will accept equipment and systems for operation when construction has been substantially completed by CONTRACTOR. "Acceptance for Operation" shall mean OWNER will assume operational and routine maintenance duties. "Acceptance for Operation" does not relieve CONTRACTOR from responsibilities related to defective materials and workmanship; neither does it constitute final acceptance of materials and equipment.
C. After OWNER has accepted a system for operation, CONTRACTOR shall continue to perform the following as requested and scheduled by OWNER at no additional cost to OWNER until final acceptance:
1. Troubleshooting, adjustments, and repairs until system operation and performance is accepted by OWNER.
2. Assist instrument and control personnel with instrument calibration.
3. Craft labor as required.
D. After OWNER has accepted a system for operation, CONTRACTOR shall continue to supply technical services when needed until final acceptance.
END OF SECTION 26 0800
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SECTION 26 0916 ELECTRICAL CONTROLS, RELAYS, AND ALARMS PART 1 – GENERAL
1.1 SCOPE OF WORK
A. This Section includes the following:
1. Pushbutton and Selector Switches
2. Relays
3. Alarms
4. Intrinsic Safety Barriers
5. Wireways
6. Watthour Transducers
7. Elapsed Time Meters and Time Clocks
1.2 RELATED WORK
A. Related Sections:
1. Section 01 3300 – Submittal Procedures
2. Section 26 0000 – General Electrical Requirements
3. Section 26 2716 – Electric Cabinets and Enclosures
1.3 REFERENCES
A. NEMA ICS 1: General Standards for Industrial Control Systems.
B. NEMA ICS 2: Standards for Industrial Control Devices, Controllers and Assemblies.
C. NEMA ICS 6: Enclosures for Industrial Controls and Systems.
D. NEMA ST 1: Standard for Specialty Transformers (Except General purpose Type).
1.4 SUBMITTALS
A. Data: a complete list of equipment and material including manufacturer's descriptive data and technical literature, performance charts, catalog cuts and installation instructions, spare parts data for each different item of equipment specified. The data shall include a complete Bill of Materials.
B. Drawings: containing 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. Drawings shall show proposed layout, anchorage, support and appurtenances of equipment and equipment relationship to other parts of the work including clearances for maintenance and operations.
C. Submit shop drawings in accordance with the Contract Documents, and NEMA ICS 1 specifications indicating control panel layouts, wiring connections and diagrams, dimensions, support points.
1.5 PROJECT RECORD DOCUMENTS
A. Submit record documents in accordance with the Contract Documents.
B. Accurately record actual locations of control equipment. Revise diagrams included in Drawings to reflect actual control device connections.
1.6 OPERATION AND MAINTENANCE DATA
A. Submit operation data in accordance with the Contract Documents.
B. Include instructions for adjusting and resetting time delay relays, timers, and counters.
C. Submit maintenance data in accordance with the Contract Documents.
D. Include recommended preventative maintenance procedures and materials. 561
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PART 2 – PRODUCTS
2.1 PUSHBUTTONS AND SELECTOR SWITCHES
A. Pushbuttons, pilot lights and selector switches shall be of the full size, heavy-duty industrial, oil tight, 120 volt, with interchangeable pilot lights, plug-in construction, double break silver contacts, chrome plated lock rings, with modular contacts, and NEMA rating equal to that of the enclosure on which devices are installed. All components shall be flush mounted on front of panel, unless otherwise noted.
B. Provide individual legend plates for indication of switch, pushbutton, and light function (e.g., Open, Closed, Hand-Off-Auto). A list shall be submitted for review and approval C. Pilot lights shall be high intensity LED type. Pilot lights shall have clear lenses and LED lamps colored as shown on the Plans. Common, remote push-to-test circuitry shall be provided for each control panel to simultaneously test all indicating lights on the panel using a single pushbutton when there are 10 or more lights on the panel. Control panels with less than 10 lights shall utilize individual push-to-test lights and control circuitry.
D. Pushbuttons shall be maintained or momentary as required and as shown on the Drawings. Provide extended head pushbutton for all stop functions, mushroom head for emergency stop functions, and flush head pushbuttons for all other functions. Where indicated on the Drawings pushbuttons shall be illuminated type. Provide locking mechanism for all lock out functions. Selector switches shall have black knob operator, be maintained contact type unless noted otherwise, number and arrangement as required to perform intended functions specified but not less than one double pole, double throw, double break contact per switch. Contact rating shall be compatible with AC or DC throughput current of devices simultaneously operated by the switch contact but not less than 10 amperes resistive at 120 volts AC or DC continuous.
E. Potentiometers shall be provided with operators and resistive elements of the type and quantity indicated on the Drawings and as required with legend plates indicating percent of span.
F. The above devices shall be manufactured by Allen Bradley, General Electric, or ENGINEERapproved equal.
2.2 RELAYS
A. Timing relays shall be heavy duty, 120VAC, 10 amps, solid state design, poles as required per application, -10 degrees C. to +60 degrees C, have timing repeatability of ±2.0% of setting, and be UL listed. The range shall be determined from the control descriptions and or schematic drawings.
Provide mounting accessories, as required. The timing relays shall be manufactured by Allen Bradley, Cutler Hammer, or ENGINEER-approved equal.
B. Control relays shall be of the plug-in socket base type with dust-proof plastic enclosures, with silver-cadmium oxide contacts rated 120VAC, 10 amperes, with contact arrangement and operating coils of the proper voltage as required by the control circuit sequence. Relays shall have indicating lamp to show energized state. Each relay shall have a minimum of two double pole, double throw contacts, or as required. Control relays shall be Allen Bradley, Cutler Hammer, or ENGINEERapproved equal.
C. Alternating relays shall be UL listed, 120VAC, with contacts rated for 10 amperes at 120VAC, life expectancy of 100,000 operations, load indicating LEDs, and switch for load locking and load selecting options. Alternating relays shall be manufactured by TimeMark models 261, 271, and 471, and Diversified Electronics model ARA for duplex, triplex, and quadplex alternators. 562
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2.3 ALARMS
A. Audible alarms shall be UL listed, 120 VAC, with solid state circuitry, vibrating horn, non-metallic corrosion resistant housing, with required mounting hardware, suitable for outdoor use capable of producing 100 dB at 10 feet. The audible alarm shall be manufactured by Federal Signal model 350, Edwards model 870--EX, or ENGINEER-approved equal.
B. Beacons for interior and/or exterior locations shall be rated NEMA 4X, flashing type (90 times per minute, minimum) with a red lens. Beacons shall be as manufactured by Federal Signal, Model 225XL, or ENGINEER-approved equal.
2.4 INTRINSIC SAFETY BARRIERS
A. Intrinsic safety barriers shall permit connection of devices located in a hazardous area to other devices located in a safe area. Intrinsic safety barriers shall be EMC compliant, 10 to 35 V dc, 35 mA output current, hazardous area terminals identified by blue labels, terminals accommodating conductors up to 12 AWG, ambient temperature rating of -20 to +60°C. The intrinsic safety barriers shall be manufactured by Allen-Bradley Bulletin 937, or ENGINEER-approved equal.
2.5 WIREWAYS
A. Wireways shall be PVC, snap-in slot design, with non-slip cover. Safe area wireways shall be light gray and marked "Safe Area Wiring." Hazardous area wireways shall be intrinsic blue and marked "Hazardous Area Wiring." The wireways shall be manufactured by Panduit Corporation, or ENGINEER-approved equal.
2.6 WATTHOUR TRANSDUCERS
A. Watthour transducers for active or reactive power shall be DIN rail and surface mount, single phase or three phase with balanced or unbalanced load, electrically isolated input and output signals, 4 to 20 mA output signal, 0-10 mA to 0-10 A input current, 0-10 V to 0-600 VAC input voltage, 16- 500 Hz selectable frequency. The watthour transducers shall be manufactured by Sineax model PQ502, or ENGINEER-approved equal.
2.7 ELAPSED TIME METERS AND TIME CLOCKS
A. Elapsed time meters shall be self-powered, non-reset, solid state counter which provides silent, accurate and noise immune operation. Elapsed time meters shall require no external power, five year minimum battery life, 120 VAC power, accessories for panel mounting, nameplate below LCD display reading "HOURS", liquid crystal display with 6 digits approximately 2 inches high with 50,000 hour minimum display life and indication of sufficient battery power. The elapsed time meters shall be manufactured by Durant, Automatic Timing and Controls a Division of Sycon Corp., or ENGINEER-approved equal.
B. Time clocks shall be microprocessor based, have 24 hour time control, up to 24 operations per day, programmable from panel face keys, skip-a-day feature allowing schedule to be skipped for one to seven days, SPDT switch contact rated at 15 amps at 120 V AC, with battery carryover to maintain time and program during power outage for 275 hours. The time clocks shall be manufactured by Tork, Paragon Electric Company, or ENGINEER-approved equal.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Fasteners shall be type 316 stainless steel.
B. Install devices in strict accordance with NEC requirements and per manufacturers recommendation.
C. Coordinate with other trades as necessary during installation of these devices. 563
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3.2 ACCEPTANCE
A. All installations are subject to evaluation in accordance with NEC requirements and manufacturers recommendations. CONTRACTOR shall remove the unacceptable work and correct work at no charge to OWNER.
END OF SECTION 26 0916
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SECTION 26 1216 - DRY TYPE 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 fighting.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with the Contract Documents prior to installation.
1.3 QUALITY ASSURANCE
A. IEEE C57.12.01, General Requirements for Dry-Type Distribution and Power Transformers B. NEMA ST 20, Dry-Type Transformers for General Applications C. UL 506, Standard for Specialty Transformers
PART 2 – PRODUCTS
2.1 DISTRIBUTION - LOW VOLTAGE LIGHTING AND POWER
A. Transformers shall be premium high efficiency quiet type in accordance with IECC 2018 Table C405.6, and shall be installed where indicated on the Plans. The primary winding of the transformers shall have two 2.5% taps above, and below normal.
B. The transformers shall have a BIL of 10 KV with a temperature class of 185°C for transformers up to 25 KVA, and a temperature class of 220°C for larger transformers.
C. 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.
D. Transformers shall be types manufactured by Square-D, Eaton, ACME, or ENGINEER-approved equal.
2.2 FERRO RESONANT ISOLATION TRANSFORMERS
A. Ferro resonant isolation transformers shall be provided where indicated on the Plans. Regulation shall be +3 percent for an input range of +10 percent. 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 ENGINEER-approved 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. CONTRACTOR shall provide painted metal wall brackets, when required.
B. Grounding shall be provided per NEC, and Section 26 0526 – Grounding and Bonding for Electrical Systems.
C. A sign with 2” high black letters on a white background shall indicate the exact (not the general) location of the transformer’s primary circuit disconnect switch.
END OF SECTION 26 1216
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SECTION 26 2416 - 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 the Contract Documents prior to installation.
B. Panel layout with alphanumeric designation, branch circuit breaker sizes and types, AIC rating, bus sizes, and other characteristics.
1.3 QUALITY ASSURANCE
A. NEMA PB-1, Panelboards
B. NEC 2020
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. 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 3R. The minimum interrupting capacity of any device shall be as indicated on the Plans.
B. Protective devices shall be replaceable without disturbing adjacent units. 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 panel. Phase busing shall be full height without reduction. Full size neutral bars shall be included, and shall have suitable lug for each outgoing circuit requiring neutral 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. 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.
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 manufactured by Cutler Hammer, General Electric, or ENGINEER-approved equal.
F. Panelboards shall be service entrance rated where required, and as shown on the Plans.
G. Panelboards shall be bolt-on type and provided with spare breakers as indicated on the drawings.
H. Panelboards shall include a typed schedule of breakers located inside the panel.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Panelboards shall be installed as indicated on the plans and according to manufacturer's instructions.
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B. Provide grounding per NEC 408.40, and Section 26 0526 – Grounding and Bonding for Electrical Systems.
C. CONTRACTOR shall verify all NEC clearance requirements prior to installation.
END OF SECTION 26 2416
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SECTION 26 2416.10 - LOW-VOLTAGE DISTRIBUTION PANELBOARDS PART 1 – GENERAL
1. 1 SCOPE
A. The ENGINEERCONTRACTOR shall furnish and install, where indicated, a wall mounted NEMA 4X, dead-front type low-voltage distribution panelboard, utilizing group mounted circuit protective devices as specified herein, and as shown on the contract drawings.
B. Related Section: Section 01 3300 – Submittal Procedures.
1.2 REFERENCES
A. The low voltage distribution panelboards and all components shall be designed, manufactured and tested in accordance with the latest applicable following standards:
1. NEMA PB-2
2. UL Standard 891
1.3 SUBMITTALS
A. The following information shall be submitted to the ENGINEER for review:
1. Master drawing index
2. Front view elevation
3. Floor plan
4. Top view
5. Single line
6. Schematic diagram
7. Nameplate schedule
8. Component list
9. Conduit entry/exit locations
10. Assembly ratings including:
a. Short-circuit rating
b. Continuous current
c. Voltage
11. Major component ratings including:
a. Voltage
b. Continuous current
c. Interrupting ratings
12. Cable terminal sizes.
B. Submit copies of the following information for record purposes:
1. Final as-built drawings and information for items listed in Section 1.4
2. Wiring diagrams
3. Certified production test reports
4. Installation information
5. Seismic certification and equipment anchorage details
1.4 QUALIFICATIONS
A. The manufacturer of the assembly shall be the manufacturer of the circuit protective devices within the assembly.
B. For the equipment specified herein, the manufacturer shall be ISO 9000, 9001 or 9002 certified. 568
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C. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the ENGINEER, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.
1.5 REGULATORY REQUIREMENTS
A. The low-voltage panelboard shall be UL labeled.
1.6 DELIVERY, STORAGE AND HANDLING
A. Equipment shall be handled and stored in accordance with manufacturer's instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment.
1.7 OPERATION AND MAINTENANCE MANUALS
A. Copies of the equipment operation and maintenance manuals shall be provided. Operation and maintenance manuals shall include the following information:
1. Instruction books and/or leaflets
2. Recommended renewal parts list
3. Drawings and information required by section 1.4.
PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Cutler-Hammer
B. Eaton
C. General Electric
D. Schneider
E. Siemens
F. ENGINEER-approved equal
2.2 RATINGS
A. The assembly shall be rated to withstand mechanical forces exerted during short-circuit rating as indicated on the Plans.
B. Voltage rating to be as indicated on the Plans.
2.3 CONSTRUCTION
A. Panelboard shall consist of the required number of vertical sections bolted together to form a rigid assembly. The sides and rear shall be covered with removable bolt-on covers. All edges of front covers or hinged front panels shall be formed. Provide adequate ventilation within the enclosure.
B. All sections of the panelboard shall be rear aligned with depth as shown on the drawings. All protective devices shall be group mounted. Devices shall be front removable and load connections front accessible enabling panelboard to be mounted against a wall.
C. The assembly shall be provided with adequate lifting means.
D. The panelboard shall be equal to Eaton type PRL4X utilizing the components herein specified and as shown on the drawings.
E. The panelboard shall be UL listed.
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2.4 BUS
A. All bus bars shall be silver-plated copper. Main horizontal bus bars shall be mounted with all three phases arranged in the same vertical plane. Bus sizing shall be based on NEMA standard current density of 1000 amps per square inch.
B. Provide a full capacity neutral bus where a neutral bus is indicated on the drawings.
C. A copper ground bus (minimum 1/4 x 2 inch), shall be famished, firmly secured to each vertical section structure, and shall extend the entire length of the panelboard.
D. All hardware used on conductors shall be high-tensile strength and zinc-plated. All bus joints shall be provided with conical spring type washers.
2.5 WIRING/TERMINATIONS
A. Small wiring, necessary fuse blocks and terminal blocks within the panelboard shall be furnished as required. Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on manufacturers wiring diagrams. Wiring diagrams shall contain terminal and wire numbers.
B. Mechanical-type terminals shall be provided for all line and load terminations suitable for copper or aluminum cable rated for 75°C of the size as indicated on the Plans.
C. Lugs shall be provided in the incoming line section for connection of the main grounding conductor. Additional lugs for connection of other grounding conductors shall be provided as indicated on the Plans.
D. All control wire shall be type SIS, bundled and secured with nylon ties. Insulated locking spade terminals shall be provided for all control connections, except where saddle type terminals are provided integral to a device. All groups of control wires leaving the panelboard shall be provided with terminals blocks with suitable numbering strips. Provide wire markers at each end of all control wiring.
2.6 MOLDED CASE PROTECTIVE DEVICES
A. Main and feeder protective devices shall be molded case circuit breakers with inverse time and instantaneous tripping characteristics and shall have ground fault protection where indicated, or as required by NEC.
B. Circuit breakers shall be operated by a toggle-type handle and shall have a quick-make/quick-break over-center switching mechanism that is mechanically trip-free. Automatic tripping of the breaker shall be clearly indicated by the handle position. Contacts shall be non-welding silver alloy, and arc extinction shall be accomplished by means of DE-ION arc chutes. A push-to-trip button on the front of the circuit breaker shall provide a local manual means to exercise the trip mechanism.
C. Circuit breakers shall have a minimum symmetrical interrupting capacity as indicated on the Drawings.
D. Where indicated on the Drawings, circuit breakers shall be UL listed for series application.
E. Where indicated on the Drawings, circuit breakers shall be current limiting.
F. Circuit breakers 400 ampere frame and below shall be thermal-magnetic trip units and inverse timecurrent characteristics.
G. On circuit breakers 800 amps and larger, a trip button and integral current reading display shall be provided
H. Where indicated, provide circuit breakers UL listed for application at 100% of their continuous ampere rating in their intended enclosure.
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I. Provide lamicoid labels for feeder circuit breakers that provide a descriptive name, as identified on the Drawings, of the load being served. Include circuit number and circuit breaker trip rating.
2.7 ACCESSORIES
A. Circuit Breaker Energy Monitoring.
B. Centralized Local Monitoring.
C. Provide transient voltage surge suppression as specified/indicated on the Plans.
2.8 MISCELLANEOUS DEVICES
A. Control power transformers with primary and secondary protection shall be provided, as indicated on the Plans, or as required for proper operation of the equipment.
B. Each section of the panelboard shall be provided with a space heater, thermostatically controlled.
Power for the space heaters shall be obtained from a control power transformer within the panelboard. Supply voltage shall be 120 volts AC.
2.9 ENCLOSURES
A. Valve vault location NEMA 4X Enclosure
1. Enclosure shall be non-walk-in and meet applicable NEMA 4X UL requirements.
2. Doors shall have provisions for padlocking.
3. Provide space heaters thermostatically controlled for each structure with adequate wattage to prevent the accumulation of moisture.
4. Power for space heaters, lights and receptacles shall be obtained from a control power transformer within the panelboard. Supply voltage shall be 120 volts AC.
2.10 NAMEPLATES
A. Engraved nameplates, mounted on the face of the assembly, shall be furnished for all main and feeder circuits as indicated on the Plans. Nameplates shall be laminated plastic, black characters on white background. Characters shall be 3/16-inch high, minimum. Nameplates shall give item designation and circuit number as well as frame ampere size and appropriate trip rating. Furnish master nameplate giving panelboard designation, voltage ampere rating, short-circuit rating, manufacturer's name, general order number, and item number.
B. Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on manufacturer's wiring diagrams.
2.11 FINISH
A. All exterior and interior steel surfaces of the panelboard shall be properly cleaned and provided with a rust-inhibiting phosphatized coating. Color and finish of the panelboard shall be ANSI 61 light gray.
PART 3 – EXECUTION
3.1 FACTORY TESTING
A. The following standard factory tests shall be performed on the equipment provided under this section. All tests shall be in accordance with the latest version of ANSI and NEMA standards.
1. The panelboard shall be completely assembled, wired, adjusted, and tested at the factory.
After assembly, the complete panelboard will be tested for operation under simulated service conditions to assure the accuracy of the wiring and the functioning of all equipment. The main circuits shall be given a dielectric test of 2200 volts for one (1) minute between live parts and ground, and between opposite polarities. The wiring and control circuits shall be given a dielectric test of 1500 volts for one (1) minute between live parts and ground.
B. The manufacturer shall provide certified copies of factory test reports. 571
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3.2 INSTALLATION
A. The CONTRACTOR shall install all equipment per the MANUFACTURER'S instructions, Contract Documents, and National Electrical Code.
B. The assembly shall be provided with adequate lifting means and shall be capable of being moved into installation position and bolted directly to the floor without the use of floor sills provided the floor is level to 1/8 inch per 3-foot distance in any direction. All necessary hardware to secure the assembly in place shall be provided by the ENGINEER.
3.3 FIELD INSPECTION AND TESTS
A. Provide the services of an authorized representative of the equipment manufacturer to make site visits to supervise the field testing and installation to be performed by the ENGINEER. The manufacturer’s representative shall state in writing that the equipment has been correctly installed and tested.
B. Perform the following minimum tests and checks before energizing equipment:
1. Megger terminals and busses for grounds after disconnecting devices sensitive to megger voltage.
2. Inspect all mechanical and electrical interlocks for proper operation.
C. Perform any other tests recommended by the equipment manufacturer and other tests as described in this specification.
D. The manufacturer’s representative shall supply results of all factory and field tests in writing for submittal to the ENGINEER.
E. The manufacturer shall supply test results to confirm that the assembly design has been tested to substantiate conformance with the applicable ANSI and NEMA Standards.
F. Touch-up paint all chips and scratches with manufacturer supplied paint and leave remaining paint with OWNER.
G. The ENGINEER/CONTRACTOR shall perform field adjustments of the protective devices as required to place the equipment in final operating condition. Necessary field settings of devices, adjustments, and minor modifications to equipment to accomplish operational condition shall be carried out by the ENGINEER/CONTRACTOR at no additional cost to the OWNER.
END OF SECTION 26 2416.10
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SECTION 26 2420 INDUCTION MOTORS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. This Section outlines the electrical requirements for squirrel-cage induction motors.
1.2 SUBMITTALS
A. Submit for approval, shop drawings, factory test reports, manufacturers' certified reports and technical data for motors supplied with driven equipment to the extent required in this Section, and the Specification Sections for mechanical equipment.
B. Shop Drawings: In addition to information to be included in the shop drawings and shall include the following:
1. Motor locked rotor and full load currents.
2. Power factors and efficiencies at full load, three quarters load and half load.
3. Motor housing material, winding material NEMA Design letter, NEMA Code Letter, ambient temperatures and maximum elevations in which motor is designed to operate continuously, service factor, NEMA insulation Class, temperature rise, type of enclosure, voltage, bearing life and dynamic balance; all of which shall comply to the requirements of these specifications.
4. Nameplate data.
5. Dimensions and weights of motors.
6. Motor construction details.
7. Speed torque/current at 100 percent rated voltage.
8. Wiring diagrams, internal and typical external connections.
C. Current Data: Submit to the ENGINEER of field recorded current data. The data shall indicate the full load current for each motor and current rating for the overload relay in each motor starter and controller.
PART 2 – PRODUCTS
2.1 GENERAL
A. Motors shall be supplied by the manufacturer of the driven equipment as specified in this section, and specifically outlined in the driven equipment specifications. The Motors shall be completely fabricated, assembled, checked, and tested at the factory in accordance with NEMA MG-1. The induction motors shall be Siemens-Allis, Louis Allis, Reliance, U.S. Electrical Motors, or ENGINEER-approved equal.
B. Motors driven by variable speed drives must be inverter-duty motors.
C. Motor Ratings (non-submersible type):
1. Torque and slip characteristics shall be as recommended by the manufacturer of the driven equipment and as specified. Motor manufacturer shall confirm motor capability to the specifications.
2. Motors shall operate continuously and satisfactorily in ambient temperatures from minus 10°C to plus 50°C at a maximum elevation of 1,200 feet without exceeding nameplate horsepower rating.
3. The motors shall have high power factor and the minimum power factor shall be 80 percent at full load.
4. Motors shall be designed for premium efficiency in accordance with IECC 2018 Tables C405.7(1) through C405.7(4) and NEMA MG-1 Table 12-12.
5. The motors shall be sized so that the BHP does not exceed 95 percent of the full load nameplate horsepower.
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6. The motor must be able to accelerate the driven machine from zero to top speed at 90 percent of rated voltage without overheating.
7. The maximum locked rotor KVA/HP code letter for motors smaller than 15 HP shall not exceed the requirements for NEMA Design B motors. The maximum locked rotor KVA/HP code letter shall be Code G for motors 15 HP through 250 HP unless otherwise indicated.
The maximum locked rotor KVA/HP code letter shall be Code F for motors 300 horsepower and larger unless otherwise indicated.
8. All motors shall be insulated and braced for full voltage across the line, starting regardless of the starting method used.
9. Motors 1/2 HP and larger shall be NEMA MG1-1.16 Design B and shall have NEMA MG1-
1.65 Class F insulation.
10. The temperature rise by resistance above the temperature of the cooling medium, for each of the various parts of the motor shall not exceed the values of the NEMA MG1-1.65 Class B insulation system as indicated in NEMA MG 1-12.42. These are total temperatures, based on maximum ambient of 40°C (104°F), plus additional heat (temperature rise) generated by motor operation. Greater than 40°C ambient shall require at a minimum, Class H insulation special application considerations or special motor designs.
11. All open and TEFC motors 250 HP and less and all vertical motors shall have a 1.15 service factor. All horizontal motors larger than 250 HP shall have a 1.0 service factor.
12. Motors 1/2 HP through 250 HP shall be 460 volts, 3 phase, 60 Hertz unless otherwise indicated.
13. Motors smaller than 1/2 HP shall be 120/240 volts, 1 phase, 60 Hertz unless otherwise indicated.
D. Motor Construction:
1. Enclosures for induction motors shall be approved for the installations and as indicated. The enclosure types shall be one of the following as outlined in the driven equipment specifications unless otherwise indicated.
a. Totally-enclosed fan cooled
b. Totally-enclosed non-ventilated
c. Weather-protected, Type I
d. Weather-protected, Type II
e. Drip-proof fully guarded
f. Drip-proof
g. Splash-proof
h. Open
2. Provide epoxy vacuum pressure impregnated (VPI) motors when indicated in the driven equipment specifications. The windings in squirrel cage induction motors shall be completely filled with an insulating resin epoxy which also forms a protective coating. a. The stator windings on all motors, except 56 and 140 frame sizes, shall be vacuum pressure impregnated with an epoxy or shall be epoxy encapsulated 56 and 140 frame size motors shall have extra dips and bakes of Class F varnish.
3. Housing, end brackets and all outside components shall be cast iron or aluminum except WP II or open drip-proof enclosures which may be fabricated steel or aluminum.
4. A condensate drain hole shall be provided on all enclosed motors. The drain hole shall be provided in each end bracket on horizontal motors. A single drain hole shall be provided in the lower bracket of vertical motors. Open motors shall be self-draining. A UL approved breather/drain shall be provided on all explosion-proof motors. 574
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5. The motors shall be equipped with terminal boxes for all conduit and wire connections as required.
a. The terminal boxes shall be properly sized, diagonally split, cast iron, and rotatable in 90 degree steps. Provide a gasket between the box and motor frame and between the box and the cover. Terminal boxes shall be attached to the motor frame with grade 5 zinc plated and chromated steel bolts or cap screws. All terminal boxes shall have threaded holes for conduit entrance.
6. The castings shall be coated with a red-oxide zinc-chromate primer, and finished with a corrosion resistant epoxy coating. All fabricated steel enclosures shall be coated on all inside and outside surfaces except shafts and register fits.
7. Provide stainless steel fasteners and nameplates of ample size with clear numerals and letters. a. Nameplates shall indicate the manufacturer, serial number, model number, type, horsepower, phase, hertz, volts, design, full load amperes, locked rotor code letter, service factor, speed, insulation class, temperature rating, information required by NEMA MG 1-10.38 and other essential data.
b. Nameplate data shall be in the English language and units. c. Nameplates shall be secured to the motor frame with corrosion resisting pins in accessible locations.
8. Ground lugs shall be provided in all main motor terminal boxes for grounding.
9. All motors shall have copper windings.
10. Antifriction bearings shall be grease lubricated except for vertical, high thrust motors, which may require oil lubrication.
a. Grease lubricated bearings shall include accessible fittings for in-service, periodic relubrication.
b. Oil lubricated bearings shall be a reservoir type with a sump for settling foreign matter, accessible and exterior fill and drain plugs and a visual oil level indicator with maximum and minimum indicator levels.
c. Horizontal, direct connected motor bearings shall be designed for 1-year minimum B10 bearing life at NEMA minimum V-belt criteria for the rating. d. Horizontal, V-belt connected motor bearings shall be designed for 3-year minimum B10 bearing life for the application V-belt drive, or 1-year minimum B-10 bearing lift at NEMA minimum V-belt criteria - whichever is more restrictive. e. Vertical motor bearings shall be designed for 2-year minimum B-10 bearing life at design operating thrust. At maximum operating thrust, B-10 life shall not be less than one year. Transient (shut-off) thrust shall not exceed 30% of the static deformation limit. Motor shall be designed for 30% momentary upthrust capacity, except 3600 RPM units, which must have 30% continuous upthrust capacity. Any system which exceeds 30% upthrust must be designed for continuous upthrust at one-year B-10 bearing lift.
f. Pre-lubricated, double shield bearings are acceptable only on single phase and 56 frame motors.
11. The dynamic balance of motors built in frame size 143 and larger shall be 0.001 inches total amplitude or peak-to-peak displacement.
12. Accessories for motors 125 HP and larger shall include the following:
a. A set of non-linear, resistance temperature detectors, "PTC thermistors" or ENGINEER-approved equal, shall be embedded in the winding. The detector relays shall have one normally open and one normally closed (spare) contacts, and shall be mounted in the motor control center. One relay shall have the normally open contact to actuate an alarm and shut down motor when the temperature rise reaches 15° Centigrade below the motor insulation temperature rating when operating in an ambient temperature of 40°C. The detector shall protect the motor against overheating caused by overloads, loss of cooling medium and single phasing. 575
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b. A set of non-linear, resistance temperature detectors, "PTC thermistors" or ENGINEER-approved equal, shall be required for bearing temperature. The detector relay shall have one normally open and one normally closed (spare) contacts, and shall be mounted in a box with cover on the motor frame. One relay shall have the normally open contact to actuate an alarm and shut down motor when the temperature rise reaches 15° centigrade below the motor insulation temperature rating when operating in an ambient temperature of 40°C. The detector shall protect the motor against overheating caused by loss of cooling medium and bearing failure. c. All of the above accessories shall have wires brought out in a terminal box or boxes.
13. Motors shall have a guaranteed maximum noise level that shall be in accordance with NEMA MG3-1974, Sound Level Prediction for Installed Rotating Electrical Machines, except where more restrictive requirements are outlined in other Sections of the Specifications.
PART 3 – EXECUTION
3.1 GENERAL
A. Provide all the equipment installations and wiring installations, including connections as indicated, specified and required. Assure proper fits for all equipment and materials in the spaces as shown on the Drawings.
B. Motors:
1. Provide power, control, alarm, and grounding installations for all motors as indicated and required.
2. Check the connections and provide correct rotation for all motors.
3. Record the full load current to each motor, and the overload relay rating in each motor starter for the certified data submittal.
4. Provide the required wiring for all control equipment that shall be furnished and installed by other Sections of the Specifications.
5. Field damaged factory finish on equipment shall be touched-up with paint that is equal in quality and color to the original factory finish.
3.2 FACTORY TESTS
A. All Motors shall be given a standard commercial test as defined by NEMA MG 1-12.51 and IEEE 112a and b.
B. All Motors 125 horsepower and Larger shall be given complete tests as defined by IEEE 112 Method A and B. Report of test shall include data on IEEE 112 Form A2, as applicable to the motor tested. Test shall confirm the following:
1. Service factor temperature.
2. Efficiency
3. Torque
4. No load, full voltage vibration level.
C. Vibration Tests shall be per NEMA MG 1-12.06 and MG 1-2053.
D. All Testing, other than lock conditions shall be at full voltage +5 percent.
3.3 FIELD CHECKS
A. Motor Installations shall be complete and correct.
B. Operation Tests shall be performed to observe that motors start, run and stop satisfactorily under design load.
END OF SECTION 26 2420
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ELECTRICAL CABINETS AND ENCLOSURES 26 2716 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 26 2716 - ELECTRICAL CABINETS AND ENCLOSURES
PART 1 – GENERAL
1.1 SCOPE OF WORK
A. This specification includes enclosures to house electrical controls, instruments, terminal blocks, and serve junction boxes where shown on the Plans.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with the Contract Documents prior to installation.
1.3 MANUFACTURERS
A. Enclosures shall be manufactured by Hammond, Hoffman, Rittal, or ENGINEER-approved 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 provided 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 phosphatized 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 outdoor, wet or wash down areas and corrosive areas, and NEMA 3R/4X for outdoor installations.
NEMA 4X enclosures shall be 316 stainless steel where called out on the plans, and 304 stainless steel otherwise. NEMA 4X enclosures shall also be used in
2.3 FIBERGLASS ENCLOSURES (where indicated in plans)
A. Where called out in the Plans, fiberglass NEMA 4X enclosures shall be compression molded, fiberglass reinforced polyester, high impact, and heat resistant.
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 26 2716
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WIRING DEVICES 26 2726 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 26 2726 - WIRING DEVICES
PART 1 – GENERAL
1.1 SUMMARY
A. Section Includes:
1. Light switches, receptacles, device plates, dimmers, plug-in strips and tele-power poles.
B. Related Sections:
1. Division 00 – Conditions of the Contract
2. Division 01 – General Requirements.
3. Section 26 0000 – General Electrical Requirements
4. Section 26 0526 - Grounding and Bonding for Electrical Systems
5. Section 26 0533 - Outlet, Pull, and Junction Boxes
1.2 QUALITY ASSURANCE
A. Referenced Standards: Refer to Section 26 0000 – General Electrical Requirements.
1.3 SUBMITTALS
A. Shop Drawings: Refer to the Contract Documents.
PART 2 – PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable:
1. Light switches (except explosion proof):
a. Hubbell.
b. Slater.
c. P&S.
d. Arrow Hart.
e. General Electric.
f. Leviton.
2. Explosion proof light switches:
a. Crouse-Hinds.
b. Appleton Electric Co.
c. Killark.
3. Door switches:
a. General Electric.
b. Slater.
c. P&S.
d. Arrow Hart.
e. Micro-switch.
4. Receptacles (except explosion proof):
a. Hubbell.
b. Slater.
c. P&S.
d. Arrow Hart.
e. General Electric.
f. Leviton.
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5. Explosion proof receptacles:
a. Crouse-Hinds.
b. Appleton Electric Co.
c. Killark.
6. Welding receptacles:
a. Crouse-Hinds.
b. Appleton Electric Co.
7. Tele-power poles:
a. Wiremold.
b. Walker.
8. Dimmers:
a. Lutron.
b. General Electric
c. P&S.
9. Plug-in strip:
a. Wiremold.
b. Walker.
B. Submit requests for substitution in accordance with Specification Section 26 0533 - Outlet, Pull, and Junction Boxes.
2.2 MATERIALS
A. Light Switches for Unclassified Areas:
1. Toggle type, quiet action, specification grade with grounding terminal.
2. Back and side wired.
3. Solid silver cadmium oxide contacts.
4. One-piece switch arm rated 20 A, 120/277 V AC.
5. UL listed.
6. Color: Ivory.
7. Wall plate: Type 304 stainless steel.
8. Type: As indicated on Drawings.
B. Receptacles for Unclassified Areas:
1. Straight blade, grounding type, specification grade.
2. Back and side wired with wrap-around bridge.
3. Rated 20 A, 125 V AC.
4. UL listed.
5. Color:
a. For use on normal power: Ivory.
b. For use on UPS systems: Red.
c. For use on isolated ground systems: Orange.
6. Wall plate: Type 304 stainless steel.
7. Type: As indicated on Drawings.
C. Light Switches for Wet Areas:
1. Presswitch type, quiet action, specification grade, with grounding terminal.
2. Back and side wired.
3. Solid silver cadmium oxide contacts.
4. One-piece switch arm rated 20 A, 120/277 V AC.
5. UL listed.
6. Color. Ivory.
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7. Wall plate: Gray weatherproof presswitch type.
8. Type: As indicated on Drawings.
D. Receptacles for Wet Areas:
1. Straight blade, grounding type, specification grade.
2. Back and side wired with wrap around bridge.
3. Rated 20 A, 125 V AC.
4. UL listed.
5. Color: Ivory.
6. Wall plate: Weatherproof, cast aluminum, UL listed, WDL open and closed.
7. Type: As indicated on Drawings.
E. Ground Fault Circuit Interrupter Receptacles:
1. Straight blade, grounding type, specification grade.
2. Rated 20 A, 125 VAC.
3. UL listed.
4. Test and reset buttons.
5. Wall plate: Indoor or weatherproof as required.
6. Feed-through type.
F. Light Switches for Corrosive Areas:
1. Corrosion-resistant NEMA 4X enclosure with switch consisting of:
a. Fiberglass reinforced polyester enclosure.
b. Fiberglass reinforced polyester gasketed wall plate with built-in toggle lever switch with stainless steel shaft.
c. Grounding bushing.
d. Rated 20 A, 125 V AC.
e. UL listed.
f. Type: As indicated on Drawings.
g. Color. Yellow.
2. Optional: Corrosion-resistant enclosure and switch consisting of:
a. Cast copper-free aluminum "FS" or "FD" ridge type hub box. b. Toggle type, quiet action, specification grade with grounding terminal. c. Rated 20 A, 125 V AC with solid silver cadmium oxide contacts. d. UL listed.
e. Neoprene gasket.
f. Cast aluminum cover with stainless steel screws and lever to activate switch. g. Type: As indicated on Drawings.
h. Color: Yellow.
G. Receptacles for Corrosive Areas:
1. Corrosion-resistant straight blade, grounding type, specification grade.
2. Back and side wired with wrap-around bridge.
3. Rated 20 A, 125 V AC.
4. UL listed.
5. Color: Yellow.
6. Box: "FS" or "FD" ridge type cast hub box of copper-free aluminum.
7. Gasket: Neoprene.
8. Wall plate: Weatherproof, cast aluminum, UL listed, WDL open or closed.
9. Type: As indicated on Drawings.
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H. Explosion proof Light Switches for Use in Hazardous Areas:
1. Explosion proof, UL listed for Class I, Division 1 and 2, Groups B, C, and D; and Class II, Division 1 and 2 areas, Groups E, F, and G.
2. EDS factory sealed.
3. Malleable iron body and cover.
4. Aluminum sealing chamber.
5. Front operated handle with stainless steel shaft.
6. Rated 20 A, 125 V AC.
7. With grounding screw.
8. Type: As indicated on Drawings.
I. Explosion-proof Receptacles for Use in Hazardous Areas:
1. Explosion-proof, UL listed for Class I, Division 1 and 2, Groups B, C, and D; and Class II, Division 1 and 2, Groups F and G.
2. Factory-sealed malleable iron receptacle with spring-loaded cover.
3. Malleable iron mounting box.
4. Rated 20 A, 125 V AC.
5. "Dead-front" construction requiring plug to be inserted and rotated to activate receptacle.
6. Type: As indicated on Drawings.
J. Welding Receptacles: 1. 60 A, 480 V, 3 pole, 4 wire, grounding type.
K. Plug-In Strip: Surface steel raceway plug-in strip with single 15 A, 125 V, 3 wire grounding-type receptacles spaced 18 IN on center.
1. Prewired with two #12 TW and one #12 TW green insulated ground.
2. Minimum 1-1/4 IN wide x 3/4 IN deep.
3. Suitable fittings and snap-in cover.
4. Finish:
a. Stainless steel.
5. Receptacle color:
a. For use on normal power: Ivory.
b. For use on UPS systems: Red.
c. For use on isolated ground systems: Orange.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Mount devices where indicated on the Drawings.
B. Surface mount receptacles and light switches in concrete construction.
C. In masonry and metal stud construction, recess mount receptacles and light switches unless device precludes recessed mounting or unless otherwise noted on the Drawings.
D. Where more than one receptacle is installed in a room, they shall be symmetrically arranged.
E. Set switches and receptacles plumb and vertical to the floor.
F. Set recess-mounted switches and receptacles flush with face of walls.
G. Do not connect dimmers to loads in excess of 80 percent of the rating of the dimmer.
H. Provide blank plates for empty outlets.
END OF SECTION 26 2726
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600 V FUSES 26 2813 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 26 2813 600V FUSES
PART 1 - GENERAL
1.1 SCOPE OF WORK
A. This section covers the requirements for protective fusing on this project. The CONTRACTOR shall furnish and install fuses and fuse holders per the Drawings and equipment manufacturers recommendations.
B. This specification includes the general requirements for various types of fuses whether they are shown on the Drawings or not. If fusing is required by codes or manufacturer’s recommendations, but not shown on the Drawings, this specification shall apply to the type of fusing provided by the CONTRACTOR.
C. 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, noncurrent-limiting.
7. Class T current-limiting.
1.2 QUALITY ASSURANCE
A. The fuse manufacturer's facilities shall be ISO 9001 certified.
1.3 CODES AND STANDARDS
A. UL Compliance and Labeling: Comply with applicable provisions of UL 248-9, Standard for LowVoltage Fuses – Part 9: 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. NEMA Compliance: Comply with applicable requirements of NEMA FU 1, Low Voltage Cartridge Fuses.
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 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 ENGINEER-approved equal.
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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
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 Electrical 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. 583
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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 three (3) spare fuses of each size and type.
END OF SECTION 26 2813
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DISCONNECT SWITCHES 26 2816 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 26 2816 DISCONNECT SWITCHES
PART 1 – GENERAL
1.1 SCOPE OF WORK
A. This section covers electrical disconnecting switches.
1.2 SUBMITTALS
A. Products shall be submitted in accordance with the Contract 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. The disconnect switches 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. Disconnect switches shall be NEMA type HD heavy duty construction, UL 98 listed.
B. Enclosures shall be rated NEMA 12 for indoor use, NEMA 4X for corrosive areas and for outdoor use, unless otherwise indicated on the Plans.
C. Disconnect switch handle shall be padlockable.
D. Disconnect switches in the corrosive areas as indicated on the Plans, shall be NEMA 4X, 316 stainless steel.
E. Disconnect switches shall be as manufactured by Square D, Cutler Hammer, Allen-Bradley, General Electric, or equal.
F. Disconnect switches for motor shall be rated for 125% of the motor HP or as indicated on the plans.
G. Where indicated on the plans, including elementary control drawings, disconnect switches may be a combination disconnect switch equipped with control equipment such as HOA switches, E-stops or other control interfaces.
PART 3 – EXECUTION
3.1 INSTALLATION
A. Disconnect switches shall be installed and labeled as indicated on the Plans.
B. Provide grounding per NEC 404.12, and Section 26 0526 – Grounding and Bonding for Electrical Systems.
END OF SECTION 26 2816
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LOW VOLTAGE CIRCUIT BREAKERS 26 2822 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 26 2822 LOW VOLTAGE 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 the Contract 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 manufactured by 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 actually 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 airbreak type, quick-make and quick-break, 600 volts, with number of poles as indicated on the Drawings.
D. Each pole of the circuit breaker shall provide inverse time delay, and instantaneous circuit 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 constructed 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 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 UL 489.
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. 586
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J. Unless mounted in a switchboard or panelboard, circuit breakers shall be housed in a NEMA rated enclosure as described in Section 26 2716 – Electrical Cabinets and Enclosures.
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 26 2822
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SECTION 26 2923 LOW-VOLTAGE VARIABLE FREQUENCY DRIVES
PART 1 – GENERAL
1.1 DESCRIPTION
A. Scope:
1. Provide all labor, materials, equipment, testing, troubleshooting, training and incidentals as shown, specified, and required to furnish and install complete and operable variable frequency drives.
B. Coordination: Coordinate speed control, starting and acceleration torque requirements with the driven equipment. Submit an acceptance letter from the driven equipment and motor manufacturers stating that each variable frequency drive (VFD), will fully meet all starting and operating requirements of the respective driven equipment/motor combination. CONTRACTOR shall be responsible for coordinating all VFD units with the driven equipment to obtain successful operation throughout the driven equipment speed range.
1.2 REFERENCES
A. Standards referenced in this Section are listed below:
1. IEEE 519, Recommended Practice and Requirements for Harmonic Control in Electric Power Systems.
2. ISO 9000, Quality Management Systems, Fundamentals and Vocabulary.
3. ISO 9001, Quality Management Systems, Requirements.
4. ISO 9002, Quality Systems, Model for Quality Assurance in Production, Installation and Servicing.
5. NEMA ICS 2, Industrial Control and Systems Controllers, Contactors and Overload Relays Rated 600 Volts.
6. NEMA ICS 7, Industrial Control and Systems Adjustable-Speed Drives.
7. NEMA MG 1, Motor and Generators.
8. UL 489, Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures.
9. UL 508, Safety for Industrial Control Equipment.
1.3 QUALITY ASSURANCE
A. Qualifications:
1. Manufacturer:
a. Low-voltage variable frequency drive manufacturer shall have not less than five years of experience designing and regularly manufacturing and servicing substantially similar equipment to that required, and upon request, shall submit documentation of not less than five installations in satisfactory operation for not less than five years each.
Prototypes or newly introduced drive unit models will not be acceptable. b. Manufacturer shall be certified under ISO 9000, ISO 9001, or ISO 9002 for materials and equipment specified.
c. Manufacturer shall maintain factory trained and authorized service facilities within 100 miles of this project.
d. The manufacturer shall demonstrate, in writing, the Quality Assurance Program in use to certify key components. In-house manufacture of key components is desirable, and will be considered in evaluating acceptance.
e. For all required factory tests, low-voltage variable frequency drive manufacturer shall use a factory test facility that has calibrated its testing apparatus in the previous twelve months, and is staffed by qualified, experienced technicians. 588
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B. Component Supply and Compatibility:
1. Drives specified under this Section employ a low switching frequency or pattern to minimize instantaneous rate of voltage change over time (dv/dt), and the adverse effects of potential bearing currents. Where alternate manufacturers are proposed, obtain manufacturer recommendations regarding bearing currents and provide equipment required at no additional cost.
2. Each low-voltage variable frequency drive shall be fully compatible with associated driven equipment and motors. Variable frequency drives shall be matched to specific load requirements for each system. Operation of variable frequency drive shall not overstress motor insulation.
3. To centralize responsibility and to ensure that all equipment is properly coordinated, variable drives specified under this Section shall be obtained from the Supplier of the associated driven equipment.
4. Similar components of drives associated with each system shall be products of a single manufacturer.
C. Certifications:
1. Certification of Compliance:
a. MANUFACTURER shall submit certification of compliance that the requirements of this Section shall be met by the MANUFACTURER. The certification shall be submitted on MANUFACTURER letterhead and shall be signed the person in charge of the product for this project. Certification by manufacturer's representatives shall not be acceptable without the signature of the manufacturer’s person in charge. b. Certification shall be worded as follows:
1) "[Insert MANUFACTURER'S name] proposes to supply [Insert MANUFACTURER'S VFD name and model number] VFDs as specified herein, including all reference sections specified, and to supply all testing and services as specified in this Section. We have examined the Contract Documents and have a clear understanding of the requirements insofar as they affect the proposed products. We certify that the products shall be as specified herein, and shall operate satisfactorily under the conditions described in the Contract Documents and that the products meet the requirements of the Contract Documents. _____________________________________ ________________
Authorized Signature & Title Date
c. List all exceptions, deviations or changes from the requirements of the Contract Documents.
d. Provide justification for exceptions, variations, deviations, or changes. OWNER will determine whether exceptions, deviations, and changes are acceptable. Exceptions, variations, deviations, and changes may result in rejection of submittals and/or products.
e. Provide certification before submitting Shop Drawings for approval. Shop Drawings will not be reviewed prior to receipt of certification. f. Acceptance of certification shall not relieve responsibility for adequacy of all equipment and successful operation of equipment under all conditions specified herein. g. Submittal of certification shall not relieve equipment manufacturer, and Supplier of equipment to comply with Submittal requirements specified herein.
D. Tests:
1. Perform factory tests on each low-voltage variable frequency drive prior to shipping. Tests shall consist of simulating expected load to be driven by operating load through speed ranges specified for driven equipment, for minimum of two hours per drive unit. 589
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2. Provide factory control and alarm tests on each drive unit by simulating each control signal and each alarm function to verify proper and correct drive unit action.
3. Perform specified tests in addition to standard factory tests typically performed.
E. Seismic Requirements: The Work shall comply with seismic requirements in Section 40 05 96, Vibration and Seismic Controls for Process Equipment. Equipment manufacturer shall provide written certification of factory prototype test or shall use a shake table to show the completed assembly meets the seismic requirements for this project. Provide a seismic certificate stating the VFD unit has successfully passed the shake table test.
1.4 SUBMITTALS
A. Action Submittals: Submit the following:
1. Shop Drawings:
a. Dimensional information and construction details of enclosures. Enclosure details shall consist of exterior and interior front door with nameplate legends, interior door front and rear views, and terminal block layout.
b. Three-line power and control wiring diagrams.
c. Wiring diagrams showing the interconnection of conductors to all devices with terminal assignments.
d. Functional description of system operation.
e. VFD heat dissipation at full load, including heat rejection/cooling system. f. Fabrication, assembly and installation drawings, and wiring diagrams. Wiring diagrams shall comply with NFPA 79, Annex “D” standards. g. Complete list of components and catalogue identification. h. List of in-house manufactured key components.
i. Complete description of schematic and wiring diagrams and functional operation.
2. Product Data:
a. Manufacturer’s technical specifications, literature, illustrations, specifications and engineering data which indicate performance, dimensions, materials, size and weight.
3. Testing Plans:
a. Not less than thirty days prior to source quality control testing, submit descriptions of proposed shop testing methods, procedures, apparatus, and limitations. b. Not less than thirty days prior to field quality control testing, submit descriptions of proposed field testing methods, procedures, and apparatus.
B. Informational Submittals: Submit the following:
1. Certificates:
a. Certification letters from low-voltage variable frequency drive manufacturer and motor manufacturer that the approved driven equipment has been reviewed and that variable frequency drive units and motors are compatible, and shall be provided in accordance with the Contract Documents and requirements of the driven equipment.
2. Source Quality Control Submittals:
a. Within five days of completing source quality control tests and inspections, submit test results with indication of whether all criteria of the Contract Documents for the specified equipment were met.
3. Field Quality Control Submittals:
a. Within five days of completing field quality control tests and inspections, submit test results with indication of whether all criteria of the Contract Documents for the specified equipment were met.
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4. Manufacturer Reports:
a. Within five days of each visit to the Site by manufacturer’s representative, submit written report of reason for visit, problems encountered, solutions implemented, and remaining work.
5. Qualifications Statements:
a. Manufacturer, when requested by ENGINEER.
C. Closeout Submittals: Submit the following:
1. Operation and Maintenance Data:
a. Submit complete installation, operation and maintenance manuals including test reports, maintenance data and schedules, description of operation, list of recommended spare parts, and spare parts ordering information.
b. Manuals shall include record drawings of control schematics, including point-to-point wiring diagrams.
c. Include a listing of all programmable drive parameters and their settings at Substantial Completion. Submit parameters as both printed pages in the operations and maintenance manual and in electronic format on compact disc that can be directly uploaded to the drive in event of drive replacement or repair. d. Comply with Section 00 7200 - General Conditions.
D. Maintenance Materials Submittals: Submit the following:
1. Spare Parts and Extra Stock Materials:
a. Furnish, tag, and box for shipment and long-term storage spare parts and special tools for low-voltage variable frequency drives. Each set of spare parts and tools shall include manufacturer's recommended spare parts inventory for one year and include, at minimum, the following:
Item Quantity
1) Transistor and diode modules
with accessories
One per HP rating
2) Power supply module One per HP rating
3) Fans One per HP rating
4) Power fuses One set of each size and type used
5) Control power fuses Two sets of each size and type used 6) Pilot lights Two per ten of each type used
b. Furnish a list of recommended spare parts for an operating period of one year. Describe each part, the quantity recommended, and current unit price.
1.5 SHOP TESTS
A. Each variable frequency drive (VFD) shall be tested at the manufacturer's facility.
B. In addition to the manufacturer's standard tests, each VFD, including all instruments, controls, solid state components, systems, and internal and external equipment which are a part of the VFDs shall be assembled, tested and thoroughly checked for proper operation of all functions and features.
Simulated signals and loads shall be employed that shall simulate actual signals and loads, if they are a part of the final installation and are not included in this Section.
C. If the test results indicate that any VFD unit does not conform to specified and/or guaranteed performance, the unit shall be modified and retested, at no additional cost, until full compliance with specified and guaranteed performance can be demonstrated. OWNER and/or ENGINEER shall be permitted to witness the retest.
D. No equipment shall be shipped until approval of all test reports. 591
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1.6 DELIVERY, STORAGE, AND HANDLING
A. Delivery:
1. Deliver materials to the site to ensure uninterrupted progress of the Work. Deliver anchor bolts and anchorage devices which are to be embedded in cast-in- place concrete in ample time to prevent delay of the Work.
B. Packing, Shipping, Handling, and Unloading:
1. Packing:
a. Inspect prior to packing to ensure that assemblies and components are complete and undamaged.
b. Protect mating connections.
c. Cover all openings into enclosures with-vapor inhibiting, water-repellent material. d. Indoor containers shall be bolted to skids.
2. Upon delivery, check materials and equipment for evidence of water that may have entered equipment during transit.
3. All boxes, crates and packages shall be inspected by CONTRACTOR upon delivery to the site. The CONTRACTOR shall replace loss and repair damage to new condition in accordance with manufacturer's instructions.
4. Handling:
a. Lift, roll or jack low-voltage variable frequency drive equipment into locations shown. b. Variable frequency drives shall be equipped for handling required for installation.
Handle equipment in accordance with manufacturer’s requirements.
C. Storage and Protection:
1. Store materials to permit easy access for inspection and identification. Keep all materials off the ground, using pallets, platforms or other supports. Protect steel members and packaged materials from corrosion and deterioration.
2. Store all electrical and electronic equipment, control panels, and like equipment and materials in heated buildings which have a concrete or wooden floor, a roof, and fully closed walls on all sides. Protect electrical and electronic equipment from contamination by dust, dirt and moisture. Maintain humidity at levels recommended by manufacturer for electric and electronic equipment.
PART 2 – PRODUCTS
2.1 EQUIPMENT PERFORMANCE
A. System Performance:
1. Driven equipment to be controlled by a low-voltage variable frequency drive shall be provided with a customized variable frequency drive. Each drive unit shall include an variable frequency controller with associated controls for continuous speed adjustment and protection of the driven equipment. Output speed control of motor shall be continuous throughout speed range of two to 60 Hertz under variable torque load or constant torque as specified for the driven equipment.
2. Low-voltage variable frequency drives associated with each set of driven equipment shall be similar to each other.
3. Variable frequency drives shall be UL-listed or ETL-listed and designed, built, and tested in accordance with UL 489, NEMA ICS 2, NEMA ICS 7, and UL 508. 592
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4. VFDs shall meet all requirements as outlined in the latest edition of IEEE 519 for total harmonic voltage and current distortion and as indicated in this Section. Individual or simultaneous operation of the VFDs shall not add more than three percent total harmonic voltage distortion while operating. Maximum allowable total harmonic current distortion limits for each VFD shall not exceed five percent as calculated and measured at the point of common coupling. The point of common coupling for all harmonic calculations and field measurements for both voltage and current distortion shall be defined as the nearest upstream motor control center or switchgear as applicable. A preliminary harmonic analysis must be submitted by the VFD manufacturer with Shop Drawings which includes all voltage and current harmonics up to the 99th harmonic; for this purpose cable lengths can be estimated on a conservative basis by the supplier. Compliance shall be verified with onsite field measurements of both the voltage and current harmonic distortion at the defined point of common coupling with and without the VFDs operating.
2.2 MANUFACTURERS
A. Provide low-voltage variable frequency drives by one of the following:
1. DANFOSS FC202
2. ENGINEER APPROVED EQUAL.
2.3 WALL MOUNTING
A. As indicated on the plans, VFDs shall be wall mounted.
B. VFD section shall provide adequate cooling for components.
C. Include thermal magnetic circuit breaker. Circuit breakers shall be in accordance with UL 489.
Switch handle shall be suitable for padlocking in the “open” position and be through-the-door type with handle height not exceeding six feet. Operation of switch shall remove the service supply from all internal components. Power devices shall be suitable for interrupting capacity of 65,000 RMS symmetrical amperes. Include current limiting semi-conductor fuses where required for protection of solid state components.
D. VFD shall include an operator interface for access to controller’s digital keypad and display. Mount on the front of the VFD.
E. Equip with front with nameplates for identification of equipment and operating functions.
Nameplates shall be in accordance with Section 26 0553 - Identification for Electrical Systems.
F. Conduit and cable entrances shall be from either top or bottom, per manufacturer specifications.
2.4 VARIABLE FREQUENCY CONTROLLER
A. General:
1. Variable frequency controller shall be microprocessor-based, pulse width modulated design, suitable for operation on a 480-volt 3 phase, 60 hertz supply. Controller shall produce an variable AC voltage/frequency output to vary speed of driven equipment.
2. VFD power assembly shall be of the diode bridge rectifier front-end type to minimize electrical noise generation, shall operate at not less than 95 percent power factor over the full operating range.
3. Provide 90 Deg C rated power and control terminals.
4. Controller switching frequency shall be adjustable and allow operation at 5,000 Hertz or less.
Controller technology shall include a switching scheme that reduces the dv/dt of output supply.
5. Equip controller with a three-percent DC bus reactor or input line reactor.
6. Controller’s solid state converter input section switching devices shall have 1600 volt PIV rating.
7. Overload rating of 110 percent variable torque, 150 percent constant torque for one minute. 593
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8. RMS harmonic content of output current shall be less than five percent of fundamental current.
9. Able to withstand output terminal line-to-line short circuits without component failure.
10. VFD manufacturer shall acknowledge the approximate motor lead lengths shown on the plans. VFD manufacturer shall evaluate the application, include an appropriately sized output filter / long lead filter, determine switching frequency, etc. to accommodate the distance between the VFD and its motor. All components necessary for successful operation shall be provided and installed in each VFD’s section. VFD cable shall be used between the VFD and the motor.
B. Operating Criteria:
1. Operating criteria shall be in accordance with the following:
a. Ambient temperature range of zero to 50 degrees C.
b. Operational humidity of up to 95 percent non-condensing. c. Altitude up to 1500 feet above sea level.
d. Nominal voltage of 480-volts plus or minus ten percent, three-phase, three-wire.
Include an under-voltage feature to allow trip-free operation down to 35 percent undervoltage.
e. Nominal frequency of 60 Hertz plus or minus three Hertz. f. Input power factor of 95 percent displacement power factor at all operating speeds. g. Efficiency of 96 percent at full speed and full load. h. Frequency accuracy: ±0.5 percent (at 25°C ±10°C).
i. Frequency range: 3 to 67 hertz, selectable by switch to 120 hertz (Except where otherwise indicated).
j. Volts per hertz ratio (V/HZ) adjustable for 3 to 60 hertz. k. For variable torque applications, overload capacity shall be one minute at 110 percent of continuous constant torque rated nameplate current. The inverter shall be designed to not be internally shutdown within the 110 percent overload operating range. For constant torque applications, overload capacity shall be one minute at 150 percent of continuous constant torque rated nameplate current. The inverter shall be designed to not be internally shutdown within the 150 percent overload operating range. l. Acceleration time: 1 to 3600 seconds adjustable.
m. Dynamic braking: 12 percent standard.
n. Ramp to stop: 1 to 3600 seconds adjustable.
o. Nominal horsepowers are indicated on the drawings, but the VFD shall be supplied with the necessary current ratings to properly operate the connected load. Coordinate with the approved manufacturer of the equipment / motor for required operating currents.
C. Features:
1. Controller shall have the following features:
a. Digital keypad and display module shall provide parameter setting, adjustments, and monitoring of control functions and faults. Display messages shall be in English. b. Integral Ethernet communication port shall be used to connect the VFD to the plant control system for status/monitoring using Ethernet/IP protocol, as shown.
Communication port shall be included in the VFD electronics and shall be native to the drive. The use of signal converters or protocol bridges shall not be acceptable.
Control of VFDs shall be via hardwired connections with the plant control system. c. Independent acceleration/deceleration rates shall provide two to 600 seconds minimum. When called to stop, motor shall decelerate to minimum speed before stopping.
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d. Power loss feature shall allow five cycle ride through capability for input supply interruptions.
e. Time delay automatic restart shall allow restart after controller fault conditions with programmable attempts.
f. Coasting motor restart shall allow controller to restart into a coasting motor without damage or tripping. Coasting motor restart feature shall allow switching from bypass mode to low-voltage variable frequency drive mode while operating, without shutdown.
g. Isolated control inputs and outputs.
D. Protection:
1. Controller shall have protective functions as follows:
a. Input line metal oxide varistor transient protection. b. Electronic over-current trip instantaneous and inverse time overload protection with thermal memory retention.
c. Short circuit trip (hall-effect current transformer). d. DC bus overvoltage trip.
e. DC bus fuses.
f. Over-temperature trip temperature protection.
g. Current limit trip protection. Current limit circuitry shall automatically phase back voltage and frequency to decrease current to 110 percent of the drive rated capacity.
This shall be programmable based on motor full load amps. h. Input line over- and under-voltage trip protection with automatic restart on voltage recovery.
i. Momentary power failure trip (greater than ten milliseconds) with automatic restart. j. The drive units shall be able to withstand phase-to-phase and phase-to-ground shorts without damage to the drive unit.
k. Ground fault trip protection.
l. Fault trip conditions, except short time or momentary line voltage loss or line voltage momentary dip, shall lock out the control. Resetting of control after fault trip shall be manual by a door-mounted pushbutton.
m. Auto restart shall be a standard feature of the drive as follows:
1) Auto restart shall be enabled or disabled by programming or jumper selection. 2) On auto restart selection, the microprocessor shall determine, in the event of a fault, if a restart should be attempted. A restart shall be attempted under the following conditions:
a) Undervoltage (UP): Every time as soon as voltage returns to a safe level.
Fault relay shall not be activated.
b) Input Overvoltage (OPS): Every time as soon as voltage returns to a safe level. Fault relay shall be activated for the duration of the high voltage condition.
c) Overcurrent (OC): Five attempts in 30 seconds. After the fifth OC, the drive shall trip out and latch the fault relay.
n. A restart shall not be attempted for any other type of fault and the drive shall trip out immediately, activate the fault relay, and make the information available on the display until the drive is reset by pressing the reset button or removing control power. 595
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o. An undervoltage condition of less than 30 ms duration shall not affect drive operation.
If main power falls below 85 percent of rated voltage for longer than 30 ms while control power is retained, the drive shall forcibly decelerate the load in an attempt to force a higher bus voltage through regeneration to allow the drive to "ride through" the undervoltage condition for up to 70 additional milliseconds for a total "ride through" of up to 100 ms for very high inertia loads. The manufacturer shall provide an option which allows control power to be maintained for 100 ms in the event of a power failure.
If the drive drops out, it shall automatically restart upon restoration of full rated voltage, as previously described.
2.5 OUTPUT / LONG LEAD FILTER
A. General:
1. Provide output filter to prevent overstressing motor insulation system and to accommodate the approximate motor lead lengths shown on the plans.
B. Features and Criteria:
1. Filter shall be three-phase, 600-volt class motor-protecting type consisting of suitable values of inductance, capacitance and resistance to form a damped, low pass filter.
2. Filter shall be low-loss type specifically designed to reduce voltage wave form dv/dt. Filter shall allow cable lengths at minimum exceeding actual application distances with waveform resulting in voltage spikes at motor terminal that are within NEMA MG 1 Part 31 voltage stress levels.
3. Filter shall be suitable for mounting within low-voltage variable frequency drive cubicle / section.
2.6 GENERAL CONTROLS
A. General:
1. Equip each low-voltage variable frequency drive control system with relays, switches, fuses, indicating lights, and components required for a complete, functional system.
2. Variable frequency drive control shall be powered from a suitably sized and protected control power transformer. Transformer shall be sized to power motor space heaters, where applicable. Coordinate to obtain motor space heater wattages, if applicable. Motor controllers shall be provided with circuitry such that the motor space heater shall be energized when the motor is not energized
3. Variable frequency drive control shall include status indicators, controller, and system fault condition displays and operating controls. Provide status indicators and operating controls associated with drive control on front door of enclosure.
4. Control arrangement shall be such that variable frequency drive internal electronic supply voltage is isolated from field wiring.
B. Control and Pilot Devices:
1. The front of each VFD compartment shall contain each equipment’s operator devices and nameplates as substantially specified herein. Operator devices (pushbuttons, push-to-test LED pilot lights and switches) shall be heavy duty, 30.5mm, round, NEMA 4X non-corrosive type as manufactured by the approved variable frequency drive manufacturer. Use control relays and timing relays as manufactured by the approved variable frequency drive.
Control/timing relay contacts shall be rated for 10A at 120VAC/24VDC.
C. Wiring and Device Identification:
1. Provide control wiring and device identification for each low-voltage variable frequency drive:
a. Identify all control conductors with permanent type wire markers. Each wire shall be identified by a unique number and shall be attached to wire at each termination point. 596
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b. Identify each control device with permanent type marker. Each device shall be identified by a unique number and shall be attached to each device. c. Numbering system for each wire and control device shall be identified on wiring diagrams and shall reflect actual designations used in the Work.
2.7 VFD INTEGRATION
A. General: The supplier of the VFDs shall supply the integral VFDs components required for operation. Each VFD shall be wall mounted. The VFDs shall be factory wired and tested as a complete package, consisting of the VFD, logic control devices, operator interface devices, instruments and equipment as required for successful operation.
PART 3 – EXECUTION
3.1 INSPECTION
A. Examine conditions under which the Work will be installed and notify in writing of conditions detrimental to proper and timely completion of the Work. Do not proceed with the Work until unsatisfactory conditions are corrected.
3.2 INSTALLATION
A. Install equipment in accordance with manufacturer’s recommendations and instructions and in conformance with Laws and Regulations, and the Contract Documents.
B. Unless otherwise shown or indicated, install equipment on a 4 inch thick (nominal) concrete pad.
Pad shall extend approximately 3 inches on both sides and back and not more than 1 inch in front, with chamfering. Install support channels in concrete according to manufacturer’s recommendations. Type 316 stainless steel anchor bolts shall be furnished in this Section.
C. Install equipment with sufficient access and working space provided for ready and safe operation and maintenance.
D. For installations against masonry walls, provide an insulation board, 1/4-inch minimum thickness, between equipment and wall for corrosion protection. Trim board neatly within outline of equipment.
E. Install all terminations, lugs, and required appurtenances necessary to properly terminate power supplies.
F. Install control wiring terminations and appurtenances necessary to complete installing control and monitoring devices.
G. Immediately prior to Substantial Completion, replace all enclosure filters and frames provided under this Contract with new filters and frames, except expanded metal filter types. Immediately prior to Substantial Completion, clean expanded metal filters.
3.3 FIELD QUALITY CONTROL
A. Site Tests:
1. After installation, inspect, adjust, and test each low-voltage variable frequency drive at the Site. Testing and inspection shall be in accordance with manufacturer’s recommendations and be performed by manufacturer’s factory-trained representative. The manufacturer’s factory-trained representative shall inform when equipment is correctly installed and ready to be energized. Do not energize equipment without permission.
2. Perform the following equipment inspection and testing and provide reports documenting procedures and results.
a. Verify all device settings and drive adjustments.
b. Inspect all mechanical and electrical interlocks and controls for proper operation. 597
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c. Test each drive through specified speed ranges and loads for a minimum of two hours per drive unit.
d. Test each drive by using actual control signal for remote and local operation. e. Test each drive alarm function.
f. Perform other tests recommended by equipment manufacturer.
B. Manufacturer Services:
1. Unloading and Installation: Manufacturer’s factory-trained representative shall be present during unloading of equipment and installation at equipment’s final location. Representative shall train installing personnel in advance in the proper handling and rigging of equipment.
Services by manufacturer’s representative under this paragraph shall be at least one (1) eighthour day at the Site.
2. Post-installation Check: Manufacturer’s factory-trained representative shall check and approve the installed equipment before initial operation. Manufacturer shall calibrate, set and program low-voltage variable frequency drives provided. Services by manufacturer’s representative under this paragraph shall be at least one (1) eight-hour day at the Site.
3. Manufacturer’s factory-trained representative shall adjust the system to final settings as specified in Article 3.4 of this Section.
4. Manufacturer’s factory-trained representative shall test the system as specified in Paragraph
3.3.A of this Section. Representative shall operate and test the system in presence of ENGINEER and verify that equipment is in conformance with the Contract Documents.
Services by manufacturer’s representative under this paragraph shall be at least one (1) eighthour day at the Site.
5. Representative shall revisit the Site as often as necessary until all deficiencies are corrected, prior to readiness for final payment.
6. Provide services of manufacturer’s factory-trained representatives to correct defective Work within 72 hours of notification by OWNER during the correction period specified in the General Conditions as may be amended by the Supplementary Conditions.
7. Replacement parts or equipment provided during the correction period shall be equal to or better than original.
8. Training: Provide services of qualified factory trained specialists from manufacturer to instruct OWNER’s operations and maintenance personnel in recommended operation and maintenance of equipment. Training requirements, duration of instruction, and other qualifications shall be submitted to the ENGINEER for review.
3.4 ADJUSTING
A. Immediately prior to Substantial Completion, when testing is acceptably completed and lowvoltage variable frequency drives are operating, manufacturer’s representative shall return to the Site and make final adjustments as required to each variable frequency drive furnished under this Section.
3.5 MANUFACTURER'S CERTIFICATION
A. A qualified factory-trained manufacturer's representative shall certify in writing that each VFD has been installed, adjusted, tested and functions in accordance with the manufacturer's recommendations and the Contract Documents. Certification shall bear the typewritten name and signature of the person responsible for the work. Certification shall list each VFD, shall state each VFD has passed all tests, is in conformance with the Contract Documents and is ready to be placed into operation.
B. Provide four (4) copies of the manufacturer's representative's certification.
END OF SECTION 26 2923
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SECTION 26 5000 – 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 1598 - Luminaires
3. UL 844 - Luminaires for Use in Hazardous (Classified) Locations
4. UL 924 - Emergency Lighting and Power Equipment
5. Illuminating Engineering Society (IES)
6. 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. Location of lighting fixtures on Plans are 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 features, 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 or ETL 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.
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 the Contract Documents.
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PART 2 – PRODUCTS
2.1 MANUFACTURERS
A. Lamps shall be manufactured by RAB, General Electric, North American/Phillips, Sylvania, or ENGINEER-approved 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, Universal, Bodine, Lithonia, or ENGINEER-approved equal.
D. Light poles shall be as indicated on the Plans. Include base template, anchor bolts, cadmium-plated hardware and pole grounding lug, handhole, anchor base and bolt covers. Pole foundations shall be as indicated on the Plans.
2.2 MATERIALS
A. General:
1. Lamps:
a. See lighting fixtures specified on Electrical 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, mark fixtures "suitable for wet locations." c. When intended for use in damp areas, mark fixtures:
"suitable for damp locations" or "suitable for wet locations." d. In wet or damp area, install fixtures so that water cannot enter or accumulate in the wiring compartment, lampholder, 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.
b. Each phase shall be protected by a 30A, 600V, type Tron waterproof fuseholder, Bussman "Limitron" type fuse, size rating 3-times load current.
C. LED Lamps:
1. Bulb finish: Clear
2. Any burning position
D. Furnish a minimum of 2 lamps, or ten percent spare lamps of each type and wattage, whichever is greater.
2.3 FIXTURES
A. LED 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
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6. Emergency ballast:
a. Integral rechargeable nickel-cadmium battery, battery charger, and automatic transfer circuitry.
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 un-switched source.
a. Provide emergency ballast also with a similar caution label. d. Refractor: UV stabilized molded acrylic
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 ENGINEER-approved 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 ENGINEERapproved 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 pressure sodium lamps with new lamps prior to final acceptance by the OWNER.
C. Surface and flush mounted fixtures shall be solidly connected to a junction box. Suspended fixtures shall be hung utilizing pendant mounting or stainless steel chains and hooks. Each suspended fixtures, 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 ENGINEERapproved 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. 601
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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.
I. Where manual lighting controls are installed, they shall be:
1. Mounted in a readily accessible location
2. Located where the controlled lights are visible or marked to identify the area served and indicate their status per IECC 2018 C405.2.5.
3.2 ADJUSTING AND CLEANING
A. Wipe all lighting fixture reflectors, lenses, lamps, and trims clean after installation and prior to acceptance of the project by the OWNER.
END OF SECTION 26 5000
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SOILS FOR EARTHWORK 31 0513 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 31 0513 SOILS FOR EARTHWORK
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Subsoil materials.
2. Topsoil materials.
1.2 SUBMITTALS
A. Product Data: Submit name of imported materials source.
B. Samples: Provide sample of each type of fill to testing laboratory in airtight containers.
C. Supplier's Certificate: Products meet or exceed specified requirements.
1.3 QUALITY ASSURANCE
A. Furnish each subsoil and topsoil material from single source throughout Work.
B. Perform work according to the authority having jurisdiction’s standards.
PART 2 - PRODUCTS
2.1 SELECT NATIVE FILL
A. Select native fill shall consist of suitable materials obtained from on-site excavations, free of peat, humus, vegetative matter, organic matter, debris, rubbish, and rocks greater than 12 inches in diameter, processed as required to be placed in the thicknesses prescribed and at the optimum moisture content to obtain the level of compaction required by the Contract Documents. This soil must be reviewed by the ENGINEER (Approved by the Geotechnical Engineer).
B. Fill and backfill materials to be placed within 6 inches of any structure or pipe shall be free of rocks or unbroken masses of earth materials having a maximum dimension larger than 3 inches.
C. Suitable Materials: Materials not defined as unsuitable by these specifications are defined as suitable materials and may be used in fills, backfilling and embankment construction, subject to any indicated limitations in the Contract Documents. In addition, when acceptable to the ENGINEER, some of the material listed as unsuitable may be used when thoroughly mixed with suitable material to form a stable composite.
D. Unsuitable Materials:
1. Soils defined as unsuitable in the Contract Documents, or Geotechnical Evaluation, or Soils Report, or by the Geotechnical Engineer.
2. Soils which, when classified under ASTM D 2487 - Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System), fall in the Classifications of PT, OH, CH, MH or OL.
3. Soils, which cannot be compacted sufficiently to achieve the density specified for the intended use.
4. Materials that contain hazardous or designated waste materials including petroleum hydrocarbons, pesticides, heavy metals, and any material which may be classified as hazardous or toxic according to applicable regulations.
5. Soils that contain greater concentrations of chloride or sulfate ions, or have a soil resistivity or pH less than the existing on-site soils.
6. Topsoil, except as allowed below.
2.2 IMPORTED FILL
A. Imported fill material shall meet the requirements for select native fill as defined above and shall be reviewed by the ENGINEER (Approved by the Geotechnical Engineer). 603
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2.3 TOPSOIL
A. Topsoil shall be the top 6 to 12 inches of existing soil containing organic matter. The ENGINEER's decision shall be final as to determination of what is of topsoil quality. Topsoil shall be stockpiled on site for later use in landscaping. Care shall be taken in collection of topsoil so as to preserve native seed stocks, which are valuable to restoring native species as part of finish landscaping.
2.4 SOURCE QUALITY CONTROL
A. Testing and Analysis:
1. Subsoil Material: Comply with AASHTO T 180.
2. Topsoil Material: Comply with AASHTO T 180.
3. If tests indicate materials do not meet specified requirements, change material and retest.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Excavation:
1. Excavate subsoil and topsoil from designated areas.
2. Strip topsoil to full depth of topsoil in designated areas.
3. Remove excess excavated materials, subsoil, and topsoil not intended for reuse from Site.
4. Remove excavated materials not meeting requirements for subsoil and topsoil materials from Site.
B. Stockpiling:
1. Stockpile excavated material meeting requirements for subsoil and topsoil materials.
2. Stockpile materials on Site at locations as indicated in elsewhere in the Contract Documents or as by the ENGINEER or OWNER.
3. Stockpile in sufficient quantities to meet Project schedule and requirements.
4. Separate differing materials with dividers or stockpile apart to prevent intermixing of soil types or contamination.
5. Stockpile topsoil maximum 8 feet high.
6. Direct surface water away from stockpile to prevent erosion or deterioration of materials.
7. Stockpile unsuitable or hazardous materials on impervious material and cover to prevent erosion and leaching until they are disposed.
3.2 CLEANING
A. Comply with Contract Document requirements for cleaning.
B. Stockpile:
1. Remove stockpile and leave area in clean and neat condition.
2. Grade Site surface to prevent freestanding surface water.
END OF SECTION 31 0513
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AGGREGATES FOR EARTHWORK 31 0516 – 1
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SECTION 31 0516 AGGREGATES FOR EARTHWORK
PART 1 - GENERAL
1.1 SUMMARY
A. Aggregate material shall be supplied when indicated on Drawings. Section Includes:
1. Sand backfill materials.
2. Crushed Rock backfill materials.
3. Gravel backfill materials.
4. Drain Rock backfill materials.
5. Aggregate Base backfill materials.
6. Disintegrated Granite (DG) backfill materials.
7. Riprap backfill materials.
8. Controlled Low Strength Material (CLSM) “flowable” backfill materials.
1.2 SUBMITTALS
A. Product Data: Submit name of imported materials source.
B. Manufacturer's Certificate: Products meet or exceed specified requirements.
1.3 QUALITY ASSURANCE
A. Furnish each aggregate material from single source throughout Work.
B. Perform Work according to Owner Code standards.
PART 2 - PRODUCTS
2.1 SAND
A. Sand shall consist of natural or manufactured granular material, or a combination thereof, free of deleterious amounts of organic material, mica, loam, clay, and other substances not suitable for the purpose intended.
B. Sand with 100% passing a 3/8-inch sieve, at least 90% passing a Number 4-sieve, and a sand equivalent value not less than 30.
2.2 CRUSHED ROCK
A. Crushed rock shall be specified by nominal size (e.g., “3/4”) as shown on the Drawings, and shall meet the gradation and other requirements according to the authority having jurisdiction standards, or the latest edition of THE “GREENBOOK” STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION.
2.3 GRAVEL
A. Gravel shall be composed entirely of particles that have no more than one fractured face.
B. Pea gravel shall be gravel with 100% passing a ½-inch sieve and not more than 10% passing a Number 4-sieve
2.4 DRAIN ROCK
A. Granular drain rock backfill material shall be crushed or uncrushed rock or gravel, be the size as shown on the Drawings, and shall be clean and free-draining. Material shall meet the gradation and other requirements according to the authority having jurisdiction standards, or the latest edition of THE “GREENBOOK” STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION.
2.5 AGGREGATE BASE
A. Aggregate base shall consist entirely of crushed rock and rock dust, and shall meet the gradation and other requirements according to the authority having jurisdiction standards, or the latest edition of THE “GREENBOOK” STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION.
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2.6 DISINTEGRATED GRANITE (DG)
A. Disintegrated granite shall be free from vegetable matter and other deleterious substances and shall be of such nature that it can be compacted readily under water and rolling to form a firm, stable base.
B. Disintegrated granite shall be any igneous rock, which has been weathered in place, or any sedimentary material principally derived from igneous rock.
2.7 RIPRAP
A. Stone for riprap shall be quarrystone or cobblestone. Quarrystone shall be angular and cobblestone shall be rounded. Flat or elongated shapes will not be accepted unless the thickness of the individual pieces is at least 1/3 of the length. Minimum diameter 6”.
B. Stone shall be sound, durable, hard, resistant to abrasion and free from laminations, weak cleavage planes, and the undesirable effects of weathering. Stone shall be of such character that it will not disintegrate from the action or air, water, or the conditions to be met in handling and placing.
C. Stone for riprap shall be designated by class and shall meet the gradation and other requirements according to the authority having jurisdiction standards, or the latest edition of THE “GREENBOOK” STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION.
2.8 CONTROLLED LOW STRENGTH MATERIAL (CLSM)
A. CLSM shall be composed of cement, pozzolans, fine aggregate, water, and admixtures. CLSM shall have a low cement content, be non-segregating, self-consolidating, free-flowing and excavatable material which will result in a hardened, dense, non-settling fill and a compressive strength at 28 days of 150 to 350 psi if not otherwise shown or specified.
B. CLSM shall meet the gradation and other requirements according to the authority having jurisdiction standards, or the latest edition of THE “GREENBOOK” STANDARD SPECIFICATIONS FOR PUBLIC WORKS CONSTRUCTION, or as specified elsewhere in the Contract Documents.
PART 3 - EXECUTION
3.1 STOCKPILING
A. Stockpile in sufficient quantities to meet Project schedule and requirements.
B. Separate different aggregate materials with dividers or stockpile apart to prevent intermixing of aggregate types or contamination.
C. Direct surface water away from stockpile site to prevent erosion or deterioration of materials
3.2 CLEANING
A. Stockpile:
1. Remove stockpile and leave area in clean and neat condition.
2. Grade Site surface to prevent freestanding surface water.
END OF SECTION 31 0516
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GEOTEXTILES FOR EARTHWORK 31 0519 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 31 0519.13 GEOTEXTILES FOR EARTHWORK
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Turf reinforcement mats (TRMs).
2. Nonwoven geotextile material.
1.2 SUBMITTALS
A. Product Data: Manufacturer information including tensile strength, elongation, thickness, UV resistance, and other material specifications.
B. Manufacturer's Certificate: Products meet or exceed specified requirements.
C. Manufacturer Instructions: Installation requirements, including storage and handling procedures.
D. Source Quality-Control Submittals: Indicate results of factory tests and inspections.
E. Field Quality-Control Submittals: Indicate results of any furnished equipment tests and inspections.
1.3 QUALITY ASSURANCE
A. Perform Work according to manufacturer instructions and industry standards.
1.4 Manufacturer: Company specializing in manufacturing products specified in this Section with minimum of three years' experience.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Store and handle materials according to manufacturer instructions.
B. Protection:
1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas.
2. Provide additional protection according to manufacturer instructions.
PART 2 - PRODUCTS
2.1 GEOTEXTILE MATERIALS
A. Description:
1. Non-biodegradable, UV-resistant, woven geotextile fabric (non-woven material to be used for draining applications such as retaining walls).
2. Calendar such that yarns will retain relative positions.
3. Color black
B. Performance and Design Criteria:
1. Comply with AASHTO M288.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify that underlying surface is smooth and free of ruts or protrusions that could damage geotextile material.
3.2 PREPARATION
A. Subgrade Material and Compaction Requirements: As specified elsewhere in the Contract Documents.
3.3 INSTALLATION
A. Geotextile Material:
1. Lay and maintain smooth and free of tensile stresses, folds, wrinkles, or creases.
2. Ensure that material is in direct contact with subgrade. 607
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B. Penetrations: As recommended by geotextile manufacturer.
C. Fill and Cover:
1. Place fill to prevent tensile stress or wrinkles in geotextile.
2. Place fill from bottom of side-slopes upward.
3. Do not drop fill from height greater than as recommended by geotextile manufacturer.
3.4 PROTECTION
A. Ballast: Adequate to prevent uplift of material by wind.
B. UV Exposure: Cover fabric as soon as possible and in no case leave fabric exposed more than four weeks, or longer than as recommended by geotextile manufacturer.
C. Do not use staples or pins to hold geotextiles in place where located adjacent to other geosynthetic layers that could be damaged.
D. Do not operate equipment directly on top of geotextile.
END OF SECTION 31 0519.13
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EXCAVATION 31 2316 - 1
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SECTION 31 2316 EXCAVATION
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Soil densification.
2. Excavating for structure foundations.
3. Excavating for paving, roads, and parking areas.
4. Excavating for slabs on grade.
5. Excavating for cast-in-place and precast structures.
6. Excavating for landscaping.
1.2 SUBMITTALS
A. Excavation Protection Plan: Describe sheeting, shoring, and bracing materials and installation required to protect excavations and adjacent structures and property; include structural calculations to support plan.
1.3 QUALITY ASSURANCE
B. Perform Work according to authority having jurisdiction standards.
C. Licensed Professional: Professional Engineer experienced in design of specified Work and registered in the same State as the project location.
PART 2 - PRODUCTS (Not Used)
PART 3 - EXECUTION
3.1 PREPARATION
A. Prior to work in this section, become familiar with site conditions. In the event discrepancies are found, notify the ENGINEER as to the nature and extent of the differing conditions.
B. Call local utility line information service not less than three working days before performing Work.
Request underground utilities to be located and marked within and surrounding construction areas.
C. Identify required lines, levels, contours, and datum locations.
D. Protect plant life, lawns, and other features remaining as portion of final landscaping.
E. Protect bench marks, existing structures, fences, sidewalks, paving, and curbs from excavating equipment and vehicular traffic.
F. Maintain and protect above and below grade utilities indicated to remain.
3.2 EXCAVATION - GENERAL
A. Clear areas required for access to Site and execution of Work to a minimum depth as indicated on Drawings or Geotechnical Report.
B. The natural ground surface shall be cleared of all plant growth, such as trees, logs, upturned stumps, roots of downed trees, brush, grass, weeds, and all other objectionable materials, within the limits of excavation and fill slope lines. Where slopes are to be rounded, the areas shall extend to the outside limits of slope rounding.
C. Excavate material of every nature and description to the lines and grades as indicated on the drawings and/or as required for construction of the facility.
D. Provide and maintain equipment to remove and dispose of water during the course of the work of this section and keep excavations dry and free of frost or ice.
E. Project dewatering is specified elsewhere. Coordinate drainage requirements with this work.
Provide temporary drainage ditches as required and regrade as indicated at completion of project.
F. Do not interfere with 45-degree bearing splay of foundations. 609
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G. Grade top perimeter of excavation to prevent surface water from draining into excavation.
H. Trim excavation and remove loose matter.
I. Notify the ENGINEER of unexpected subsurface conditions.
J. Compact disturbed load-bearing soil in direct contact with foundations to original bearing capacity, as specified in Section 31 2323 – Fill and Section 31 2323 – Trenching and Backfilling.
K. Correct over-excavated areas as specified in Section 31 2323 – Fill.
L. Stockpile topsoil at locations approved by the OWNER. Grade the surface of stockpiles remaining over rainy months to prevent ponding of water. Cover stockpiles to minimize the infiltration of water. See other provisions for erosion control.
M. All excess material not suitable or not required for backfill and grading shall be hauled off site and disposed of at a location approved by the OWNER. The CONTRACTOR shall make arrangements for disposal of the material at the CONTRACTOR’s expense. If a landfill permit is to be obtained by the CONTRACTOR, a copy shall be provided to the OWNER prior to commencement of disposal.
N. Obtain permission from OWNER prior to removing any excess subsoil.
3.3 STRUCTURE, ROADWAY, AND EMBANKMENT EXCAVATION
A. Excavation beneath Structures and Embankments: Except where otherwise indicated on Drawings, excavation shall be carried to the grade of the bottom of the footing or slab and prepared in accordance with the Contract Documents or Geotechnical Report.
B. Excavation beneath Paved Areas: Except where otherwise indicated on Drawings, excavation under areas to be paved shall extend to the bottom of the aggregate base and prepared in accordance with the Contract Documents or Geotechnical Report.
3.4 PIPELINE AND UTILITY TRENCH EXCAVATION
A. See Section 31 2323 – Trenching and Backfilling.
3.5 FIELD QUALITY CONTROL
A. Request visual inspection of bearing surfaces by inspection agency before installing subsequent Work.
3.6 PROTECTION
A. Prevent displacement or loose soil from falling into excavation and maintain soil stability.
B. Protect bottom of excavations and soil adjacent to and beneath foundation from freezing.
C. Protect structures, utilities, and other facilities from damage caused by settlement, lateral movement, undermining, washout, and other hazards that may be created by earth operations.
D. Underpin adjacent structures which may be damaged by excavation Work.
END OF SECTION 31 2316
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FLOWABLE FILL 31 2323.33 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 31 2323.33 FLOWABLE FILL
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Flowable fill for the following:
a. Structure backfill.
b. Utility bedding.
c. Utility backfill.
d. Filling abandoned utilities.
1.2 DEFINITIONS
A. Utility: Any buried pipe, duct, conduit, manhole, tank, or cable.
B. Flowable Fill: A self-compacted, self-leveling, lean cement concrete fill. For purposes of this section, a fill utilizing Controlled Low Strength Material (CLSM).
C. Controlled Low Strength Material (CLSM): A self-consolidating, cementing material used primarily as a backfill as an alternative to compacted fill. CLSM is intended to result in a compressive strength of 1200 psi or less.
D. Excavatable Flowable Fill: CLSM fill used where future excavation may be required such as fill for utility trenches, bridge abutments, and culverts.
E. Non-excavatable Flowable Fill: CLSM fill used where future excavation is not anticipated such as fill below structure foundations and filling abandoned utilities.
1.3 SUBMITTALS
A. Only request submittals needed to verify compliance with Project requirements.
B. MaterialsManufacturer's Certificate: Products meet or exceed specified requirements.
C. Mix Design:
1. Furnish flowable fill mix design for each specified strength. Furnish separate mix designs when admixtures are required for the following:
a. Flowable fill Work during hot and cold weather.
b. Air entrained flowable fill Work.
2. Identify design mix ingredients, proportions, properties, admixtures, and tests.
3. Furnish test results to certify flowable fill mix design properties meet or exceed specified requirements.
D. Delivery Tickets:
1. Furnish duplicate delivery tickets indicating actual materials delivered to Project Site.
1.4 QUALITY ASSURANCE
A. Perform Work according to authority having jurisdiction standards.
B. Manufacturer: Company specializing in manufacturing products specified in this Section with 3 years' experience.
1.5 ENVIRONMENTAL REQUIREMENTS
A. Do not install flowable fill during inclement weather or when ambient temperature is less than 40 degrees F.
1.6 FIELD MEASUREMENTS
A. Verify field measurements before installing flowable fill to establish quantities required to complete Work.
PART 2 - PRODUCTS
2.1 FLOWABLE FILL (CLSM)
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A. Furnish materials according to authority having jurisdiction standards.
B. Flowable Fill: Excavatable type and non-excavatable type as indicated on Drawings or as specified elsewhere. Provide non-excavatable type when not designated otherwise.
2.2 MATERIALS
A. Portland Cement: ASTM C150.
B. Fine Aggregates: ASTM C33.
C. Water: Clean and not detrimental to concrete.
2.3 ADMIXTURES
A. Furnish materials according to authority having jurisdiction standards.
B. Air Entrainment: ASTM C260.
C. Chemical Admixture: ASTM C494/C494M.
D. Fly Ash: ASTM C618 Class C or F obtained from residue of electric generating plant using ground or powdered coal.
E. Plasticizing: ASTM C1017/C1017M.
2.4 MIXES
A. CLSM shall be proportioned by the ready mixed concrete supplier on the basis of field experience and/or laboratory trial mixtures to produce a cohesive and non-segregating mixture meeting the specified properties.
B. Mix and deliver flowable fill according to ASTM C94/C94M, Option C.
C. Flowable Fill (CLSM) Design Mix:
1. Cement Content:
a. Excavatable: 75 to 100 lb/cu yd.
b. Non-Excavatable: 100 to 150 lb/cu yd.
2. Fly Ash Content:
a. Excavatable: None.
b. Non-Excavatable: 150-600 pcf.
3. Water Content:
a. Excavatable: As specified.
b. Non-Excavatable: As specified.
4. Air Entrainment:
a. Excavatable: 5 to 35 percent.
b. Non-Excavatable: 5 to 15 percent.
5. 28-Day Compressive Strength:
a. Excavatable: Minimum 50 psi, Maximum 125 psi.
b. Non-Excavatable: Minimum 150 psi, Maximum 350 psi.
6. Unit Mass (Wet):
a. Excavatable: 80 to 110 pcf.
b. Non-Excavatable: 100 to 125 pcf.
7. Temperature, Minimum, at Point of Delivery:
a. Excavatable: 50 degrees F.
b. Non-Excavatable: 50 degrees F.
D. Provide water content in design mix to produce self-leveling, non-segregating, flowable fill material at time of placement.
E. Design mix air entrainment and unit mass are for laboratory design mix and source quality control only.
2.5 SOURCE QUALITY CONTROL
A. Test and analyze properties of flowable fill design mix and certify results for the following:
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1. Design mix proportions by weight of each material.
2. Aggregate: ASTM C33 for material properties and gradation.
3. Properties of plastic flowable fill design mix including:
a. Temperature.
b. Slump.
c. Air entrainment.
d. Wet unit mass.
e. Yield.
f. Cement factor.
4. Properties of hardened flowable fill design mix including:
a. Compressive strength at 1 day, 7 days, and 28 days. Report compressive strength of each specimen and average specimen compressive strength. b. Unit mass for each specimen and average specimen unit mass at time of compressive strength testing.
B. Prepare delivery tickets containing following information:
1. Project designation.
2. Date.
3. Time.
4. Class and quantity of flowable fill.
5. Actual batch proportions.
6. Free moisture content of aggregate.
7. Quantity of water withheld.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify excavation or trenching is complete.
B. Verify utility installation is complete and tested before placing flowable fill.
C. Verify excavation is dry and dewatering system is operating if applicable.
3.2 PREPARATION
A. Support and restrain utilities to prevent movement and flotation during installation of flowable fill.
B. Protect structures and utilities from damage caused by hydraulic pressure of flowable fill before fill hardens.
C. Protect utilities to prevent intrusion of flowable fill.
3.3 INSTALLATION - FILL, BEDDING, AND BACKFILL
A. Place flowable fill by chute, pumping or other methods approved by authority having jurisdiction.
1. When required, place flowable fill under water using tremie procedure.
2. Do not place flowable fill through flowing water.
B. Place flowable fill in lifts to prevent lateral pressures from exceeding structural capacity of structures and utilities.
C. Place flowable fill evenly on both sides of utilities to maintain alignment.
D. Place flowable fill to elevations indicated without vibration or other means of compaction.
3.4 INSTALLATION - FILLING ABANDONED UTILITIES
A. Verify pipes and conduits are not clogged and are sufficiently empty to permit gravity installation of flowable fill for entire length indicated to be filled.
B. Seal lower end of pipes and conduits by method to contain flowable fill and to vent trapped air caused by filling operations.
C. Place flowable fill using method to ensure there are no voids. 613
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1. Fill pipes and conduits from high end.
2. Fill manholes, tanks, and other structures from grade level access points.
D. After filling pipes and conduits seal both ends.
3.5 FIELD QUALITY CONTROL
A. Perform inspection and testing according to ASTM C94/C94M.
1. Take samples for tests for every 150 cu yd of flowable fill, or fraction thereof, installed each day.
2. Sample, prepare and test four compressive strength test cylinders according to ASTM D4832.
Test one specimen at 3 days, one at 7 days, and two at 28 days.
3. Measure temperature at point of delivery when samples are prepared.
B. Perform in place penetration (density) tests using hand held penetrometer to measure penetration resistance of hardened flowable fill, according to ASTM C403. Or perform in-place density tests using nuclear test device, according to ASTM C1040.
1. Perform tests at locations as directed by Geotechnical Engineer.
C. Defective Flowable Fill: Fill failing to meet following test requirements or fill delivered without following documentation.
1. Test Requirements:
a. Minimum temperature at point of delivery.
b. Compressive strength requirements for each type of fill.
2. Documentation: Duplicate delivery tickets.
3.6 CLEANING
A. Remove spilled and excess flowable fill from Project Site.
B. Restore facilities and Site areas damaged or contaminated by flowable fill installation to existing condition before installation.
END OF SECTION 31 2323.33
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SECTION 31 2323 - FILL
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Backfilling building perimeter to subgrade elevations.
2. Backfilling Site structures to subgrade elevations.
3. Fill under slabs on grade.
4. Fill under paving.
5. Fill for over-excavation.
1.2 SUBMITTALS
A. Samples: In air-tight containers, 10 lb sample of each type of fill, or as requested by testing laboratory.
B. Materials Source: Name of imported fill materials suppliers.
C. Manufacturer's Certificate: Products meet or exceed specified requirements.
1.3 QUALITY ASSURANCE
A. Perform Work according to authority having jurisdiction standards.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Backfill Materials: As indicated on Drawings and specified elsewhere.
B. Subsoil Fill: As specified in Section 31 05113 – Soils for Earthwork.
C. Structural Fill: As specified in Section 31 05113 – Soils for Earthwork and 31 0516 – Aggregates for Earthwork.
D. Granular Fill: As specified in Section 31 0516 – Aggregates for Earthwork.
E. Flowable Fill: As specified in Section 31 2323.33 – Flowable Fill.
2.2 ACCESSORIES
A. Geotextile Fabric: As specified in Section 31 0519.13 - Geotextiles for Earthwork.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify that any subdrainage, dampproofing, and waterproofing installations have been inspected.
B. Verify that any underground tanks are anchored to their own foundations to avoid flotation after backfilling.
C. Verify structural integrity of unsupported walls to support loads imposed by fill.
3.2 PREPARATION
A. Compact subgrade to specified density requirements for subsequent backfill materials.
B. Soft Subgrade:
1. Cut out soft areas of subgrade not capable of compaction in place.
2. Backfill with Aggregate Base and compact to density equal to or greater than specified requirements for subsequent fill material.
C. Scarify subgrade surface to depth as indicated on Drawings or recommended by Geotechnical Engineer.
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3.3 BACKFILLING AND GRADING
A. Do not allow or cause any work performed or installed to be covered up or enclosed prior to required tests, inspections, and approvals. Any work be enclosed or covered up, the work shall be uncovered at the CONTRACTOR’s expense.
B. Backfilling and grading operations shall not take place when weather conditions and moisture content of fill materials prevent the attainment of specified density. Vertical curves or roundings at abrupt changes in slope shall be established as approved by the ENGINEER. Bring all graded areas to a relatively smooth, even grade and slope by blading or dragging. Remove high spots and fill depressions.
C. Backfill areas to contours and elevations as indicated on Drawings.
D. Systematically backfill to allow maximum time for natural settlement.
E. Do not backfill over porous, wet, frozen, or spongy subgrade surfaces, and do not backfill with frozen materials.
F. Backfill materials shall be placed and spread evenly in layers. When compaction is achieved using mechanical equipment, the layers shall be evenly spread so that when each layer compacted shall not exceed 6 inches in thickness. The compaction lift depth may be adjusted at the direction of the Geotechnical Engineer.
G. Structures:
1. Backfill shall not be dropped directly upon any structure or pipe.
2. Backfill shall not be placed around or upon any structure until the concrete has attained sufficient strength to withstand the loads imposed.
3. Backfill simultaneously on each side of unsupported foundation walls until supports are in place.
4. Slope grade away from building minimum 2 percent slope for minimum distance of 10 feet, unless otherwise indicated on Drawings.
H. Make gradual grade changes, and blend slope into level areas.
I. Remove surplus backfill materials from Site.
J. Leave fill material stockpile areas free of excess fill materials.
3.4 TOPSOIL FILL
A. Scarify prepared subgrade to a depth of 4 inches immediately prior to placing topsoil.
B. Place topsoil in areas to be seeded to the depths indicated, with a minimum depth of six inches.
Place loose, do not compact unless otherwise specified.
C. Do not place in wet or muddy conditions.
3.5 COMPACTION
A. Maintain optimum moisture content of fill materials to attain required compaction density.
B. Embankment Construction: All fill material within 3 feet of the top of fill elevations shall be compacted 95 percent maximum density unless otherwise specified. All fill material below the 3- foot limit to 90 percent maximum density unless otherwise specified.
C. Backfill beneath structures and hydraulic structures: 95 percent maximum density unless otherwise specified.
D. Beneath paved areas or structures: 95 percent maximum density unless otherwise specified.
E. Not beneath paved areas or structures: 90 percent maximum density unless otherwise specified.
3.6 TOLERANCES
A. Top Surface of Backfilling within Structural Areas: Plus or minus 1 inch from required elevations.
B. Top Surface of Backfilling under Paved Areas: Plus or minus 1/2 inch from required elevations.
C. Top Surface of General Backfilling: Plus or minus 1 inch from required elevations. 616
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3.7 FIELD QUALITY CONTROL
A. Testing shall be the Owner’s responsibility unless otherwise specified in the Contract Documents.
B. All field soils testing will be done by a testing laboratory as specified in the Contract Documents.
C. Perform laboratory material tests according to Method C of ASTM D1557. Where cohesionless, free draining soil material is required to be compacted to a percentage of relative density, the calculation of relative density will be determined in accordance with ASTM D 4253 and D 4254.
D. In-Place Compaction Testing:
1. Density Tests: ASTM D1556/D1556M or ASTM D6938.
2. Moisture Tests: ASTM D6031/6031M.
E. If tests indicate that Work does not meet specified requirements, remove Work, replace, compact, and retest.
F. Testing Frequency: As indicated on Drawings or recommended by Geotechnical Engineer.
G. Proof-roll compacted fill surfaces when recommended by Geotechnical Engineer.
H. Control operations by testing to verify and confirm that compaction work complies, and is complying at all times, with requirements specified in this Section concerning compaction, control, and testing.
I. If Compaction Fails to Meet Specified Requirements: Perform remedial work by one of the following methods.
1. Remove and replace backfill at proper density.
2. Bring density up to specified level by other means acceptable to the ENGINEER.
J. Retesting:
1. Costs of Retesting: Costs of retesting required to confirm and verify that remedial work has brought compaction within specified requirements shall be borne by the OWNER.
2. Tests during performance of remedial work shall be at a frequency double amount specified for initial confirmation tests, or as recommended by the Geotechnical Engineer.
3.8 PROTECTION
A. Reshape and recompact fills subjected to vehicular traffic during construction.
END OF SECTION 31 2323
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SECTION 31 2333 TRENCHING AND BACKFILLING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Excavating trenches, fine grading, pipe bedding.
2. Compacted fill from top bedding to subgrade elevations.
3. Backfilling and compaction.
1.2 SUBMITTALS
A. Samples: In air-tight containers, 10 lb sample of each type of fill, as requested by testing laboratory.
B. Materials Source: Name of imported fill materials suppliers.
C. Manufacturer's Certificate: Products meet or exceed specified requirements.
1.3 QUALITY ASSURANCE
A. Perform work according to authority having jurisdiction standards.
B. Prepare excavation protection plan under direct supervision of Professional Engineer experienced in design of this Work and licensed in the state of the project.
1.4 FIELD MEASUREMENTS
A. Verify field measurements prior to fabrication.
1.5 COORDINATION
A. Verify Work associated with lower elevation utilities is complete before placing higher elevation utilities.
PART 2 - PRODUCTS
2.1 FILL MATERIALS
A. Subsoil Fill: As specified in Section 31 05113 – Soils for Earthwork.
B. Structural Fill: As specified in Section 31 05113 – Soils for Earthwork and 31 0516 – Aggregates for Earthwork.
C. Granular Fill: As specified in Section 31 0516 – Aggregates for Earthwork.
D. Flowable Fill: As specified in Section 31 2323.33 – Flowable Fill.
PART 3 - EXECUTION
3.1 LINES AND GRADES
A. Lay pipes to lines and grades indicated.
1. CONTRACTOR may make changes in lines, grades, and depths of utilities when changes are required for Project conditions.
B. Use laser-beam instrument with qualified operator to establish lines and grades.
3.2 PREPARATION
A. Call local utility line information service not less than three working days before performing Work.
Request underground utilities to be located and marked within and surrounding construction areas.
B. Insert local utility's locating service telephone number.
C. Identify required lines, levels, contours, and datum locations.
D. Protect plant life, lawns, and other features remaining as portion of final landscaping.
E. Protect bench marks, existing structures, fences, sidewalks, paving, and curbs from excavating equipment and vehicular traffic.
F. Maintain and protect above and below grade utilities indicated to remain. 618
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G. Establish temporary traffic control and detours when trenching is performed in public right-of-way.
Relocate controls and reroute traffic as required during progress of Work.
H. Before laying pipes or electrical conduits in fill, place fill and compact it to not less than 1 foot above top of pipe or conduit. After placing and compacting fill, excavate through fill then fine grade as required in this Section.
3.3 EXPLORATORY TEST PITS
A. The CONTRACTOR shall dig such exploratory test pits as may be necessary in advance of excavation to determine the exact location and elevation of subsurface structures, pipelines, duct banks, conduits, and other obstructions which are likely to be encountered or need to be connected to and shall make acceptable provision for their protection, support, and maintenance of their continued operation.
B. Excavate and expose buried points of connection to existing utilities where indicated on the Drawings. Excavation shall be performed prior to preparation of Shop Drawings for connections and before fabrication of pipe, and the data obtained shall be used in preparing Shop Drawings.
C. Data, including dates, locations excavated, and sketches, shall be submitted to the ENGINEER within one week of excavation.
D. Damage to utilities from excavation activities shall be repaired at the CONTRACTOR’s expense.
3.4 TRENCH EXCAVATION
A. Excavate subsoil required for trench.
B. Remove lumped subsoil, boulders, and rock up to 1/6 cu yd, measured by volume. Remove larger material as specified in Contract Documents. If bottom of excavation is found to consist of rock or any material that by reason of its hardness cannot be excavated to provide uniform bearing surface, remove such rock or other material to a depth of not less than 4 inches below bottom of pipe and refill to grade with aggregate base course material or sand placed at uniform density, with minimum possible compaction, at no additional cost.
C. Remove water or materials that interfere with Work.
D. Do not advance open trench more than 200 feet ahead of installed pipe.
E. Cut trenches to width indicated, or sufficiently wide to enable installation and allow inspection. If, because of soil conditions, safety requirements or other reasons, trench width at top of pipe is increased beyond width specified, upgrade laying conditions or install stronger pipe designed in conformance with the appropriate pipe specification section for the increased trench width, without additional cost.
F. Excavate bottom of trenches maximum 24 inches wider than outside diameter of pipe.
G. Excavate trenches to depth indicated on Drawings. Provide uniform and continuous bearing and support for bedding material and pipe, conduit, or other utilities.
H. Do not interfere with 45-degree bearing splay of foundations.
I. When Project conditions permit, slope side walls of excavation starting 24 inches above top of pipe.
When side walls cannot be sloped, provide sheeting and shoring to protect excavation as specified in this Section.
J. When subsurface materials at bottom of trench are loose or soft, excavate to greater depth as directed by the ENGINEER until suitable material is encountered.
K. Cut out soft areas of subgrade not capable of compaction in place. Backfill with engineered fill and compact to density equal to or greater than requirements for subsequent backfill material. If bottom of excavation is found to consist of soft or unstable material which is incapable of properly supporting pipe, remove such material to a depth and for the length required, as determined by the ENGINEER, and then refill trench to grade with aggregate base course or sand, compacted to 90 percent of maximum density.
L. Trim excavation. Remove loose matter.
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M. Correct areas over excavated areas with compacted backfill as specified for authorized excavation or replace with fill concrete as directed by the ENGINEER.
N. Potable and Non-Potable Water Pipe Appurtenances:
1. Lay in trenches separate from those used for sewers.
2. Unless otherwise specified or indicated on the Drawings, lay in trenches having cover of not less than 3 feet below surface of ground and located at distance of not less than 6 feet from any parallel sewer trench, or as required by authority having jurisdiction.
O. At Road Crossings or Existing Driveways: Make provision for trench crossings at these points, either by means of backfills, tunnels, or temporary bridges.
P. Remove excess subsoil not intended for reuse, from Site.
Q. Obtain permission from OWNER prior to removing any excess subsoil.
3.5 TRENCH FINE GRADING
A. For Pipes 16 Inches in Nominal Diameter and Under: Unless otherwise specified, accurately grade bottom of trench to provide uniform bearing and support for each section of pipe, on undisturbed soil at every point along pipe's entire length, except for portions of pipe where it is necessary to excavate for bells and for proper sealing of pipe joints.
B. For Pipe over 16 Inches in Diameter:
1. Over-excavate bottom of trench by at least 4 inches, or 1/12 outside diameter of pipe, whichever is greater.
2. Fill overcut with bedding material specified herein, and fine graded as specified above.
3. Place bedding material at uniform density, with minimum possible compaction.
4. Where trench excavation is below grade of bedding material, restore trench bottom to proper grade by backfilling and compacting backfill to 95 percent of maximum density, at no additional cost. Use bedding material as specified in this Section.
C. Depressions for Joints: Make in accordance with recommendations of joint manufacturer for particular joint used.
3.6 SHEETING AND SHORING
A. Sheet, shore, and brace excavations to prevent danger to persons, structures, and adjacent properties and to prevent caving, erosion, and loss of surrounding subsoil.
B. Support trenches more than 5 feet deep excavated through unstable, loose, or soft material. Provide sheeting, shoring, bracing, or other protection to maintain stability of excavation.
C. If a moveable trench shield is used during excavation, pipe installation and backfill operations, the shield shall be moved by lifting the shield free of the trench bottom or backfill and then moving the shield horizontally. No trench shields shall be dragged along the trench causing damage or displacement to the trench sidewalls, the pipe, or the bedding and backfill.
D. Design sheeting and shoring to be removed at completion of excavation Work.
E. Repair damage caused by failure of sheeting, shoring, or bracing and for settlement of filled excavations or adjacent soil.
F. Repair damage to new and existing Work from settlement, water or earth pressure or other causes resulting from inadequate sheeting, shoring, or bracing.
3.7 TRENCH BACKFILLING
A. Pipe Zone Backfill:
1. The pipe zone is defined as that portion of the vertical trench cross-section lying between a plane below the bottom surface of the pipe and a plane at a point above the top surface of the pipe. The bedding is defined as that portion of pipe zone backfill material between the trench sub-grade and the bottom of the pipe. The embedment is defined as that portion of the pipe zone backfill material between the bedding and a level line. 620
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2. After compacting the bedding, perform a final trim using a laser or approved method for establishing grade, such that each pipe section when first laid will be continually in contact with the bedding along the extreme bottom of the pipe. Excavation for pipe bells and welding shall be made as required.
3. The pipe zone shall be backfilled with the indicated backfill material. Care to prevent damage to the pipeline coating, cathodic bonds, and the pipe itself during the installation and backfill operations shall be exercised.
B. Trench Zone Backfill: After the pipe zone backfills have been placed, backfilling of the trench zone may proceed. The trench zone is defined as that portion of the vertical trench cross-section lying as indicated between a plane above the top surface of the pipe and a plane at a point, 18 inches below the finished surface grade, or if the trench is under pavement, 18 inches below the roadway sub-grade.
C. Final Backfill: Final backfill is all backfill in the trench cross-sectional area within 18 inches of finished grade, or if the trench is under pavement, all backfill within 18 inches of the roadway subgrade.
D. Backfill shall not be dropped directly upon any pipe. Backfill shall not be placed around or upon any structure until the concrete has attained sufficient strength to withstand the loads imposed.
E. Except for drainrock materials being placed in over-excavated areas or trenches, backfill shall be placed after all water is removed from the excavation and the trench sidewalls and bottom have been dried to moisture content suitable for compaction.
F. Immediately prior to placement of backfill materials, the bottoms and sidewalls of trenches and structure excavations shall have all loose sloughing, or caving soil and rock materials removed.
Trench sidewalls shall consist of excavated surfaces that are in a relatively undisturbed condition before placement of backfill materials.
G. During spreading, each layer shall be thoroughly mixed as necessary to promote uniformity of material in each layer. Pipe zone backfill materials shall be manually spread around the pipe so when compacted the pipe zone backfill will provide uniform bearing and side support.
H. Where the backfill material moisture content is below the optimum moisture content, water shall be added before or during spreading until the moisture content is between optimum and 3% over the optimum.
I. Where the backfill material moisture content is too high to permit the specified degree of compaction the material shall be dried until the moisture content is between optimum and 3% over the optimum.
J. Backfill trenches to contours and elevations with unfrozen fill materials.
K. Systematically backfill to allow maximum time for natural settlement. Do not backfill over porous, wet, frozen, or spongy subgrade surfaces.
L. Place material in continuous layers as follows:
1. Subsoil Fill: Maximum 8 inches compacted depth, unless specified elsewhere.
2. Structural Fill: Maximum 6 inches compacted depth, unless specified elsewhere.
3. Granular Fill: Maximum 6 inches compacted depth, unless specified elsewhere.
M. Employ placement method that does not disturb or damage foundation perimeter drainage, utilities in trench, and other installed work.
N. Maintain optimum moisture content of fill materials to attain required compaction density.
O. Do not leave more than 50 feet of trench open at end of working day.
P. Protect open trench to protect personnel and the public.
3.8 TOLERANCES
A. Top Surface of Backfilling within Structural Areas: Plus or minus 1 inch from required elevations.
B. Top Surface of Backfilling under Paved Areas: Plus or minus 1/2 inch from required elevations. 621
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C. Top Surface of General Backfilling: Plus or minus 1 inch from required elevations.
3.9 FIELD QUALITY CONTROL
A. Testing shall be the CONTRACTOR’s responsibility unless otherwise specified in the Contract Documents.
B. All field soils testing will be done by a testing laboratory as specified in the Contract Documents.
C. Perform laboratory material tests according to Method C of ASTM D1557. Where cohesionless, free draining soil material is required to be compacted to a percentage of relative density, the calculation of relative density will be determined in accordance with ASTM D 4253 and D 4254.
D. In-Place Compaction Testing:
1. Density Tests: ASTM D1556/D1556M or ASTM D6938.
2. Moisture Tests: ASTM D6031/6031M.
E. If tests indicate that Work does not meet specified requirements, remove Work, replace, compact, and retest.
F. Testing Frequency: As indicated on Drawings or recommended by Geotechnical Engineer.
G. Proof-roll compacted fill surfaces when recommended by Geotechnical Engineer.
H. Control operations by testing to verify and confirm that compaction work complies, and is complying at all times, with requirements specified in this Section concerning compaction, control, and testing.
I. If Compaction Fails to Meet Specified Requirements: Perform remedial work by one of the following methods.
1. Remove and replace backfill at proper density.
2. Bring density up to specified level by other means acceptable to the ENGINEER.
J. Retesting:
1. Costs of Retesting: Costs of retesting required to confirm and verify that remedial work has brought compaction within specified requirements shall be borne by the CONTRACTOR.
2. Tests during performance of remedial work shall be at a frequency double amount specified for initial confirmation tests.
K. Frequency of Tests:
1. For Trenches: At each test location include tests for each type or class of backfill from bedding to finish grade.
2. In Open Fields: Two every 1,000 linear feet.
3. Along Dirt or Gravel Road or off Traveled Right-of-way: Two every 500 linear feet.
4. Crossing Paved Roads: Two locations along each crossing.
5. Under Pavement Cuts or within 2 Feet of Pavement Edges: one location every 400 linear feet.
L. Leak Testing Pipe:
1. After bedding the pipe, the CONTRACTOR has the option to either immediately perform leak testing or backfill to surface, at his own risk, and then leak test pipe.
2. If pipe does not pass test, uncover pipe, locate leaks, repair and retest, repeating until pipe section under test passes.
3.10 PROTECTION OF FINISHED WORK
A. Reshape and re-compact fills subjected to vehicular traffic during construction.
END OF SECTION 31 2333
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SECTION 31 2500 EROSION AND SEDIMENTATION CONTROLS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Diversion Channels.
2. Rock Energy Dissipator.
3. Paved Energy Dissipator.
4. Rock Basin.
5. Rock Barriers.
6. Sediment Ponds.
7. Sediment Traps.
1.2 SUBMITTALS
A. Proposed Mix Design: Furnish design of each class of concrete for review prior to commencement of Work.
B. Samples:
1. Two samples or rock, minimum 5 tons each or one-half total Project quantity, whichever is smaller. Provide one sample in place at construction Site and provide other sample at quarry. Construction Site sample may be incorporated into Work. Samples will be used as reference for judging size, and graduation of rock supplied and placed.
1.3 ROCK MATERIALS
A. Furnish materials according to Owner standards.
B. Rock: Sound, hard and angular shape; well graded; without shale seams, structural defects and foreign substances; with width and thickness greater than one third its length; minimum specific gravity of 2.5, as determined according to AASHTO T88, bulk saturated, and surface dry basis.
PART 2 - PRODUCTS (Not Used)
PART 3 - EXECUTION
3.1 DIVERSION CHANNELS
A. Windrow excavated material on low side of channel.
B. Compact to 95 percent maximum density.
C. On entire channel area, apply soil supplements and sow seed as specified elsewhere in Contract Documents.
D. Mulch seeded areas with hay as specified elsewhere in Contract Documents.
E. Install Work according to Owner standards.
3.2 ROCK ENERGY DISSIPATOR
A. Excavate to indicated depth of rock lining or nominal placement thickness as follows. Remove loose, unsuitable material below bottom of rock lining, then replace with suitable material.
Thoroughly compact and finish entire foundation area to firm, even surface.
B. Lay and overlay geotextile fabric over substrate. Lay fabric parallel to flow from upstream to downstream. Overlap edges upstream over downstream and upslope over downslope. Cover fabric as soon as possible and in no case leave fabric exposed more than four weeks.
C. Carefully place rock on geotextile fabric to produce an even distribution of pieces, with minimum of voids and without tearing geotextile.
D. Unless indicated otherwise, place full course thickness in one operation to prevent segregation and to avoid displacement of underlying material. Arrange individual rocks for uniform distribution. 623
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E. Install Work according to Owner standards.
3.3 PAVED ENERGY DISSIPATOR
A. Embed stones or blocks in plastic concrete at indicated separation on slopes and channel bottom.
B. Pave in uniform 10 foot lengths or sections.
C. Pave in shorter sections as necessary for closures or curves.
D. Place pre-molded expansion joint filler, 1/2 inch thick, cut to conform to paving cross sections, at ends of curved sections at intervals of not more than 100 feet, at end of day's work, and where paving is adjacent to rigid structure. Use joint filler with depth of 1/2 inch less than paving depth and press firmly against adjacent concrete.
E. Form intermediate joints between sections, with two thicknesses of bituminous paper cut neatly to paving cross section.
F. Seal joint top with joint sealer.
G. Install Work according to Owner standards.
3.4 ROCK BASIN
A. Construct generally according to rock energy dissipator requirements to indicated shape and depth.
Rock courses may be placed in several operations but minimum depth of initial course must be 3 feet or greater.
B. Install Work according to Owner standards.
3.5 ROCK BARRIER
A. Determine length required for ditch or depression slope and excavate, compact and foundation area to firm, even surface.
B. Produce an even distribution of rock pieces, with minimum voids to indicated shape, height and slope.
C. Construct coarse aggregate filter blanket against upstream face of rock barrier to indicated thickness.
D. Install Work according to Owner standards.
3.6 SEDIMENTATION POND
A. Clear and grub storage area and embankment foundation area site as specified elsewhere in the Contract Documents.
B. Excavate key trench for full length of dam. Excavate emergency spillway in natural ground.
C. Install pipe spillway, with anti-seep collar attached, at location indicated.
D. Place forms, and reinforcing for concrete footing at bottom of riser pipe. Construction of embankment and trench prior to placing pipe is not required.
E. Do not use coarse aggregate as backfill material around pipe. Backfill pipe with suitable embankment material to prevent dam leakage along pipe.
F. Construct rock basin at outlet end of pipe, as specified in this Section.
G. On entire sedimentation pond area, apply soil supplements and sow seed as specified elsewhere in the Contract Documents.
H. Mulch seeded areas with hay as specified elsewhere in the Contract Documents.
I. Install Work according to Owner standards.
3.7 SEDIMENT TRAPS
A. Construct trap by excavating and forming embankments.
B. Place coarse aggregate or rock at outlet as indicated on Drawings.
C. Place geotextile fabric, as specified for rock energy dissipator. 624
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D. On entire sediment trap area, apply soil supplements and sow seed as specified elsewhere in the Contract Documents.
E. Mulch seeded areas with hay as specified elsewhere in the Contract Documents.
F. Install Work according to Owner standards.
3.8 SITE STABILIZATION
A. Incorporate indicated erosion control devices into Project at earliest practicable time.
B. Construct, stabilize and activate erosion controls before Site disturbance within tributary areas of those controls.
C. Stockpile and waste pile heights shall not exceed 35 feet. Slope stockpile sides at 2:1 or flatter.
D. Stabilize any disturbed area of affected erosion control devices on which activity has ceased and which will remain exposed for more than 20 days.
E. Stabilize diversion channels, sediment traps, and stockpiles immediately.
3.9 FIELD QUALITY CONTROL
A. Inspect erosion control devices on a weekly basis and after each runoff event. Make necessary repairs to ensure erosion and sediment controls are in good working order.
3.10 CLEANING
A. When sediment accumulation in sedimentation structures has reached a point one-third depth of sediment structure or device, remove, and dispose of sediment.
B. Do not damage structure or device during cleaning operations.
C. Do not permit sediment to erode into construction or Site areas or natural waterways.
D. Clean channels when depth of sediment reaches approximately one half channel depth.
3.11 PROTECTION
A. Immediately after placement, protect paving from premature drying, excessive hot or cold temperatures, and mechanical injury.
B. Protect paving from elements, flowing water, or other disturbance until curing is completed.
END OF SECTION 31 2500
625
ASPHALT PAVING 32 1216 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 32 1216 - ASPHALT PAVING
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Perform all WORK associated with Asphalt Concrete (AC) Pavement and base as shown and specified herein including all labor, materials, equipment supplies, and facilities associated with providing a finished product satisfying all the requirements of the Contract Documents.
B. Verify all requirements with Geotechnical Report and notify the ENGINEER immediately if discrepancies exist.
1.2 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Codes: All codes, as referenced herein.
B. References: These specifications refer to the California Department of Transportation (Caltrans) Standard Specifications, referred to herein as the Standard Specifications.
1.3 SUBMITTALS
A. Submit, in writing, materials testing reports, mix designs and other pertinent information satisfactory to the ENGINEER demonstrating that materials and methods it proposes to utilize will comply with the referenced provisions of the Standard Specifications, in accordance Submittal Requirements.
PART 2 - PRODUCTS
MATERIALS REQUIREMENTS
A. Aggregate Base: Materials for aggregate base shall be maximum ¾ inch Class 2 Aggregate Base as specified in Section 26-1.02B of the Caltrans State Standard Specifications, unless otherwise specified in the project soils report.
B. Asphalt Concrete:
1. AC shall be Type A, 1/2" (12.5mm) max medium and shall conform to the provisions of Section 39 of the Caltrans State Standard Specifications, unless otherwise specified in the project soils report.
2. AC shall have a viscosity grade of AR-4000 as specified in Section 92 of the Caltrans State Standard Specification.
3. Asphalt content as a percentage of the dry aggregate weight shall be approved by the ENGINEER. In the absence of such a determination, the amount of asphalt binder to be mixed with the aggregate shall be between 5.6% and 5.9% by weight of the dry aggregate.
C. Pavement Marking Paint: Pavement marking paint shall be an approved product having a proven record of performance and durability.
PART 3 - EXECUTION
3.1 CONSTRUCTION REQUIREMENTS FOR NEW ROADWAY PAVEMENT
A. Subgrade preparation shall comply to the Geotechnical Report.
B. Aggregate Base: Aggregate base shall be provided where shown and to the thickness shown.
Construction of the aggregate base course shall be as indicated on the drawings. AB thickness to be determined after R-value tests are completed using samples of soil obtained from completed subgrade.
C. Asphalt Concrete
1. AC paving shall be constructed as indicated within the Contract Documents with a minimum thickness of 4”. AB shall be as indicated within the Contract Documents with a minimum 626
ASPHALT PAVING 32 1216 - 2
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thickness of 10”. When/Where restoring AC, the restoration shall be completed per the AHJ’s standards and/or at a minimum of 1” thicker than the existing, whichever is greater.
2. Alternate compacting equipment or substitution of a vibratory roller for a pneumatic-tired roller must be approved by the ENGINEER.
3. All mixtures shall be spread at a temperature of not less than 250°F. Base material compaction shall be completed before the mix reaches 200°F.
D. Pavement Marking Paint: Application of the paint shall be in accordance with the paint manufacturer's instructions. Traffic markings obliterated by the WORK shall be repainted, unless otherwise directed by the ENGINEER.
3.2 CONSTRUCTION REQUIREMENTS FOR PAVEMENT REPAIR
A. Street excavation and pavement restoration shall be in accordance with the AHJ’s Standards and the Contract Documents.
B. The restored pavement shall be placed according to the provisions herein of a similar thickness to the existing adjacent pavement plus 1 inch deeper. The restored pavement shall have a finished surface 1/8-inch higher than the existing adjacent pavement.
C. The CONTRACTOR shall diamond saw cut joining pavement edges and tack coat edges.
END OF SECTION 32 1216
627
CONCRETE PAVING 32 1313 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 32 1313 - CONCRETE PAVING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Concrete paving for sidewalks, curbs and gutters, and parking areas and roads as indicated in the Contract Documents.
1.2 SUBMITTALS
A. Product Data:
1. Submit data on concrete materials, per Section 03 0300.
B. Design Data:
1. Submit concrete mix design for each concrete strength. Submit separate mix designs when admixtures are required.
1.3 QUALITY ASSURANCE
A. Perform Work in accordance with ACI 301.
B. Perform work according to authority having jurisdiction’s standards.
PART 2 - PRODUCTS
2.1 CONCRETE PAVING
A. Form Materials:
1. Form Materials: Conform to ACI 301.
B. Reinforcement:
1. Reinforcing Steel and Wire Fabric: As specified elsewhere in the Contract Documents.
C. Concrete Materials:
1. Concrete Materials: Per Section 03 0300, and as specified elsewhere in the Contract Documents.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify gradients and elevations of base.
B. Verify subgrade is ready to support paving and imposed loads.
3.2 PREPARATION
A. Moisten substrate to minimize absorption of water from fresh concrete.
3.3 INSTALLATION
A. Placing Concrete:
1. Place concrete in accordance with ACI 301 and Section 03 3000.
2. Do not disturb reinforcing or formwork components during concrete placement.
3. Place concrete continuously between predetermined joints.
4. Place bumpers secure.
B. Finishing:
1. Light broom, unless specified elsewhere in the Contract Documents.
2. Apply curing compound on exposed concrete surfaces immediately after finishing. 628
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3.4 TOLERANCES
A. Maximum Variation of Surface Flatness: 1/4 inch in 10 ft.
B. Maximum Variation from True Position: 1/4 inch.
END OF SECTION 32 1313
629
CONCRETE CURBS, GUTTERS, SIDEWALKS, AND DRIVEWAYS 32 1600-1 B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 32 1600 CONCRETE CURBS, GUTTERS, SIDEWALKS, AND DRIVEWAYS PART 1 – GENERAL
1.1 SUMMARY
A. Section Includes: Concrete curbs, gutters, sidewalks, driveways, access ramps, and alley intersections.
1.2 SYSTEM DESCRIPTION
A. Performance Requirements: Construct various types of concrete curb, gutter, sidewalk, driveways, and alley intersections to dimensions and details indicated on the Drawings.
1.3 SUBMITTALS
A. Submittals shall be made in accordance with Section 01 3300 - Submittals.
B. Product Data: Submit data completely describing products.
PART 2 – PRODUCTS
2.1 MATERIALS
A. Concrete: 3,000 psi, conforming to the applicable requirements of Section 03 3300.
B. Curb Finishing Mortar: 1 part Portland cement to two parts sand.
C. Form Release Material: Light oil or other releasing agent of type which does not discolor concrete or interfere with the application of finishing mortar to curb tops and faces.
D. Joint Materials:
1. Expansion: Comply with requirements as specified in Section 03 0150.
2. Construction: Steel dividers or plastic inserts.
PART 3 – EXECUTION
3.1 EXAMINATION
A. Verification of Conditions: Verify field conditions, including subgrade condition and interferences, before beginning construction.
3.2 PREPARATION
A. Surface Preparation:
1. Subgrade:
a. Construct and compact true to grades and lines indicated on the Drawings. b. Remove soft or unsuitable material to depth of not less than 6 inches below subgrade elevation and replace with satisfactory material following Division 31.
2. Forms and Subgrade: Water immediately in advance of placing concrete.
3.3 INSTALLATION
A. Special Techniques:
1. CONTRACTOR's Option:
a. Construct concrete curbs and gutters by conventional use of forms, or by means of curb and gutter machine when acceptable to the ENGINEER. b. When use of machines designed specifically for work of this Section are accepted by the ENGINEER, results must be equal to or better than those produced by use of forms.
c. Applicable requirements of construction that apply to use of forms also apply to use of machines.
d. Discontinue use of machines when results are not satisfactory to the ENGINEER. 630
CONCRETE CURBS, GUTTERS, SIDEWALKS, AND DRIVEWAYS 32 1600-2 B810 ADELANTO WWTP IMPROVEMENT PLAN
B. Forms:
1. Carefully set to line and grade and securely stake in position forms conforming to dimensions of items to be constructed.
2. Thoroughly clean prior to each use and coat with form releasing material.
C. Expansion and Contraction Joints:
1. Expansion Joints:
a. Construct vertically, and at right angles to centerline of street and match joints in adjacent pavement or sidewalks.
b. Constructed at radius points, driveways, alley entrances, and at adjoining structures. c. Fill joints with expansion joint filler material.
2. Contraction Joints:
a. Constructed not more than 15 feet apart.
b. Make joints of construction joint material, scoring or saw cutting to depth of not less than 1-1/2 inches, and matching joints in adjacent pavement or sidewalk.
D. Concrete:
1. Placing:
a. Thoroughly spade concrete away from forms so that no rock pockets exist next to forms and so that no coarse aggregate will show when forms are removed.
2. Compacting:
a. Compact by mechanical vibrators accepted by the ENGINEER. b. Continue tamping or vibrating until mortar flushes to surface and coarse aggregate is below concrete surface.
3. Form Removal:
a. Front Form Faces: Do not remove before concrete has taken initial set and has sufficient strength to carry its own weight.
b. Gutter and Rear Forms: Do not remove until concrete has hardened sufficiently to prevent damage to edges. Take special care to prevent damage.
4. Finishing and Curing: Comply with requirements as specified in Section 033300 except as modified here:
a. As soon as curb face forms are stripped, apply finishing mortar to the top and face of curb and trowel to a smooth, even finish. Finish with fine haired broom in direction of work.
b. Where curb is installed without integral gutter, extend finish 2 inches below grade. c. Edge concrete at expansion joints to 1/4-inch radius. d. Flow lines of gutters shall be troweled smooth 4 inches out from curb face for integral curb and gutter and 4 inches on both sides of flowline for gutters without curbs.
E. Backfilling: Unless otherwise specified, backfill behind curbs, gutters, or sidewalks and to lines and grades indicated on the Drawings with Geotechnical Engineer approved soil.
3.4 FIELD QUALITY CONTROL
A. Tests:
1. Curbs and Gutters:
a. Test face, top, back, and flow line with 10-foot straight edge or curve template longitudinally along surface.
b. Correct deviations in excess of 1/4 inch.
2. Gutters:
a. Frequency of Testing: When required by the ENGINEER, where gutters have slope of 0.8 foot per hundred feet or less, or where unusual or special conditions cast doubt on capability of gutters to drain.
631
CONCRETE CURBS, GUTTERS, SIDEWALKS, AND DRIVEWAYS 32 1600-3 B810 ADELANTO WWTP IMPROVEMENT PLAN
b. Test Method: Establish flow in length of gutter to be tested by supplying water from hydrant, tank truck, or other source.
c. Required Results:
1) 1 hour after supply of water is shut off, inspect gutter for evidence of ponding or improper shape.
2) In event water is found ponded in gutter to depth greater than ½ inch, or on adjacent asphalt pavement, correct defect or defects in manner acceptable to the ENGINEER without additional cost to the Contract.
3.5 ADJUSTING
A. Repair portions of concrete damaged while stripping forms or, when damage is severe, replace such work at no additional cost to the Contract. Evidence of repairs shall not be noticeable in the finished product.
B. Remove and replace sections of work deficient in depth or not conforming to requirements indicated on the Drawings and specified in the Specifications at no additional cost to the Contract.
Removal and replacement shall be the complete section between two joints.
END OF SECTION 32 1600
632
PIPELINE CONNECTION TO EXISTING FACILITIES 33 0010-1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 33 0010 PIPELINE CONNECTIONS TO EXISTING FACILITIES PART 1 - GENERAL
1.1 DESCRIPTIONS
A. This section includes requirements for connection to and abandonment of existing water facilities.
1.2 LOCATION
A. The connection points to the existing water system shall be potholed to identify depth, diameter and pipe material. Coordinates and dimensions to locate the exact pothole location shall also be documented. Pothole information shall be immediately provided to the ENGINEER for review.
The ENGINEER will not review any other submittals until after the pothole data is received.
1.3 SUBMITTALS
A. Submittals shall be furnished in accordance with Section 01 3300 - Submittals.
B. CONTRACTOR shall submit to the authority having jurisdiction at least six weeks prior to any connections to existing facilities which require the shutdown of that facility, their plan to perform the shut down and requirements of which facilities will be shut down to accomplish the connection.
PART 2 - MATERIALS
2.1 All materials used in making the connection or removing the facility from service shall conform to the applicable sections of these specifications and the contract drawings.
PART 3 - EXECUTION
3.1 CONNECTION TO EXISTING WATERLINES
A. Notification: The CONTRACTOR shall give the authority having jurisdiction a minimum of ten (10) working days’ notice in writing before the time of any required shutdown of existing mains or services. The authority having jurisdiction shall determine the actual time and date of shutdown.
B. Authorization: Connections shall be made only in the presence of the authority having jurisdiction Representative. No connection work shall be performed prior to authorization by the authority having jurisdiction.
C. Time Schedule: The CONTRACTOR is restricted to a time limit not exceeding 4 hours to connect the new pipelines to the existing pipeline, with required fittings, and restore water service, after the authority having jurisdiction has drained the pipeline.
D. Material: The CONTRACTOR shall furnish all pipe and materials as may be required for connections including but not limited to: labor and equipment necessary to make the connections; all required excavation; backfill; lights; barricades; water truck; highline hose; and fittings for making the connections. The CONTRACTOR shall provide verification to the authority having jurisdiction that all necessary materials and personnel are on-site before requesting shutdown or commencing with connection to existing mains or services.
E. Inadequate Progress: If progress is inadequate during the connection operations to complete the connection in the time specified, the CONTRACTOR shall order necessary corrective measures.
F. Connections: Connections shall be made with as little change as possible in the grade of new main.
If the grade of the existing pipe is below that of the new pipeline, a sufficient length of the new line shall be deepened so as to prevent the creation of any high spot or abrupt changes in grade of the new line. Where the grade of the existing pipe is above that of the new pipeline, the new line shall be laid at specified depth, except for the first joint adjacent to the connection, which shall be deflected as necessary to meet the grade of the existing pipe. If sufficient change in direction cannot be obtained by the limited deflection of the first joint, a fitting of the proper angle shall be installed.
Where the connection creates a high or low spot in the line, a standard air release or blow-off 633
PIPELINE CONNECTION TO EXISTING FACILITIES 33 0010-2
B810 ADELANTO WWTP IMPROVEMENT PLAN
assembly shall be installed as directed by the ENGINEER.
G. Testing: The new pipeline shall be disinfected and hydrostatically tested as required.
3.2 CONNECTION TO NON WATERLINE PIPES
A. Notification: The CONTRACTOR shall give the authority having jurisdiction a minimum of ten (10) working days’ notice in writing before the time of any required shutdown of existing pipelines.
The authority having jurisdiction shall determine the actual time and date of shutdown.
B. Authorization: Connections shall be made only in the presence of the authority having jurisdiction Representative. No connection work will be performed prior to authorization by the authority having jurisdiction.
C. Time Schedule: The CONTRACTOR is restricted to a time limit not exceeding 4 hours (unless previously negotiated with the authority having jurisdiction in writing) to connect the new pipelines to the existing pipeline, with required fittings, and restore service.
D. Material: The CONTRACTOR shall furnish all pipe and materials as may be required for connections including but not limited to: labor and equipment necessary to make the connections; all required excavation; backfill; lights; barricades; water truck; highline hose; and fittings for making the connections. The CONTRACTOR shall provide verification to the authority having jurisdiction that all necessary materials and personnel are on-site before requesting shutdown or commencing with connection to existing mains or services.
E. Inadequate Progress: If progress is inadequate during the connection operations to complete the connection in the time specified, the CONTRACTOR shall order necessary corrective measures.
F. Connections: Connections shall be made with as little change as possible in the grade of new main.
If the grade of the existing pipe is below that of the new pipeline, a sufficient length of the new line shall be deepened so as to prevent the creation of any high spot or abrupt changes in grade of the new line. Where the grade of the existing pipe is above that of the new pipeline, the new line shall be laid at specified depth, except for the first joint adjacent to the connection, which shall be deflected as necessary to meet the grade of the existing pipe. If sufficient change in direction cannot be obtained by the limited deflection of the first joint, a fitting of the proper angle shall be installed.
Where the connection creates a high or low spot in the line, a standard air release or blow-off assembly shall be installed as directed by the ENGINEER.
END OF SECTION 33 0010
634
DISINFECTION OF WATER UTILITY PIPING SYSTEMS 33 0110 - 1 B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 33 0110 - DISINFECTION OF WATER UTILITY PIPING SYSTEMS PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Disinfection of potable water distribution system.
2. Testing and reporting of results.
1.2 SUBMITTALS
A. Disinfection Procedure:
1. Type of disinfectant and calculations indicating quantities of disinfectants required to produce specified chlorine concentration.
B. Product Data: Manufacturer information for proposed chemicals and treatment doses.
C. Manufacturer's Certificate: Products meet or exceed specified requirements.
D. Certify that final water complies with disinfectant quality standards of the authority having jurisdiction.
E. Include separate Paragraphs for additional certifications.
F. Test and Evaluation Reports: Indicate testing results comparative to specified requirements.
G. Field Quality-Control Submittals: Indicate results of furnished equipment tests and inspections.
H. Qualifications Statements:
1. Qualifications for manufacturer and applicator.
1.3 CLOSEOUT SUBMITTALS
A. Disinfection Report:
1. Type and form of disinfectant used.
2. Date and time of disinfectant injection start and completion.
3. Test locations.
4. Name of person collecting samples.
5. Initial and 24-hour disinfectant residuals in treated water in ppm for each outlet tested.
6. Date and time of flushing start and completion.
7. Disinfectant residual after flushing in ppm for each outlet tested.
1.4 QUALITY ASSURANCE
A. Perform Work according to AWWA C651.
B. Manufacturer: Company specializing in manufacturing products specified in this Section with three years' experience.
C. Applicator: Company specializing in performing Work of this Section with three years' experience.
PART 2 - PRODUCTS
2.1 DISINFECTION CHEMICALS
A. Chemicals:
1. Hypochlorite: Comply with AWWA B300.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify that piping system has been cleaned, inspected, and pressure tested.
B. Perform scheduling and disinfecting activity with startup, water pressure testing, adjusting and balancing, and demonstration procedures, including coordination with related systems. 635
DISINFECTION OF WATER UTILITY PIPING SYSTEMS 33 0110 - 2 B810 ADELANTO WWTP IMPROVEMENT PLAN
3.2 INSTALLATION
A. Maintain disinfectant in system for a minimum of 24 hours.
B. Flush, circulate, and clean until required disinfectant quality standard has been achieved using municipal domestic water.
3.3 FIELD QUALITY CONTROL
A. Disinfection, Flushing, and Sampling:
1. Disinfect pipeline installation according to AWWA C651, and per AHJ requirements.
2. Use of liquid chlorine is not permitted.
3. Upon completion of retention period required for disinfection, flush pipeline until chlorine concentration in water leaving pipeline is no higher than that generally prevailing in existing system or is acceptable for domestic use.
4. Disposal:
a. Legally dispose of chlorinated water.
b. If chlorinated discharge may cause damage to environment, apply neutralizing chemical to chlorinated water to neutralize chlorine residual remaining in water.
5. After final flushing and before pipeline is connected to existing system or placed in service, certify that disinfectant level meets quality standards of authority having jurisdiction.
END OF SECTION 33 0110
636
SANITARY SEWER SYSTEM TESTING 33 0130-1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 33 0130 SANITARY SEWER SYSTEM TESTING
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Perform all pipeline flushing and testing, complete, for sanitary sewer and storm drainage system piping as specified herein and in accordance with the requirements of the Contract Documents.
B. Be responsible for providing conveyance of test water to the point of usage and also for disposal, as required, of water used in the testing operations.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards:
ASTM A746 Ductile Iron Gravity Sewer Pipe
ASTM F1417 Standard Test Method for Installation Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air
1.3 SUBMITTALS
A. Submittals shall be made in accordance with Section 01 3300 - Submittals.
B. Proposed plans for testing of the sanitary sewer system. The methods used may be air or water as described herein. If water method is used then provide the water conveyance, control and disposal.
Advance written notice of the proposed testing schedule for review and concurrence of the ENGINEER shall be submitted.
PART 2 -PRODUCTS
2.1 MATERIALS REQUIREMENTS
A. Temporary valves, plugs, bulkheads, and other air pressure testing and water control equipment and materials shall be provided, subject to the ENGINEER's review. No materials shall be used which would be injurious to pipeline structure and future function. Air test gages shall be laboratory-calibrated test gages and shall be recalibrated by a certified laboratory at the subcontractor’s expense prior to the leakage test, if required by the ENGINEER.
PART 3 -EXECUTION
3.1 GENERAL
A. Unless otherwise specified, water for testing will be furnished however, all necessary provisions for conveying the water from the designated source to the points of use shall be made.
B. Release of water from pipelines, after testing has been completed, shall be performed as reviewed by the ENGINEER.
C. All testing operations shall be performed in the presence of the ENGINEER.
D. All testing shall be performed per the authority having jurisdiction’s standards, and or Adopted Environmental Codes, or equal. If local requirements exist on testing, use most stringent.
3.2 TESTING OF PIPING
A. General: All gravity sewer pipes and service laterals shall be tested for exfiltration, infiltration and deflection, as specified. All manholes shall be tested for leakage, as specified. Manholes shall be tested prior to backfill placement. All leakage tests shall be completed and approved prior to placing of permanent resurfacing. When leakage or infiltration exceeds the amount allowed by the Specifications, locate the leaks and make the necessary repairs or replacements in accordance with the Specifications to reduce the leakage or infiltration to the specified limits. Any individually detectable leaks shall be repaired, regardless of the results of the tests. The OWNER reserves the right to require testing of the entire installation. Cost of repairs or corrections necessary to conform to the following testing requirements will be borne by the subcontractor at no additional cost to the ENGINEER.
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SANITARY SEWER SYSTEM TESTING 33 0130-2
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B. Pressure sewers (force mains); water pressure test at 120% of maximum operating pressure, measured at the lowest point of the pipeline section being tested.
C. Gravity sewers pipe lines and manholes shall be subject to acceptance testing after backfilling has been completed but prior to the placement of the finished surface material.
1. Low Pressure Air Test: Testing will be accomplished by the means of “Low Pressure Air Testing.” Tests may be conducted by the subcontractor or an independent testing firm.
However, acceptance tests shall be made only in the presence of the ENGINEER or an authority having jurisdiction representative.
a. Test Procedure:
1) Before testing, the pipe shall be thoroughly cleaned. 2) The subcontractor shall seal off the section of pipe to be tested at each manhole connection. Test plugs must be securely braced within the manholes. 3) A minimum of two connecting hoses to link the air inlet test plug with an above ground test monitoring panel must be provided.
a) One hose is to induce air through the test plug and into the test chamber. b) The second hose is for the purpose of monitoring the test pressure from within the enclosed pipe.
4) Under no circumstances are workers to be allowed in the connecting manholes while a pressure test is being conducted.
5) Add air slowly into the test section. After an internal pressure of 4.0 psi is obtained, allow internal air temperature to stabilize.
6) After stabilization period, adjust the internal air pressure to 3.5 psi, disconnect the air supply and begin timing the test.
7) Refer to Table 3.3-1 to determine the length of time (minutes) the section under test must sustain while not losing in excess of 1 psi as monitored by the test gauge. If the section of line to be tested includes more than one pipe size, calculate the test time for each size and add the test times to arrive at the total test time for the section.
8) Sections so determined to have lost 1 psi or less during the test period will have passed the leakage test. Those sections losing in excess of 1 psi during the test period will have failed the leakage test.
9) Appropriate repairs must then be completed and the line retested for acceptance.
TABLE 3.3-1
SANITARY SEWER AIR TEST
Minimum Test Time for Various Pipe Sizes*
Nominal Pipe Size, in. T (time), min/100 ft. Nominal Pipe Size, in. T (time), min/100 ft. 3 0.2 21 3.0
4 0.3 24 3.6
6 0.7 27 4.2
8 1.2 30 4.8
10 1.5 33 5.4
12 1.8 36 6.0
15 2.1 39 6.6
18 2.4 42 7.3
* The time has been established using the formulas contained in ASTM C-828, Appendix. 638
SANITARY SEWER SYSTEM TESTING 33 0130-3
B810 ADELANTO WWTP IMPROVEMENT PLAN
2. Hydrostatic Test: Exfiltration Testing (water): Sanitary sewer testing by means of exfiltration should only be considered when low pressure air testing cannot be used and only with the approval of the Engineer.
a. Testing Procedure:
1) The subcontractor shall furnish all equipment for testing. 2) Seal off the downstream end of the line and fill with water to a minimum head of 4 feet in a stand pipe at the high end.
3) A period of at least one hour will be allowed for absorption time before making the test.
4) A suitable meter or method of measuring the quantity of water used is necessary.
5) The allowable water loss for sanitary sewers shall not exceed 0.158 gallons per hour per 100 feet of pipe per inch of diameter of pipe under a minimum test head of 4 feet above the top of the pipe at the upper end.
D. Deflection Test for HDPE and PVC Pipe:
1. In addition to the tests prescribed above, the subcontractor shall perform a deflection test on the system as directed by the Engineer. Any part of the installation which shows deflection in excess of 5% of the nominal inside diameter per Section 738 for HDPE pipe or in excess of 5% of the average inside diameter per ASTM D-3034 for PVC pipe, shall be corrected.
2. After acceptance by prior to the termination of the warranty period, the ENGINEER may test the long term deflection of the sewer. If the ENGINEER determines that the deflection has exceeded 7 ½ % of the average inside diameter, that portion of the installation shall be corrected by the subcontractor at no cost to the ENGINEER.
3.3 HYDROSTATIC TESTING OF MANHOLES – SEE SECTION 330505.31 A. General: All sewer manholes shall be hydrostatically tested for leakage after installation, but prior to being backfilled. Prior to hydrostatic testing, all manholes shall be visually inspected for leaks.
All leaks or cracks shall be repaired, prior to hydrostatic testing, to the satisfaction of the ENGINEER. All pipes entering the manhole shall be sealed at a point outside the manhole walls so as to include testing of the pipe/manhole joints. The manhole shall be filled with water to a level 2 inches below the top of the frame. Safety lines shall be secured to all plugs utilized. After a period of at least one hour to allow the water level to stabilize, the manhole shall be refilled and the water level shall be checked. The water level shall again be checked after a period of 4 hours. If the water level is reduced by more than ¼-inch, the leakage shall be considered excessive, the required repairs shall be made and the manhole retested. The exterior of the manhole shall be inspected during this period for visible evidence of leakage. Visible moisture, sweating or beads of water on the exterior of the manhole shall not be considered leakage, but any water running across the surface will be considered leakage and shall be repaired to the satisfaction of the ENGINEER regardless of the volume of water lost.
END OF SECTION 33 0130.13
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HYDROSTATIC TESTING 33 0505 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 33 0505 - HYDROSTATIC TESTING
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: Hydrostatic testing of pressure piping. See also authority having jurisdiction’s standards for requirements.
1.2 SUBMITTALS
A. Submit following items prior to start of testing:
1. Testing procedures.
2. List of test equipment.
3. Testing sequence schedule.
4. Provisions for disposal of flushing and test water.
5. Certification of test gage calibration.
B. Test and Evaluation Reports: Indicate results of piping tests.
C. Qualifications Statement:
1. Qualifications for applicator.
1.3 QUALITY ASSURANCE
A. Perform work according to authority having jurisdiction standards.
B. Applicator: Company specializing in performing Work of this Section with three years' experience.
PART 2 - PRODUCTS
2.1 HYDROSTATIC TESTING
A. Equipment:
1. Pressure pump.
2. Pressure hose.
3. Water meter.
4. Test connections.
5. Pressure relief valve.
6. Pressure Gage: Calibrated to 0.1 psi
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify that piping is ready for testing.
B. Verify that trenches are backfilled.
C. Verify that pressure piping thrust restraints have been installed.
3.2 FIELD QUALITY CONTROL
A. Testing of Pressure Piping:
1. Test system according to AWWA C600 and following:
a. Hydrostatically test each portion of pressure piping, including valved section, at 1.5 times working pressure of piping, based on elevation of lowest point in piping corrected to elevation of test gage.
b. Conduct hydrostatic testing for at least two hours.
c. Slowly fill with water portion of piping to be tested, expelling air from piping at high points.
d. Install corporation cocks at high points.
e. Close air vents and corporation cocks after air is expelled. f. Raise pressure to specified test pressure.
g. Observe joints, fittings, and valves undergoing testing. 640
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h. Remove and renew cracked pipes, joints, fittings, and valves that show visible leakage. i. Retest.
j. Correct visible deficiencies and continue testing at same test pressure for additional two hours to determine leakage rate.
k. Maintain pressure within plus or minus 5.0 psi of test pressure. l. Leakage is defined as quantity of water supplied to piping necessary to maintain test pressure during period of testing.
m. Compute maximum allowable leakage using following formula:
1) L = [SD x sqrt(P)]/C.
2) L = testing allowance, gph.
3) S = length of pipe tested, feet.
4) D = nominal diameter of pipe, inches.
5) P = average test pressure during hydrostatic testing, psig. 6) C = 148,000.
7) If pipe undergoing testing contains sections of various diameters, calculate allowable leakage from sum of computed leakage for each pipe size.
2. If testing of piping indicates leakage greater than that allowed, locate source of leakage, make corrections, and retest until leakage is within acceptable limits.
3. Correct visible leaks regardless of quantity of leakage.
END OF SECTION 33 0505.31
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SECTION 33 0526 UTILITY IDENTIFICATION
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide safety signs and identification devices for all exposed piping and valves using color bands, lettering, flow direction arrows, and related permanent identification devices, and all appurtenant works, in accordance with the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Commercial Standards: ANSI A13.1 Scheme for the Identification of Piping Systems
1.3 SUBMITTALS
A. Submit samples of all types of identification devices and signs to be used in the work.
B. All submittals shall be in strict accordance with the requirements of Section 01 3300 – Submittal Procedures.
1.4 QUALITY ASSURANCE
A. Manufacturer and model shall be described on the Drawings or ENGINEER approved equal.
B. The manufacturer shall provide a minimum 2-year warranty.
PART 2 - PRODUCTS
2.1 IDENTIFICATION OF PIPING
A. Identification of all exposed pipe shall be accomplished by color-coding with bands or painting of the pipe and by lettering as specified in Part 3, herein. Color bands shall either be painted directly upon the pipe or shall be pressure-sensitive adhesive-backed vinyl cloth or plastic tape.
B. Each pipe identification shall consist of two 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. Arrows and labels may be stenciled on the pipes at the discretion of the ENGINEER.
C. Letter sizes and colors for lettering, arrows and background shall conform to ANSI A13.1.
2.2 IDENTIFICATION OF VALVES AND SHORT PIPE LENGTHS
A. Identifying devices for valves and the sections of pipe that are too short to be identified with color bands, lettered labels, and arrows shall be identified with metal or plastic tags as specified herein.
B. Metal tags shall be supplied with embossed lettering. Plastic tags shall be of solid black phenolic with white letters. All tags shall be designed to be attached, by chain, to the valves or short pipes.
2.3 SAFETY SIGNS
A. Color, legend, and layout shall conform to OSHA 1910.145 requirements.
B. “DANGER” Signs: Two-inch high white letters “Danger” in red oval surrounded by a rectangular black field. Text wording 1½-inch high black capital letters on white field.
C. Signs: Two-inch high yellow letters on black field. Text wording 1½-inch high black capital letters on yellow field.
D. Chemical precaution signs:
1. In accordance with ANSI Z129.1
2. 12-inch x 14-inch
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3. Made to withstand most chemicals. Special ink for printing to be absorbed into sign surface.
Ultraviolet inhibitors and clear face coating for resisting fading and scratching. Semi-rigid linear polyethylene.
PART 2 - EXECUTION
3.1 GENERAL
A. All labels and identification tags shall be installed in accordance with the manufacturer's printed instructions, and shall be neat and uniform in appearance. All such tags or labels shall be readily visible from all normal working locations.
3.2 VALVE TAGS
A. Valve tags shall be attached to the valve or structure by means of a chain.
3.3 PIPE IDENTIFICATION
A. Each pipe shall be identified at intervals of 30-feet, and at least one time in each room (where applicable). Piping shall also be identified at a point approximately within 2-feet of all turns, elbows, valves and on the upstream side of all distribution fittings or branches.
B. Pipe identification shall consist of 2 elements, i.e., a lettered label, and a directional label.
3.4 IDENTIFICATION SCHEDULE
A. Application of identifying devices shall conform to the following color codes in Table in Section 09 9700 – Special Coatings, Part 3.6.
END OF SECTION 33 0526
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SECTION 33 1416 SITE WATER AND WASTEWATER DISTRIBUTION PIPING – PVC PART 1 – GENERAL
1.1 REQUIREMENT
A. Polyvinyl chloride pressure pipe for water distribution, in nominal diameters 4 inches through 20 inches.
B. Polyvinyl chloride sewer pipe for gravity sewers in nominal diameters 4 inches through 48 inches.
C. Polyvinyl chloride pressure pipe for gravity sewers and force mains in nominal diameters 4 inches through 20 inches.
1.2 REFERENCES
A. Commercial Standards:
ANSI A 21.16 (AWWA C 116) Protective Fusion Bonded Epoxy Coating for the Interior and Exterior Surfaces of Ductile Iron and Grey Iron Fittings for Water Supply Service.
ASTM D1248 Standard Specification for Polyethylene Plastics Molding and Extrusion Materials.
ASTM D1784 Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC)
Compounds.
ASTM D2241 Standard Specification for Poly (Vinyl Chloride) (PVC) PressureRated Pipe (SDR Series).
ASTM D2321 Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications.
ASTM D2444 Standard Test Method for Determination of the Impact Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight).
ASTM D2680 Specification for Acrylonitrile-Butadiene-Styrene (ABS) and Poly (Vinyl Chloride) (PVC) Composite Sewer Piping.
ASTM D3034 Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings.
ASTM D3139 Standard Specification for Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals.
ASTM D3212 Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals.
ASTM F477 Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.
ASTM F679 Standard Specification for Poly (Vinyl Chloride) (PVC) LargeDiameter Plastic Gravity Sewer Pipe and Fittings.
ASTM F794 Standard Specification for Poly (Vinyl Chloride) (PVC) Profile Gravity Sewer Pipe and Fittings Based on Controlled Inside Diameter.
ASTM F949 Standard Specification for Poly (Vinyl Chloride) (PVC) Corrugated Sewer Pipe with Smooth Interior and Fittings.
AWWA C110 American National Standard for Ductile-Iron and Gray-Iron Fittings, 3 Inches Through 48 Inches for Water.
AWWA C111 American National Standard for Rubber-Gasket Joints for 644
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Ductile-Iron Pressure Pipe and Fittings.
AWWA C900 Standard for Polyvinyl Chloride (PVC) Pressure Pipe, 4 Inches Through 12 Inches for Water Distribution.
AWWA C905 Standard for Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 14 In. Through 48 In., for Water Transmission and Distribution.
AWWA C909 Standard for Molecularly-Oriented Polyvinyl Chloride (PVCO) Pressure Pipe, 4 Inches through 12 Inches (100mm through 300 mm), for Water Distribution.
PPI TR3 Policies and Procedures for Developing Recommended Hydrostatic Design Stresses for Thermoplastic Pipe Materials.
UNI-B-13 Recommended Standard Performance Specification for Joint Restraint Devices for Use with Polyvinyl Chloride Pipe.
1.3 SUBMITTALS
A. Submittals shall be made in accordance with Section 01 3300 - Submittals.
B. Submit shop drawings showing design of new pipe and fittings indicating alignment and grade, laying dimensions, fabrication, fittings, flanges, and special details.
1.4 QUALITY CONTROL
A. Submit manufacturer's certifications that PVC pipe and fittings meet requirements of this Section and AWWA C900, AWWA C909 and AWWA C905 for pressure pipe applications, or appropriate ASTM standard specified for gravity sewer pipe.
B. Submit manufacturer's certification that PVC pressure pipe for water lines and force mains has been hydrostatically tested at factory in accordance with AWWA C900, AWWA C909 and AWWA C905, and this Section.
C. When foreign manufactured material is proposed for use, have material tested for conformance to applicable ASTM requirements by certified independent testing laboratory located in United States.
Certification from other source is not acceptable. Furnish copies of test reports to ENGINEER for review. The cost of testing shall be paid by subcontractor.
PART 2 – PRODUCTS
2.1 MATERIAL
A. Use PVC compounds in manufacture of pipe that contain no ingredient in amount that has been demonstrated to migrate into water in quantities considered to be toxic.
B. Furnish PVC pressure pipe manufactured from Class 12454-A or Class 12454-B virgin PVC compounds as defined in ASTM D 1784. Use compounds qualifying for rating of 4000 psi for water at 73.4 F per requirements of PPI TR3. Provide pipe which is homogeneous throughout, free of voids, cracks, inclusions, and other defects, uniform as commercially practical in color, density, and other physical properties. Deliver pipe with surfaces free from nicks and scratches with joining surfaces of spigots and joints free from gouges and imperfections which could cause leakage.
C. PVC Restrained Pipe: Must be listed on Owner's current Product Approval List.
1. Pipe Material
a. DR 18: For restrained joints where shown on Drawings. b. DR 14: For alternate to offset pipe sections shown on Drawings. Do not use PVC for offset sections with depth of cover greater than 20 feet or less than 4 feet. Do not use PVC in potentially petroleum contaminated areas.
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D. Water Service
1. Provide self-extinguishing PVC pipe that bears Underwriters' Laboratories mark of approval and is acceptable without penalty to the State Fire Insurance Committee for use in fire protection lines.
2. Bear National Sanitation Foundation Seal of Approval (NSF-PW).
E. Gaskets:
1. Gaskets shall meet requirements of ASTM F 477. Use elastomeric factory-installed gaskets to make joints flexible and watertight.
2. Flat Face Mating Flange
a. Full faces 1/8-inch-thick ethylene propylene (EPR) rubber.
3. Raised Face Mating Flange
a. Flat ring 1/8-inch ethylene propylene (EDR) rubber, with filler gasket between OD of raised face and flange OD to protect flange from bolting moment.
F. Lubricant for rubber-gasketed joints: Water soluble, non-toxic, non-objectionable in taste and odor imparted to fluid, non-supporting of bacteria growth, having no deteriorating effect on PVC or rubber gaskets.
G. Do not use PVC in potentially or known contaminated areas.
H. Do not use PVC in areas exposed to direct sunlight.
2.2 WATER SERVICE PIPE
A. Pipe 4 inch through 12 inch: AWWA C 900, AWWA C 909, Class 150, DR 18; AWWA C 900, Class 200, DR 14 as alternate to offset pipe sections; nominal 20-foot lengths; cast-iron equivalent outside diameters.
B. Pipe 14 inch through 20 inch: AWWA C 905; Class 235; DR 18; nominal 20-foot lengths; castiron equivalent outside diameter.
C. Provide Polyvinyl Chloride Pipe from approved manufacturers.
D. Make curves and bends by deflecting joints. Do not exceed maximum deflection recommended by pipe manufacturer. Submit details of other methods of providing curves and bends for review by the ENGINEER.
E. Hydrostatic Test: AWWA C 900, AWWA C 905, AWWA C 909, ANSI A 21.10 (AWWA C 110); at point of manufacture; submit manufacturer's written certification.
2.3 GRAVITY SEWER PIPE
A. PVC gravity sanitary sewer pipe and storm sewer pipe shall be in accordance with provisions in following table:
WALL
MANUFACTURER
CONSTRUCTION
ASTM
DESIGNATION
SDR (MAx.)/
STIFFNESS
(MIN.)
DIAMETER
SIZE RANGE
Solid J-M Pipe
CertainTeed D3034 SDR 26 / PS 115 6" to 10"
Diamond Uponor ETI D3034 SDR 35 / PS 46 12" & 15"
North American F679 SDR 35 / PS 46 18" to 27"
AWWA
AWWA
AWWA
C900
C909
C905
DR 18 / N/A
DR 18 / N/A
DR 18 / N/A
4" to 12"
4" to 12"
14" to 16"
Truss (Gasketed)
Contech D2680 N/A /200 psi 8" to 15"
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Profile Contech A-2000 F949 N/A / 46 psi 12" to 36"
Contech A-2026 F949 N/A / 115 psi 8" to 10"
ETI, Ultra-Rib F794 N/A / 46 psi 8" to 30"
ETI, Ultra-Con F794 N/A / 46 psi 24" to 36"
B. When solid wall PVC pipe 18 inches to 27 inches in diameter is required in SDR 26, provide pipe conforming to ASTM F 679, except provide wall thickness as required for SDR 26 and pipe strength of 115 psi.
C. For sewers up to 12-inch diameter crossing over water lines, or crossing under water lines with less than 2-feet separation, provide minimum 150 psi pressure-rated pipe conforming to ASTM D 2241 with suitable PVC adapter couplings.
D. Joints: Spigot and integral wall section bell with solid cross section elastomeric or rubber ring gasket conforming to requirements of ASTM D 3212 and ASTM F 477, or ASTM D 3139 and ASTM F 477. Gaskets shall be factory-assembled and securely bonded in place to prevent displacement. Manufacturer shall test sample from each batch conforming to requirements ASTM D 2444.
E. Fittings: Provide PVC gravity sewer sanitary bends, tee, or wye fittings for new sanitary sewer construction. PVC pipe fittings shall be full-bodied, either injection molded or factory fabricated.
Saddle-type tee or wye fittings are not acceptable.
F. Conditioning: Conditioning of samples prior to and during tests is subject to approval by the ENGINEER. When referee tests are required, condition specimens in accordance with Procedure A in ASTM D 618 at 73.4 degrees F plus or minus 3.6 degrees F and 50 percent relative humidity plus or minus 5 percent relative humidity for not less than 40 hours prior to test. Conduct tests under same conditions of temperature and humidity unless otherwise specified.
G. Pipe Stiffness: Determine pipe stiffness at 5 percent deflection in accordance with Test Method D 2412. Minimum pipe stiffness shall be 46 psi. For diameters 4 inches through 18 inches, test three specimens, each a minimum of 6 inches (152 mm) in length. For diameters 21 inch through 36 inch, test three specimens, each a minimum of 12 inch (305 mm) in length.
H. Flattening: Flatten three specimens of pipe, prepared in accordance with Paragraph 2.04F, in suitable press until internal diameter has been reduced to 60 percent of original inside diameter of pipe. Rate of loading shall be uniform. Test specimens, when examined under normal light and with unaided eye, shall show no evidence of splitting, cracking, breaking, or separation of pipe walls or bracing profiles. Perform the flattening test in conjunction with pipe stiffness test.
I. Joint Tightness: Test for joint tightness in accordance with ASTM D 3212, except that joint shall remain watertight at minimum deflection of 5 percent. Manufacturer will be required to provide independent third party certification for joint testing each diameter of storm sewer pipe.
J. Purpose of Tests: Flattening and pipe stiffness tests are intended to be routine quality control tests.
Joint tightness test is intended to qualify pipe to specified level of performance.
2.4 SANITARY SEWER FORCE MAIN PIPE
A. Provide approved PVC pressure pipe conforming to requirements for water service pipe.
B. Acceptable pipe joints are integral bell-and-spigot, containing a bonded-in elastomeric sealing ring meeting requirements of ASTM F 477. In designated areas requiring restrained joint pipe and fittings, use approved joint restraint device conforming to UNI-B-13, for PVC pipe 12-inch diameter and less.
C. Fittings: Provide approved ductile iron fittings as per Section 40 0519 - Ductile Iron Pipe except furnish fittings with one of following approved internal linings:
1. Nominal 40 mils (35 mils minimum) virgin polyethylene complying with ASTM D 1248, 647
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heat fused to interior surface of fitting
2. Nominal 40 mils (35 mils minimum) polyurethane
3. Nominal 40 mils (35 mils minimum) ceramic epoxy
4. Nominal 40 mils (35 mils minimum) fusion bonded epoxy D. Exterior Protection: Provide polyethylene wrapping of ductile-iron fittings.
E. Hydrostatic Tests: Hydrostatically test pressure rated pipe in accordance with Paragraph 2.02E.
2.5 BENDS AND FITTINGS FOR PVC PRESSURE PIPE
A. Bends and Fittings: ANSI A 21.10 or ANSI A 21.53, ductile iron; ANSI A 21.11 single rubber gasket push-on type joint; minimum 150 psi pressure rating. Approved restrained joints, 250 psi, may be provided for up to 12 inches in diameter (water or sanitary).
B. Provide approved restrained joint fittings: Integral restrained joint fittings and pipe do not require secondary restraint.
PART 3 – EXECUTION
3.1 PROTECTION
A. Store pipe under cover out of direct sunlight and protect from excessive heat or harmful chemicals in accordance with manufacturer's recommendations.
3.2 INSTALLATION
A. Install PVC pipe in accordance with Section 31 2333 - Trenching, ASTM D 2321 for Sewer Pipe, and manufacturer's recommendations.
B. Install PVC water service pipe to clear utility lines and have minimum depth of cover below property line grade of street, unless otherwise required by Drawings:
1. Water service pipe 12 inches in diameter and smaller 4 feet of cover.
2. Water service pipe 16 inches in diameter and larger 5 feet of cover.
C. Avoid imposing strains that will overstress or buckle pipe when lowering pipe into trench.
D. Hand shovel pipe bedding under pipe haunches and along sides of pipe barrel and compact to eliminate voids and ensure side support.
E. Store PVC pipe under cover out of direct sunlight. Protect pipe from excessive heat or harmful chemicals. Prevent damage by crushing or piercing.
F. Allow PVC pipe to cool to ground temperature before backfilling when assembled out of trench to prevent pullout due to thermal contraction.
3.3 PVC RESTRAINED MECHANISM
A. Do not apply lubricant to spline or pipe or coupling spline grooves.
B. Do not use excessive force while inserting the spline through coupling.
C. Insert spline until it is fully seated around circumference of pipe.
D. Field Cutting of Pipe Ends:
1. Perform by workers certified by manufacturer.
2. Use a PVC pipe cutter and provide square ends.
3. Use manufacturer approved power routing and grooving tool to field fabricate required pipe groove.
END OF SECTION 33 1416
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SECTION 33 1417 SITE WATER AND WASTEWATER DISTRIBUTION PIPING – DIP PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Provide ductile iron pipe and perform all appurtenant work, complete in place, in accordance with the Contract Documents.
1.2 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Commercial Standards
ANSI/AWWA C104/A21.4 Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water
ANSI/AWWA C105/A21.5 Polyethylene Encasement for Ductile-Iron Piping for Water and Other Liquids
ANSI/AWWA C110/A21.10 Ductile-Iron and Gray-Iron Fittings, 3-inches through 48-inches for Water and Other Liquids
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 C151/A21.51 Ductile-Iron Pipe, Centrifugally Cast in Metal Molds or SandLined Molds, for Water or Other Liquids ANSI/AWWA C153/A21.53 Ductile-Iron Compact Fittings, 3-inches through 12-inches for Water and Other Liquids
AWWA C209 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines
AWWA C214 Tape Coating Systems for the Exterior of Steel Water Pipelines AWWA C600 Installation of Ductile Iron Water Mains and Their Appurtenances ASTM C 150 Specification for Portland Cement
ASTM A746 Ductile Iron Gravity Sewer Pipe
B. Related Sections: DIVISION 40
1.3 SUBMITTALS
A. Submittals shall be made in accordance with Section 01 3300 - Submittals.
B. Shop Drawings: Submit shop drawings of pipe and fittings in accordance with the requirements in Section 01 3300 - Submittals, the requirements of the referenced standards, and the following supplemental requirements as applicable:
1. Dimensional drawings of all valves, fittings and appurtenances.
2. For pipe 24 inches in diameter and larger, line layout and marking diagrams which indicate the specific number of each fitting and the location and the direction of each fitting in the completed line. In addition, the line layouts shall include: the pipe station and invert elevation at all changes in grade or horizontal alignment; all elements of curves and bends, both in horizontal and vertical alignment; and the limits of each reach of restrained joints, or of concrete encasement.
1.4 QUALITY ASSURANCE
A. Inspection: 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. 649
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B. During the manufacture of the pipe, the ENGINEER shall be given access to all areas where manufacturing is in process and shall be permitted to make all inspections necessary to confirm compliance with the Specifications.
PART 2– PRODUCTS
2.1 GENERAL
A. Mortar-lined ductile iron pipe shall conform to ANSI/AWWA C151, C104 and C105, subject to the following supplemental requirements. The pipe shall be of the diameter and class noted in the Contract Documents. The pipe shall be furnished complete with rubber gaskets, with all specials and fittings provided as required under the Contract Documents.
B. Markings: Legibly mark specials 24 inches in diameter and larger in accordance with the laying schedule and marking diagram. All fittings shall be marked at each end with top field centerline.
C. Handling and Storage: The pipe shall be handled by devices acceptable to the ENGINEER, designed and constructed to prevent damage to the pipe coating/exterior. The use of equipment that might injure the pipe coating/exterior will not be permitted. Stockpiled pipe shall be suitably supported and shall be secured to prevent accidental rolling. All other pipe handling equipment and methods shall be acceptable to the ENGINEER.
D. Laying Lengths: Maximum pipe laying lengths shall be 20-feet with shorter lengths provided as required by the Drawings.
E. Finish: The pipe shall have smooth dense interior surfaces and shall be free from fractures, excessive interior surface crazing and roughness.
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 corrections may be made to adjust the pipe laying to conform to pipe stationing shown on the Drawings. The locations of correction pieces and closure assemblies are shown on the Drawings. Any change in location or number of said items shall be acceptable to the ENGINEER.
2.2 PIPE DESIGN CRITERIA
A. General: Ductile iron pipe shall be designed in accordance with the requirements of ANSI/AWWA C150 as applicable and as modified in this Section.
B. Pipe Wall Thickness for Internal Pressure: The pipe shall be designed with a net thickness to withstand the design pressure in accordance with the hoop stress formula.
C. Pipe Wall Thickness for External Load: The pipe shall also be designed with a net thickness to withstand external loads using ANSI/AWWA C150 Design Equation (2) with the appropriate bending moment and deflection coefficients for Laying Condition Types 4 and 5 as applicable.
D. The pipe deflection shall be checked using ANSI/AWWA C150 Design Equation (3) and the coefficients stated above. The allowable deflection shall not exceed the manufacturer’s recommended amount.
E. In lieu of ANSI/AWWA C150 Design Equation (4), the earth loads will be computed using the following 2 equations for trench or embankment loading as applicable:
1. Trench Condition:
Wd = CdwBd
2 Where: Wd = Earth Load in pounds per linear foot
Cd = Calculation Coefficient
Ku' = [0.13]
w = [120] lb/ft3
Bd = Trench width at top of pipe, feet
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2. Positive Projecting Embankment Condition:
Wc = CcwBc
2 Where: Wc = Earth Load in pounds per linear foot
Cc = Calculation Coefficient (based on rsdP of 0.25)
Ku = [0.19]
w = [120] lb/ft3
Bc = Outside diameter of pipe, feet
F. The above 2 formulas are based on a depth of cover of 10-feet or greater. For depths of cover of less than 10-feet, HS-20 live load shall be included. For depths of cover of 3-feet or less, HS-20 live load plus impact shall be included. The determination of live load and impact factors shall be as recommended by AASHTO in "Standard Specifications for Highway Bridges." G. If the calculated deflection exceeds 0.0225 times the nominal diameter, the pipe class shall be increased.
H. Minimum Pipe Wall Thickness: In addition to the requirements of this Section, the minimum wall thickness shall be in accordance with Table 50.5 of ANSI/AWWA C150.
2.3 MATERIALS
A. Ductile Iron Pipe: Pipe materials shall conform to the requirements of ANSI/AWWA C151.
B. Cement: Cement for mortar lining shall conform to the requirements of ANSI/AWWA C104, provided, that cement for mortar lining shall be Type II or V. Cement shall not originate from kilns that burn metal-rich hazardous waste fuel, nor shall a fly ash or pozzolan be used as a cement replacement.
2.4 SPECIALS AND FITTINGS
A. Fittings for ductile iron pipe shall conform to the requirements of ANSI/AWWA C153/A21.53 for diameters 3-inches through 24 inches and shall have a minimum pressure rating of 350 psi. Ductile iron fittings larger than 24 inches shall conform to the above referenced standard with the necessary modifications for the larger size.
2.5 DESIGN OF PIPE
A. General: The pipe furnished shall be ductile iron pipe, with rubber-gasketed joints or as specified on the plans.
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. Pipe Dimensions: The pipe shall be of the diameter and class shown. The minimum wall thickness for each pipe size shall be as specified or shown.
D. Fitting Dimensions: The fittings shall be of the diameter and class shown.
E. Joint Design: Ductile iron pipe and fittings shall be furnished with mechanical joints, push-on joints, flanged joints and restrained joints as required.
1. Mechanical and push-on joints shall conform to ANSI/AWWA C111/A21.11.
2. Mechanical and push on joints gaskets shall be “fast Grip” Gaskets by American Ductile Iron Pipe, or “Field Locks” Gaskets by U.S. Pipe, or equal.
3. Restrained joints shall be "Lok-Ring" Restrained Joint by American Ductile Iron Pipe, "TR FLEX" Restrained Joint by U.S. Pipe, or equal. Provide as indicated on the plans.
4. Flanged joints shall conform to ANSI/AWWA C115/A21.15. Special ductile iron flanges to match up to 250 psi valve and equipment flanges shall meet ANSI/AWWA C110 and be specially drilled to ANSI/ASME B16.1 Class 250 standard dimensions with raised face. 651
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F. 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. Require the pipe manufacturer to submit details complete with significant dimensions and tolerances and 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.
G. Shop-applied interior linings and exterior coatings shall be held back from the ends of the pipe as shown or as otherwise acceptable to the ENGINEER.
2.6 CEMENT-MORTAR LINING
A. Cement-Mortar Lining for Shop Application: Except as otherwise provided herein, interior surfaces of all ductile iron pipe, fittings and specials shown on the plans shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with ANSI/AWWA C104. 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. Every precaution shall be taken to prevent damage to the lining. 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
(inches)
Minimum Lining Thickness
(inches)
3 - 12 1/8
14 - 24 3/16
30 - 54 1/4
C. Protection of Pipe Lining/Interior: All shop-applied cement mortar lining shall be given a seal coat of asphaltic material in conformance with ANSI/AWWA C104.
2.7 EXTERIOR COATING OF PIPE
A. Exterior Coating of Exposed Piping: The exterior surfaces of 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 099700 - Protective Coating.
B. Exterior Coating of Buried Piping: The exterior coating shall be an asphaltic coating approximately 1mil thick. Pipe shall be encased in polyethylene sleeves, unless noted otherwise.
PART 3 – EXECUTION
3.1 INSTALLATION OF PIPE
A. Handling and Storage: 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 that will protect the pipe against injury whenever stored at the trench site or elsewhere. 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.
B. All pipe that is damaged prior to Substantial Completion shall be repaired or replaced.
C. Inspect each pipe and fitting prior to installation to insure that there are no damaged portions of the pipe.
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D. Before placement of 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.
E. Pipe Laying: The pipe shall be installed in accordance with ANSI/AWWA C600.
F. Pipe shall be laid directly on the 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 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.
G. Each section of pipes 24 inches in diameter and larger shall be laid in the order and position shown on the laying schedule. In laying pipe, it shall be laid to the setline and grade, within approximately one inch plus or minus. On grades of zero slopes, the intent is to lay to grade.
H. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the CONTRACTOR 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. No joint shall be misfit any amount that will be detrimental to the strength and water tightness of the finished joint.
I. Except for short runs that may be permitted by the ENGINEER, pipes shall be laid uphill on grades exceeding 10%. Pipe that is laid on a downhill grade shall be blocked and held in place until sufficient support is furnished by the following pipe to prevent movement. All bends shall be properly installed as shown.
J. Shallow buried pipes and pipes underneath structures shall be concrete encased where noted in the Contract Documents.
K. Cold Weather Protection: 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.
L. Pipe and Specials Protection: The openings of all pipe and specials 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.
M. Pipe Cleanup: As pipe laying progresses, the pipe interior shall be kept 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, pointing of joints and any necessary interior repairs prior to testing and disinfecting the completed pipeline.
3.2 RUBBER GASKETED JOINTS
A. Rubber Gasketed Joints: 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.
3.3 INSTALLATION OF PIPE APPURTENANCES
A. Protection of Appurtenances: Where the joining pipe is tape-coated, buried appurtenances shall be coated with cold-applied tape in accordance with ANSI/AWWA C209, Type II. Where pipe is encased in polyethylene sleeves, buried appurtenances shall also be encased in polyethylene. 653
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B. Installation of Valves: All valves shall be handled in a manner to prevent any injury or damage to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation.
Adjust all stem packing and operate each valve prior to installation to insure proper operation.
C. All valves shall be installed so that the valve stems are plumb and in the location shown.
END OF SECTION 33 1416.01
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SECTION 40 0500 – PIPING, GENERAL
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide all piping systems indicated, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all piping sections in Division 2, 33, and 40.
C. The mechanical drawings define the general layout, configuration, routing, method of support, pipe size and pipe type. The mechanical drawings are not pipe construction or fabrication drawings.
Details for construction shall be developed as necessary to construct all mechanical piping systems, to accommodate the specific equipment provided, and to provide all spools, spacers, adapters, and connectors for a complete and functional system.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Section 01 3300 – Submittal Procedures
B. Section 01 6010 – Seismic Design Criteria
1.3 SUBMITTALS
A. Submittals shall be furnished in accordance with Section 01 3300 – Submittal Procedure.
B. Shop Drawings shall contain the following information:
1. Layout drawings including all necessary dimensions, details, pipe joints, fittings, specials, bolts and nuts, gaskets, valves, appurtenances, anchors, guides, and material lists.
Fabrication drawings shall indicate all spool pieces, spacers, adapters, connectors, fittings and supports to accommodate the equipment and valves in a complete and functional system.
2. Where indicated or required by the ENGINEER, Shop Drawings shall include clear, concise calculations showing equipment anchorage forces and the capacities of the anchorage elements (including seismic and structural anchoring calculations).
C. Certifications: All necessary certificates, test reports, and affidavits of compliance shall be obtained.
PART 2 - PRODUCTS
2.1 GENERAL
A. Extent of WORK: Pipes, fittings, and appurtenances shall be provided in accordance with the requirements of the applicable Sections of Division 40 and as indicated.
B. Pipe Supports: Pipes shall be adequately supported, restrained, and anchored in accordance with Section 40 0507 - Hangers and Supports for Process Piping, and as indicated.
C. Lining: Application, thickness and curing of pipe lining shall be in accordance with the applicable Sections of Section 09 9700 Special Coatings, unless otherwise indicated.
D. Coating: Application, thickness, and curing of pipe coating shall be in accordance with the applicable Sections of Division 2, unless otherwise indicated. Pipes above ground or in structures shall be field-coated in accordance with Section 09 9700 – Special Coatings.
E. Pressure Rating: Piping systems shall be designed for the maximum expected pressure and as indicated on the Piping Schedule.
F. Inspection: Pipe shall be subject to inspection at the place of manufacture. During the manufacture of the pipe, the ENGINEER shall be given access to all areas where manufacturing is in progress and shall be permitted to make all inspections necessary to confirm compliance with requirements. 655
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G. Tests: Except where otherwise indicated, materials used in the manufacture of the pipe shall be tested in accordance with the applicable specifications and standards. Welds shall be tested as indicated.
H. Welding Requirements: Welding procedures used to fabricate pipe shall be prequalified under the provisions of ANSI/AWS D1.1 - Structural Welding Code. Welding procedures shall be reviewed for longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections.
I. Welder Qualifications: Welding shall be done by skilled welders and welding operators who have had adequate experience in the methods and materials to be used. Welders shall be qualified under the provisions of ANSI/AWS D1.1 by an independent local, approved testing agency not more than 6 months prior to commencing WORK on the pipeline. Machines and electrodes similar to those used in the WORK shall be used in qualification tests. Qualification testing of welders and materials used during testing are part of the WORK.
2.2 EQUIPMENT SUPPORTS AND FOUNDATIONS
A. Equipment Supports: Unless otherwise indicated, equipment supports, anchors, and restrainers shall be adequately designed for static, dynamic, wind, and seismic loads. The design horizontal seismic force shall be the greater of: that noted in Section 01 6010 (Seismic Design Criteria) the general structural notes, or as required by the governing building code, or 10 percent of gravity.
Submitted design calculations for equipment supports shall bear the signature and seal of a Professional Engineer registered in the State wherein the project is to be built, unless otherwise indicated.
2.3 PIPE FLANGES
A. General: Flanges shall have flat faces and shall be attached with bolt holes straddling the vertical axis of the pipe unless otherwise indicated. Attachment of the flanges to the pipe shall conform to the applicable requirements of ANSI/AWWA C207. Flange faces shall be perpendicular to the axis of the adjoining pipe. Flanges for miscellaneous small pipes shall be in accordance with the standards indicated for these pipes.
B. Pressure Ratings:
1. 150 psi or less: Flanges shall conform to either ANSI/AWWA C207 - Steel Pipe Flanges for Waterworks Service--Sizes 4-inch through 144-inch, Class D, or ANSI/ASME B16.5 - Pipe Flanges and Flanged Fittings, 150-lb class.
2. 150 psi to 275 psi: Flanges shall conform to either ANSI/AWWA C207 Class E or Class F, or ANSI/ASME B16.5 150-lb class.
3. 275 psi to 700 psi: Flanges shall conform to ANSI/ASME B16.5, 300-lb class.
4. Selection based on test pressure: AWWA flanges shall not be exposed to test pressures greater than 125 percent of rated capacity. For higher test pressures, the next higher rated AWWA flange or an ANSI-rated flange shall be selected.
C. Blind Flanges: Blind flanges shall be in accordance with ANSI/AWWA C207, or as indicated for miscellaneous small pipes.
D. Flange Coating: Machined faces of metal blind flanges and pipe flanges shall be coated with a temporary rust-inhibitive coating to protect the metal until the installation is completed.
E. Flange Bolts: Bolts and nuts shall conform to Section 05 5000 – Metal Fabrications. Bolts and nuts shall be installed with anti-seize per Loctite, or ENGINEER-approved equal (or thread locker to be confirmed with WWTP Operations). Studs and bolts shall extend through the nuts a minimum of ¼-inch. All-thread studs shall be used on all valve flange connections, where space restrictions preclude the use of regular bolts.
F. Insulating Flanges: Insulated flanges shall have bolt holes ¼-inch diameter greater than the bolt diameter.
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G. Insulating Flange Sets: Insulating flange sets shall be provided where indicated or as needed. Each insulating flange set shall consist of an insulating gasket, insulating sleeves and washers and a steel washer. Insulating sleeves and washers shall be one piece when flange bolt diameter is 1½-inch or smaller and shall be made of acetal resin. For bolt diameters larger than 1½-inch, insulating sleeves and washers shall be 2-piece and shall be made of polyethylene or phenolic material. Steel washers shall be in accordance with ASTM A325 - Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength. Insulating gaskets shall be full-face.
H. Flange Gaskets:
1. Gaskets for flanged joints used in general water and wastewater service shall be full-faced type, with material and thickness in accordance with ANSI/AWWA C207. Blind flanges shall have gaskets covering the entire inside face of the blind flange and shall be cemented to the blind flange. Ring gaskets shall not be permitted, unless otherwise indicated.
2. Gaskets for flanged joints used in chemicals, air, solvents, hydrocarbons, steam, chlorine, and other fluids shall be made of materials compatible with the service, pressure and temperature.
2.4 THREADED INSULATING CONNECTIONS
A. General: Threaded insulating bushings, unions, or couplings, as appropriate, shall be used for joining threaded pipes of dissimilar metals and for piping systems where corrosion control and cathodic protection are involved.
B. Materials: Threaded insulating connections shall be of nylon, Teflon, polycarbonate, polyethylene, or other non-conductive materials, and shall have ratings and properties to suit the service and loading conditions.
2.5 MECHANICAL-TYPE COUPLINGS (GROOVED OR BANDED PIPE)
A. General: Cast mechanical-type couplings shall be provided where indicated. The couplings shall conform to the requirements of ANSI/AWWA C606 - Grooved and Shouldered Joints. Bolts and nuts shall conform to the requirements of Section 05 5000 – Metal Fabrications. Gaskets for mechanical-type couplings shall be compatible with the piping service and fluid utilized, in accordance with the coupling manufacturer's recommendations. The wall thickness of grooved piping shall conform with the coupling manufacturer's recommendations to suit the highest expected pressure. To avoid stress on equipment, equipment connections with mechanical-type couplings shall have rigid-grooved couplings or flexible type coupling with harness in sizes where rigid couplings are not available, unless thrust restraint is provided by other means.
Mechanical-type couplings shall be bonded. The subcontractor shall have the coupling manufacturer's service representative verify the correct choice and application of couplings and gaskets, and the workmanship, to assure a correct installation. To assure uniform and compatible piping components, all grooved fittings, couplings, and valves shall be from the same manufacturer.
2.6 SLEEVE-TYPE COUPLINGS
A. Construction: Sleeve-type couplings shall be provided where indicated, in accordance with ANSI/AWWA C219 - Standard for Bolted Sleeve-Type Couplings for Plain-End Pipe.
Couplings shall be steel with steel bolts, without pipe stop. Couplings shall be of sizes to fit the pipe and fittings indicated. The middle ring shall be not less than ¼-inch thick or at least the same wall thickness as the pipe to which the coupling is connected. If the strength of the middle ring material is less than the strength of the pipe material, the thickness of the middle ring shall be increased to have the same strength as the pipe. The coupling shall be either 5 or 7 inches long for sizes up to and including 30 inches and 10 inches long for sizes greater than 30 inches, for standard steel couplings, and 16 inches long for long-sleeve couplings. 657
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The followers shall be single-piece contoured mill sections welded and cold-expanded as required for the middle rings, and of sufficient strength to accommodate the number of bolts necessary to obtain adequate gasket pressures without excessive rolling. The shape of the follower shall be of such design as to provide positive confinement of the gasket. Bolts and nuts shall conform to the requirements of Section 05 5000 – Metal Fabrications. Buried sleeve-type couplings shall be epoxy-coated at the factory as indicated.
B. Pipe Preparation: Where indicated, the ends of the pipe shall be prepared for flexible steel couplings. Plain ends for use with couplings shall be smooth and round for a distance of 12 inches from the ends of the pipe, with outside diameter not more than 1/64-inch smaller than the nominal outside diameter of the pipe. The middle ring shall be tested by cold-expanding a minimum of one percent beyond the yield point, to proof-test the weld to the strength of the parent metal. The weld of the middle ring shall be subjected to air test for porosity.
C. Gaskets:
1. Gaskets for sleeve-type couplings shall be rubber-compound material that will not deteriorate from age or exposure to air under normal storage or use conditions. Gaskets for wastewater and sewerage applications shall be Buna "N," Grade 60, or equivalent suitable elastomer.
The rubber in the gasket shall meet the following specifications:
a. Color - Jet Black
b. Surface - Non-blooming
c. Durometer Hardness - 74 plus and minus 5
d. Tensile Strength - 1000 psi Minimum
e. Elongation - 175 percent Minimum
2. The gaskets shall be immune to attack by impurities normally found in water or wastewater.
All gaskets shall meet the requirements of ASTM D2000 - Classification System for Rubber Products in Automotive Applications, AA709Z, meeting Suffix B13 Grade 3, except as noted above. Where sleeve couplings are used in water containing chloramine or other fluids, which attack rubber materials, gasket material shall be compatible with the piping service and fluid utilized.
D. Insulating Couplings: Where insulating couplings are required, both ends of the coupling shall have a wedge-shaped gasket which assembles over a rubber sleeve of an insulating compound in order to obtain insulation of all coupling metal parts from the pipe.
E. Restrained Joints: Sleeve-type couplings on pressure lines shall be harnessed unless thrust restraint is provided by other means. Harnesses shall be designed by the pipe manufacturer in accordance with AWWA Manual M11, or as indicated. Harness sets shall be designed for the maximum test pressure of the pipe in which they are installed. Where harness sets are installed near the suction and discharge of the pump, harness bolts shall have zero elongation to prevent misalignment of the pump imparted by the thrust within the piping system.
2.7 DISMANTLING JOINTS
A. General: Dismantling joints shall be provided where indicated, and provide up to 5” of longitudinal adjustment and up to 2 degrees of misalignment in flanged piping systems. The flange spool shall meet the requirements of AWWA Class D Ring Flange, compatible with ANSI Class 125 and 150 bolt circles. The end and body ring shall meet the requirements of ASTM A536 ductile iron meeting or exceeding Grade 65-45-12 for 3” to 12” sizes and ASTM A36 Carbon Steel with AWWA C207 Class D flanges for 14” to 72” sizes. Dismantling joints shall be provided with gaskets compounded for water and sewer service in accordance with ASTM D2000. Dismantling joints shall have a fusion bonded epoxy coating. Bolts and nuts (including tie-rods) shall conform to the requirements of Section 05 5000 – Metal Fabrications. Dismantling joints shall be per Romac Industries, or ENGINEER-approved equal.
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2.8 EXPANSION JOINTS
A. Piping subject to expansion and contraction shall be provided with sufficient means to compensate for such movement without exertion of undue forces to equipment or structures. This may be accomplished with expansion loops, bellow-type expansion joints or sliding-type expansion joints.
Expansion joints shall be of stainless steel, monel, rubber, or other materials best suited for each individual service.
2.9 PIPE THREADS
A. Pipe threads shall be in accordance with ANSI/ASME B1.20.1 - Pipe Threads, General Purpose (inch), and be made up with Teflon tape or chemical sealant unless otherwise indicated.
2.10 PIPE INSULATION
A. Pipe thermal insulation for exterior freeze protection shall be self-sealing, flexible, tubular polyolefin/ polyethylene foam insulation. The insulation shall have a low thermal conductivity (not to exceed 0.04 W/mK) and shall have a service temperature range between -330°F and 120°F.
Minimum thickness shall be 1-inch. Insulation shall be acceptable for use with heat tracing/ heat tape.
B. Where called out in the Contract Documents, heat tape shall be provided for freeze protection. Heat tape shall be wrap-type cable with built-in thermostat for automatic heat control and energy efficiency. It shall be used in conjunction with foam insulation. The low wattage design shall utilize a 120-volt power with outlet plug. Heat tape shall be manufactured by Wrap-On Co., Inc or ENGINEER-approved equal.
C. Where called out in the Contract Documents, Pipe insulation for personnel protection against high temperature shall be provided. Protective insulation shall be fiber glass bonded with a thermosetting resin with a jacket designed to protect personnel again accidental contact with hot pipes. The insulation shall be designed to be used on systems operating up to 1000°F. Minimum thickness shall be 1-inch.
2.11 GENERAL
A. Pipes, fittings, and appurtenances shall be installed in accordance with the requirements of the applicable Sections of Divisions 31 - Earthwork and 40 – Process Interconnections B. Lined Piping Systems: The lining manufacturer shall take full responsibility for the complete, final product and its application. Pipe ends and joints of lined pipes at screwed flanges shall be epoxycoated to assure continuous protection.
C. Core Drilling: Where core drilling is required for pipes passing through existing concrete, core drilling locations shall be determined by radiograph of concrete construction to avoid damage to embedded raceways and reinforcing bars.
D. Cleanup: After completion of the WORK, cuttings, joining and wrapping materials, and other scattered debris shall be removed from the Site. The entire piping system shall be handed over in a clean and functional condition.
PART 3 - EXECUTION
3.1 INSTALLATION OF PIPE
A. Piping shall be installed in accordance with the respective piping material Sections within Division 31 and 40.
END OF SECTION 40 0500
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B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 40 0501 – IDENTIFICATION FOR PROCESS PIPING
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Provide safety signs and identification devices for all exposed piping and valves using color bands, lettering, flow direction arrows, and related permanent identification devices, and all appurtenant works, in accordance with the Contract Documents. Piping Identification and Signage Systems shall match existing facility identification and signage, where applicable.
1.2 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Commercial Standards: ANSI A13.1 Scheme for the Identification of Piping Systems
1.3 SUBMITTALS
A. Submit samples of all types of identification devices and signs to be used in the work.
B. All submittals shall be in strict accordance with the requirements of Section 01 3300 –Submittal Procedures.
1.4 QUALITY ASSURANCE
A. Manufacturer and model shall be described on the Drawings or approved equal.
B. The manufacturer shall provide a 2-year warranty.
PART 2 – PRODUCTS
2.1 IDENTIFICATION OF PIPING
A. Identification of all exposed pipe shall be accomplished by color-coding with bands or painting of the pipe and by lettering as specified in Part 3, herein. Color bands shall either be painted directly upon the pipe or shall be pressure-sensitive adhesive-backed vinyl cloth or plastic tape.
B. Each pipe identification shall consist of two 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. Letter sizes and colors for lettering, arrows and background shall conform to ANSI A13.1.
2.2 IDENTIFICATION OF VALVES AND SHORT PIPE LENGTHS
A. Identifying devices for valves and the sections of pipe that are too short to be identified with color bands, lettered labels, and arrows shall be identified with metal or plastic tags as specified herein.
B. Metal tags shall be supplied with embossed lettering. Plastic tags shall be of solid black phenolic with white letters. All tags shall be designed to be attached, by chain, to the valves or short pipes.
2.3 SAFETY SIGNS
A. Color, legend, and layout shall conform to OSHA 1910.145 requirements.
B. “DANGER” Signs: Two-inch high white letters “Danger” in red oval surrounded by a rectangular black field. Text wording 1½-inch high black capital letters on white field.
C. “CAUTION” Signs: Two-inch high yellow letters on black field. Text wording 1½-inch high black capital letters on yellow field.
D. Chemical precaution signs:
1. In accordance with ANSI Z129.1
2. 12-inch x 14-inch
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3. Made to withstand most chemicals. Special ink for printing to be absorbed into sign surface.
Ultraviolet inhibitors and clear face coating for resisting fading and scratching. Semi-rigid linear polyethylene.
PART 3 –EXECUTION
3.1 GENERAL
A. All labels and identification tags shall be installed in accordance with the manufacturer's printed instructions, and shall be neat and uniform in appearance. All such tags or labels shall be readily visible from all normal working locations.
3.2 VALVE TAGS
A. Valve tags shall be attached to the valve or structure by means of a chain.
3.3 PIPE IDENTIFICATION
A. All visible piping ½-inch and greater which is accessible for maintenance and operations shall have appropriate identification markers. Direction of flow arrows are to be included with each identification mark unless otherwise specified. All none stainless steel pipe shall be color-coded.
B. Each marker shall be black lettering on a yellow or white background and have a clearly printed legend to identify the contents of the pipe.
C. Locations for pipe markers to be as follows:
1. Adjacent to each valve (except as plumbing fixtures and equipment).
2. At each branch and riser take-off.
3. At each pipe passage through wall, floor, and ceiling construction.
4. At each pipe passage to underground
5. On all horizontal pipe runs, marked every 30 feet.
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3.4 IDENTIFICATION SCHEDULE
A. Application of identifying devices shall conform to the following color codes:
Process or Fluid Description Color Tnemec Color #
Potable Water (“PW”) Dark Blue 11SF
Raw Sewage (“RAW”)
Influent (“RAW”)
Emergency Storage Basin (“RAW”)
Dark Gray 33GR
Tertiary/Recycled (“RW”) Purple (Pantone) 14SF
Sludge (“WAS”)
WAS (“WAS”)
RAS ("RAS")
Dark Brown 84BR
Backwash Waste ("BW") Light Brown 62BR
Compressed Air (“AIR”) Dark Green 91GN
Fire Protection (“FIRE”) Red 06SF
Foul Air (“ODOR”) White 11WH
Sodium Hypochlorite (Solution)
(“NAOCL2”) Yellow 02SF
Polymer (“POLY”) Orange
Sodium Aluminate (“ALUM”) Orange w/White Band
04SF
Sodium Hydroxide ("BASE") Green 49HT
END OF SECTION 40 0501
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HANGERS AND SUPPORTS FOR PROCESS PIPING 40 0507-1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 40 0507 – HANGERS AND SUPPORTS FOR PROCESS PIPING PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Provide pipe supports, hangers, guides, and anchors, complete, in accordance with the Contract Documents.
1.2 SUBMITTALS
A. Submittals shall be in accordance with Section 01 3300 – Submittal Procedures and Section 01 6010 – Seismic Design Criteria.
B. Shop Drawings shall include the following information:
1. Drawings of pipe supports, hangers, anchors and guides.
2. Calculations for special supports and anchors for floor and wall mounted equipment over 500 pounds.
PART 2 – PRODUCTS
2.1 GENERAL REQUIREMENTS
A. Code Compliance: All piping systems and pipe connections to equipment shall be properly anchored and supported to prevent undue deflection, vibration, dislocation due to line pressures, and stresses on piping, equipment and structures. All supports and parts thereof shall conform to the requirements of ANSI/ASME B31.1 - Power Piping, except as supplemented or modified in the tables within this Specification. Supports for plumbing piping shall be in accordance with the latest edition of the applicable plumbing code or local administration requirements.
B. Structural Members: Wherever possible, pipes shall be supported from structural members. Where it is necessary to frame structural members between existing members, such supplementary members shall be provided. All supplementary members shall be in accordance with the requirements of the building code and the American Institute of Steel Construction.
C. Pipe Hangers: Pipe hangers shall be capable of supporting the pipe in all conditions of operation, allowing free expansion and contraction of the piping, and preventing excessive stress on equipment. All hangers shall have a means of vertical adjustment after erection. Hangers shall be designed to prevent becoming disengaged by any movement of the supported pipe. Hangers subject to shock or thrust imposed by the actuation of safety valves, shall include hydraulic shock suppressors. All hanger rods shall be subject to tensile loading only.
D. Hangers Subject to Horizontal Movements: At hanger locations where lateral or axial movement is anticipated, suitable linkage shall be provided to permit such movement. Where horizontal pipe movement is greater than 1/2-inch, or where the hanger rod deflection from the vertical is greater than 4 degrees from the cold to the hot position of the pipe, the hanger rod and structural attachment shall be offset in such a manner that the rod is vertical in the hot position.
E. Spring-Type Hangers: Spring-type pipe hangers shall be provided for piping subject to vibration or vertical expansion and contraction, such as engine exhausts and similar piping. All spring-type hangers shall be sized to the manufacturer's printed recommendations and the loading conditions encountered. Variable spring supports shall be provided with means to limit misalignment, buckling, eccentric loading, or to prevent overstressing of the spring, and with means to indicate at all times the compression of the spring. Supports shall be capable of accommodating at least 4 times the maximum travel due to thermal expansion.
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F. Thermal Expansion: Wherever expansion and contraction of piping is expected, a sufficient number of expansion loops or joints shall be provided, together with the necessary rolling or sliding supports, anchors, guides, pivots, and restraints permitting the piping to expand and contract freely in directions away from the anchored points. All components shall be structurally suitable to withstand all loads imposed.
G. Heat Transmission: Supports, hangers, anchors, and guides shall be so designed and insulated, that excessive heat will not be transmitted to the structure or to other equipment.
H. Riser Supports: Where practical, risers shall be supported on each floor with riser clamps and lugs, independent of the connected horizontal piping.
I. Freestanding Piping: Free-standing pipe connections to equipment such as chemical feeders and pumps shall be firmly attached to steel frames fabricated from angles, channels, or I-beams anchored to the structure. Exterior, free-standing overhead piping shall be supported on fabricated pipe stands consisting of pipe columns anchored to concrete footings, with horizontal, welded steel angles and U-bolts or clamps securing the pipes.
J. Materials of Construction:
1. General: All pipe support assemblies, including framing, hardware, and anchors, shall be steel construction, galvanized after fabrication, unless otherwise indicated.
2. Submerged Supports: All submerged piping, as well as piping, conduits, and equipment in hydraulic structures within 24 inches of the water level, shall be supported with support, assemblies, including framing, hardware, constructed of Type 304 stainless steel, unless otherwise indicated. All bolts and nuts shall be 316 stainless steel conforming to ASTM A193, Grade B8M, for bolts and ASTM A194, Grade 8M, for nuts.
K. Point Loads: Any meters, valves, heavy equipment, and other point loads on PVC, FRP, and other plastic pipes, shall be supported on both sides, according to manufacturer's recommendations to avoid undue pipe stresses and failures. To avoid point loads, all supports on PVC, FRP, and other plastic piping shall be equipped with extra wide pipe saddles or galvanized steel shields.
L. Noise Reduction: To reduce transmission of noise in piping systems, all copper tubes in buildings and structures shall be wrapped with a 2-inch-wide strip of rubber fabric or similar, suitable material at each pipe support, bracket, clip, or hanger.
2.2 SUPPORT SPACING
A. Supports for piping with the longitudinal axis in approximately a horizontal position shall be spaced to prevent excessive sag, bending, and shear stresses in the piping, with special consideration given where components such as flanges and valves impose concentrated loads. Pipe support spacing shall not exceed the maximum spans in the tables on the following pages. For temperatures other than ambient temperatures, or those listed, and for other piping materials or wall thicknesses, the pipe support spacings shall be modified in accordance with the pipe manufacturer's recommendations. Vertical supports shall be provided to prevent the pipe from being overstressed from the combination of all loading effects.
664
HANGERS AND SUPPORTS FOR PROCESS PIPING 40 0507-3
B810 ADELANTO WWTP IMPROVEMENT PLAN
1. Support Spacing for Schedule 40 and Schedule 80 Steel Pipe:
Nominal Pipe Diameter
(inches)
Maximum Span
(feet)
½ 6
¾ and 1 8
1¼ to 2 10
3 12
4 14
6 17
8 and 10 19
12 and 14 23
16 and 18 25
20 and Greater 30
2. Support Spacing for Welded Fabricated Steel Pipe:
a. The support spacing shall be designed so that the stress on the pipe does not exceed 5,000 psi. Maximum deflection of pipe shall be limited to 1/360th of the span and shall be calculated by using the formula:
L = (7500tD/(32t+D))1/2
where: t = Thickness (inches)
D = Diameter (inches)
L = Maximum span (feet)
3. Support Spacing for Ductile-Iron Pipe:
Nominal Pipe Diameter
(inches)
Maximum Span
(feet)
All Diameters Two supports per pipe length or 10 feet
(one of the 2 supports located at joint)
4. Support Spacing for Copper Tubing:
Nominal Pipe Diameter
(inches)
Maximum Span
(feet)
½ to 1½ 6
2 to 4 10
6 and greater 12
665
HANGERS AND SUPPORTS FOR PROCESS PIPING 40 0507-4
B810 ADELANTO WWTP IMPROVEMENT PLAN
5. Support Spacing for Schedule 40 or 80 PVC Pipe:
Nominal Pipe Diameter
(inches)
Maximum Span
(at 100 degrees F)
(feet)
½ 4
3/4 4
1 5
1¼ 5
1½ 5
2 6
3 7
4 8
6 10
8 11
10 12
12 13
2.3 MANUFACTURED SUPPORTS
A. Stock Parts: Where not specifically indicated, designs which are generally accepted as exemplifying good engineering practice and use stock or production parts, shall be utilized wherever possible. Such parts shall be locally available, new, of best commercial quality, designed and rated for the intended purpose.
B. Manufacturers, or ENGINEER-approved equal:
1. TOLCO Inc.
2. Bergen-Paterson Pipesupport Corp., Woburn, MA;
3. Grinnell Corp. (Supply Sales Company), Cranston, RI;
4. NPS Products, Inc., Westborough, MA;
5. Power Piping Company, Pittsburgh, PA;
6. ZSI
2.4 COATING
A. Galvanizing: Unless otherwise indicated, all fabricated pipe supports other than stainless steel or non-ferrous supports shall be blast-cleaned after fabrication and hot-dip galvanized in accordance with ASTM A123 - Specifications for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
B. Other Coatings: Other than stainless steel or non-ferrous supports, all supports shall receive protective coatings in accordance with the requirements of Section 09 9700 – Special Coatings.
PART 3 – EXECUTION
3.1 INSTALLATION
A. General: All pipe supports, hangers, brackets, anchors, guides and inserts shall be fabricated and installed in accordance with the manufacturer's printed instructions and ANSI/ASME B31.1 - Power Piping. All concrete inserts for pipe hangers and supports shall be coordinated with the formwork.
666
HANGERS AND SUPPORTS FOR PROCESS PIPING 40 0507-5
B810 ADELANTO WWTP IMPROVEMENT PLAN
B. Appearance: Pipe supports and hangers shall be positioned to produce an orderly, neat piping system. All hanger rods shall be vertical, without offsets, unless noted otherwise. Hangers shall be adjusted to line up groups of pipes at the proper grade for drainage and venting, as close to ceilings or roofs as possible, without interference with other work.
3.2 FABRICATION
A. Quality Control: Pipe hangers and supports shall be fabricated and installed by experienced welders and fitters, using the best welding procedures available. Fabricated supports shall be neat in appearance without sharp corners, burrs, and edges.
END OF SECTION 40 0507
667
DUCTILE IRON PROCESS PIPE 40 0519 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 40 0519 – DUCTILE IRON PROCESS PIPE
PART 1 – GENERAL
1.1 DESCRIPTION
A. Furnish and install all ductile iron pipe and fittings in accordance with this Section.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Related Sections:
1. Division 31 – Earthworks
3. Section 40 0507 – Pipe Supports
4. Section 40 0554 – Valves, General
1.3 REFERENCES
A. Standards of the following agencies are referenced herein: American National Standards Institute (ANSI), American Society for Testing and Materials (ASTM), American Water Works Association (AWWA), Ductile Iron Pipe Research Association (DIPRA).
B. Referenced standards shall be the latest revision.
C. In case of conflict with referenced standards, the provisions of this Section shall prevail.
1.4 SUBMITTALS
A. In accordance with Section 01 3300 – Submittal Procedures.
B. Catalog data sheets naming each product to be used identified by manufacturer and type number and additional documentation as required to demonstrate full compliance with this specification.
PART 2 – MATERIALS
2.1 DUCTILE IRON PIPE
A. Pipe shall conform to the following standards as applicable:
1. AWWA C104: Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water.
2. AWWA C111: Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings
3. AWWA C115: Flanges Ductile-Iron Pipe with Threaded Flanges
4. AWWA C150: Thickness Design of Ductile-Iron Pipe
5. AWWA C151: Ductile-Iron Pipe, Centrifugally Cast, for Water of Other Liquids
6. AWWA C606: Grooved and Shouldered Joints
B. Pipe wall thickness for push-on joint and mechanical joint pipe shall be Pressure Class 350 psi minimum, or as indicated in the Contract Documents.
C. Unless otherwise noted or required, all pipe shall have a cement mortar lining with asphaltic seal coat.
Nominal Pipe Diameter
(inches)
Minimum Lining Thickness
(inches)
3 - 12 1/8
14 - 24 3/16
30 - 54 1/4
2.2 FITTINGS AND SPECIALS
A. Fittings and specials shall be ductile iron and shall conform to the following standards as applicable:
1. AWWA C104: Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water.
2. AWWA C110: Ductile-Iron and Gray Iron Fittings, 3 inches through 48 inches, for Water and Other Liquids.
668
DUCTILE IRON PROCESS PIPE 40 0519 - 2
B810 ADELANTO WWTP IMPROVEMENT PLAN
3. AWWA C111: Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.
4. AWWA C153: Ductile-Iron Compact Fittings, 3 inches through 24 inches and 54 inches through 64 inches for Water Service.
5. AWWA C606: Grooved and Shouldered Joints.
B. Unless otherwise noted or required, either standard or compact fittings may be used.
C. Unless otherwise noted, all fittings shall have a cement mortar lining with asphaltic seal coat.
D. Grooved and flanged fittings shall have center to end dimensions in accordance with AWWA C111, wall thickness in accordance with AWWA C153, and shall be Class 350 minimum, or as indicated in the Contract Documents.
2.3 GROOVED JOINT COUPLINGS
A. In accordance with ASSA C606, except as modified herein.
B. Coupling body shall be ductile iron, ASTM A536
C. All bolts and nuts shall be 316 stainless steel conforming to ASTM A193, Grade B8M, for bolts and ASTM A194, Grade 8M, for nuts.
2.4 TYPE OF JOINTS
A. Buried joints shall be push-on, mechanical joint, or flexible grooved joint unless otherwise shown or required for installation.
B. Exposed joints shall be flanged or rigid grooved unless otherwise shown or required for the installation.
2.5 RESTRAINED PUSH-ON JOINTS
A. Where specified, called for on the drawings, or otherwise required for thrust restraint, push-on joints shall be Flex-Ring as manufactured by American Ductile Iron Pipe, TR Flex as manufactured by US Pipe, or ENGINEER-approved equal. Restrained joint shall provide for joint deflection after assembly.
2.6 RESTRAINED MECHANICAL JOINTS
A. Where specified, called for on the drawings or otherwise required fro thrust restraint, mechanical joints shall be made using retainer glands with set screws or clamping lugs. Retainer glands shall be as manufactured by EBAA Iron; Tyler Pipe, or ENGINEER-approved equal.
2.7 FLANGE GASKETS
A. Full face or ring, except that ring gaskets shall be used for sizes 14-inch and greater. Gaskets shall be 1/8-inch thick synthetic rubber for test pressures up to 250 psi. For test pressures greater than 250 psi, provide suitable gasket as recommended by manufacturer.
2.8 FASTENERS EXCEPT GROOVED COUPLINGS
A. 316 stainless steel conforming to ASTM A193, Grade B8M, for bolts and ASTM A194, Grade 8M, for nuts. Bolts and nuts shall be installed with anti-seize per Loctite, or ENGINEER-approved equal (or thread locker to be confirmed with WWTP Operations).
B. Washers, where required, shall be of the same material as the nuts.
2.9 POLYETHYLENE ENCASEMENT
A. Buried pipe and fittings shall be protected by polyethylene encasement in accordance with AWWA C105.
2.10 PROTECTO 401 CERAMIC EPOXY LINING
A. Where specified or called for on the drawings, ductile iron pipe shall be lined with Protecto 401 Ceramic Epoxy Lining in accordance with the manufacturer’s specifications.
2.11 Direct Tap
669
DUCTILE IRON PROCESS PIPE 40 0519 - 3
B810 ADELANTO WWTP IMPROVEMENT PLAN
A. Ductile iron pipe shall have a minimum wall thickness allowed by ANSI/AWWA C151/A21.51.
B. The maximum direct tap sizes for 3- though 24-inch ductile iron pipe shall be per the following table.
Sizes
(in) Pressure Class
150 200 250 300 350
Maximum Direct Tap Size (in)
3 - - - - 3/4
4 - - - - 3/4
6 - - - - 1
8 - - - - 1
10 - - - - 1
12 - - - - 1 ¼
14 - - 1 ¼ 1 ½ 1 ½
16 - - 1 ½ 2 2
18 - - 2 2 2
20 - - 2 2 2
24 - 2 2 2 2
C. All classes of ductile iron pipe 24 inches or larger in diameter can be direct tapped for 2-inch corporation stop.
PART 3 – EXECUTION
3.1 INSTALLATION OF PIPE
A. Handling and Storage: 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 that will protect the pipe against injury whenever stored at the trench site or elsewhere. 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.
B. All pipe that is damaged prior to Substantial Completion shall be repaired or replaced.
C. Inspect each pipe and fitting prior to installation to insure that there are no damaged portions of the pipe.
D. Before placement of 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.
E. Pipe Laying: The pipe shall be installed in accordance with ANSI/AWWA C600. 670
DUCTILE IRON PROCESS PIPE 40 0519 - 4
B810 ADELANTO WWTP IMPROVEMENT PLAN
F. Pipe shall be laid directly on the 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 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.
G. Each section of pipes 24 inches in diameter and larger shall be laid in the order and position shown on the laying schedule. In laying pipe, it shall be laid to the setline and grade, within approximately one inch plus or minus. On grades of zero slopes, the intent is to lay to grade.
H. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the CONTRACTOR 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. No joint shall be misfit any amount that will be detrimental to the strength and water tightness of the finished joint.
I. Except for short runs that may be permitted by the ENGINEER, pipes shall be laid uphill on grades exceeding 10%. Pipe that is laid on a downhill grade shall be blocked and held in place until sufficient support is furnished by the following pipe to prevent movement. All bends shall be properly installed as shown.
J. Shallow buried pipes and pipes underneath structures shall be concrete encased where noted in the Contract Documents.
K. Cold Weather Protection: 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.
L. Pipe and Specials Protection: The openings of all pipe and specials 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.
M. Pipe Cleanup: As pipe laying progresses, the pipe interior shall be kept 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, pointing of joints and any necessary interior repairs prior to testing and disinfecting the completed pipeline.
3.2 RUBBER GASKETED JOINTS
A. Rubber Gasketed Joints: 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.
3.3 INSTALLATION OF PIPE APPURTENANCES
A. Protection of Appurtenances: Where the joining pipe is tape-coated, buried appurtenances shall be coated with cold-applied tape in accordance with ANSI/AWWA C209, Type II. Where pipe is encased in polyethylene sleeves, buried appurtenances shall also be encased in polyethylene.
B. Installation of Valves: All valves shall be handled in a manner to prevent any injury or damage to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation.
Adjust all stem packing and operate each valve prior to installation to insure proper operation.
C. All valves shall be installed so that the valve stems are plumb and, in the location shown.
END OF SECTION 40 0519
671
STAINLESS STEEL PIPE 40 0523 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 40 0523 – STAINLESS STEEL PROCESS PIPE AND TUBING PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Furnish all materials, tools, equipment, transportation, labor, supervision, and incidentals required to supply, store, install, clean, and test the shop fabricated stainless steel pipe and fittings as shown on the drawings and as specified herein.
B. The requirements of Section 40 0553 – Piping, General apply to the WORK of this Section.
1.2 QUALIFICATIONS
A. All shop fabricated stainless steel pipe and fitting shall be furnished by a single manufacturer who is experienced, reputable and qualified in the manufacture and fabrication of the items to be furnished. The pipe and fittings shall be shop fabricated and field installed in accordance with common industry wide practices and methods and shall comply with these specifications.
1.3 SUBMITTALS
A. Submit for review and approval piping layouts, schedules, shop fabrication drawings, specifications, catalog cuts and other data necessary to show conformance of the complete piping systems to the specifications. The submittal shall include dimensions, fittings, locations of equipment, valves, and appurtenances, joint locations and details, types and locations of supports, coordination with all other work and existing conditions, and all other pertinent technical specifications for the piping systems to be furnished.
B. Shop fabrication drawings shall show alloys, diameters, pipe wall thicknesses, flanges and other joint preparation details, finishing details, dimensions, fittings and other appurtenances to be supplied.
PART 2 – PRODUCTS
2.1 PIPE AND FITTINGS
A. Pipe shall be manufactured from ASTM A240 annealed and pickled sheets and plates in accordance with ASTM A778 in type (304L and 316L) stainless steel. Pipe shall be manufactured to nominal pipe sizes as listed in ANSI B36.19, and shall have the following nominal wall thicknesses. 304L stainless is required for all project stainless piping, with the exception of the permeate piping upstream of the permeate pump, and the stainless piping above the chlorine contact basin as depicted in M8.4, which shall be 316L stainless. Rolled grooved ends will be acceptable. *See Table
Identification
Steel
Pipe Size
(inches)
Outside
Diameter
(inches) Iron Pipe Size Schedule No.
Stainless Steel
Schedule No.
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
1/8 0.405
.
STD
XS
.
40 80
10S
40S
80S
.049
.068
.095
.307
.269
.215
1/4 0.540 .
STD
.
40 10S
40S
.065
.088
.410
.364
672
STAINLESS STEEL PIPE 40 0523 - 2
B810 ADELANTO WWTP IMPROVEMENT PLAN
Pipe Size
(inches)
Outside
Diameter
(inches)
Identification
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
Steel
Stainless Steel
Iron Pipe Size Schedule No. Schedule No.
XS 80 80S .119 .302
3/8 0.675
.
STD
XS
.
40 80
10S
40S
80S
.065
.091
.126
.545
.493
.423
1/2 0.840
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.065
.083
.109
.147
.187
.294
.710
.674
.622
.546
.466
.252
3/4 1.050
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.065
.083
.113
.154
.219
.308
.920
.884
.824
.742
.612
.434
1 1.315
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.065
.109
.133
.179
.250
.358
1.185
1.097
1.049
.957
.815
.599
1 1/4 1.660
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.065
.109
.140
.191
.250
.382
1.530
1.442
1.380
1.278
1.160
.896
1 1/2 1.900
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.065
.109
.145
.200
.281
.400
1.770
1.682
1.610
1.500
1.338
1.100
673
STAINLESS STEEL PIPE 40 0523 - 3
B810 ADELANTO WWTP IMPROVEMENT PLAN
Pipe Size
(inches)
Outside
Diameter
(inches)
Identification
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
Steel
Stainless Steel
Iron Pipe Size Schedule No. Schedule No.
2 2.375
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.065
.109
.154
.218
.344
.436
2.245
2.157
2.067
1.939
1.687
1.503
2 1/2 2.875
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.083
.120
.203
.276
.375
.552
2.709
2.635
2.469
2.323
2.125
1.771
3 3.500
.
.
STD
XS
.
XXS
.
.
40 80
160
.
5S
10S
40S
80S
.
.
.083
.120
.216
.300
.438
.600
3.334
3.260
3.068
2.900
2.624
2.300
3 1/2 4.000
.
.
STD
XS
.
.
40 80
5S
10S
40S
80S
.083
.120
.226
.318
3.834
3.760
3.548
3.364
4 4.500
.
.
STD
XS
.
.
XXS
.
.
40 80
120
160
.
5S
10S
40S
80S
.
.
.
.083
.120
.237
.337
.438
.531
.674
4.334
4.260
4.026
3.826
3.624
3.438
3.152
5 5.563
.
.
STD
XS
.
.
.
.
40 80
120
160
5S
10S
40S
80S
.
.
.109
.134
.258
.375
.500
.625
5.345
5.295
5.047
4.813
4.563
4.313
674
STAINLESS STEEL PIPE 40 0523 - 4
B810 ADELANTO WWTP IMPROVEMENT PLAN
Pipe Size
(inches)
Outside
Diameter
(inches)
Identification
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
Steel
Stainless Steel
Iron Pipe Size Schedule No. Schedule No.
XXS . . .750 4.063
6 6.625
.
.
STD
XS
.
.
XXS
.
.
40 80
120
160
.
5S
10S
40S
80S
.
.
.
.109
.134
.280
.432
.562
.718
.864
6.407
6.357
6.065
5.761
5.501
5.187
4.897
8 8.625
.
.
.
.
STD
.
XS
.
.
.
XXS
.
.
.
20 30
40 60
80 100
120
140
.
160
5S
10S
.
.
40S
.
80S
.
.
.
.
.
.109
.148
.250
.277
.322
.406
.500
.594
.719
.812
.875
.906
8.407
8.329
8.125
8.071
7.981
7.813
7.625
7.437
7.187
7.001
6.875
6.813
10 10.750
.
.
.
.
STD
XS
.
.
.
.
.
.
.
20 30
40 60
80 100
120
140
160
5S
10S
.
.
40S
80S
.
.
.
.
.
.134
.165
.250
.307
.365
.500
.594
.719
.844
1.000
1.125
10.482
10.420
10.250
10.136
10.020
9.750
9.562
9.312
9.062
8.750
8.500
12 12.75
.
.
.
.
STD
.
XS
.
.
20 30
.
40 .
5S
10S
.
.
40S
.
80S
.156
.180
.250
.330
.375
.406
.500
12.438
12.390
12.250
12.090
12.000
11.938
11.750
675
STAINLESS STEEL PIPE 40 0523 - 5
B810 ADELANTO WWTP IMPROVEMENT PLAN
Pipe Size
(inches)
Outside
Diameter
(inches)
Identification
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
Steel
Stainless Steel
Iron Pipe Size Schedule No. Schedule No.
.
.
.
.
.
.
60 80
100
120
140
160
.
.
.
.
.
.
.562
.688
.844
1.000
1.125
1.312
11.626
11.374
11.062
10.750
10.500
10.126
14 14.00
.
.
.
.
STD
.
XS
.
.
.
.
.
..
.
.
10 20
30 40
.
60 80
100
120
140
160
5S
10S
.
.
.
.
.
.
.
.
.
.
.
156
.188
.250
.312
.375
.438
.500
.594
.750
.938
1.094
1.250
1.406
13.688
13.624
13.500
13.376
13.250
13.124
13.000
12.812
12.500
12.124
11.812
11.500
11.188
16 16.00
.
.
.
.
STD
XS
.
.
.
.
.
.
.
.
10 20
30 40
60 80
100
120
140
160
5S
10S
.
.
.
.
.
.
.
.
.
.
.165
.188
.250
.312
.375
.500
.656
.844
1.031
1.219
1.438
1.594
15.670
15.624
15.500
15.376
15.250
15.000
14.688
14.312
13.938
13.562
13.124
12.812
18 18.00
.
.
.
.
STD
.
XS
.
.
.
.
.
.
10 20
.
30 .
40 60
80 100
5S
10S
.
.
.
.
.
.
.
.
.
.165
.188
.250
.312
.375
.438
.500
.562
.750
.938
1.156
17.670
17.624
17.500
17.376
17.250
17.124
17.000
16.876
16.500
16.124
15.688
676
STAINLESS STEEL PIPE 40 0523 - 6
B810 ADELANTO WWTP IMPROVEMENT PLAN
Pipe Size
(inches)
Outside
Diameter
(inches)
Identification
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
Steel
Stainless Steel
Iron Pipe Size Schedule No. Schedule No.
.
.
.
120
140
160
.
.
.
1.375
1.562
1.781
15.250
14.876
14.438
20 20.00
.
.
.
STD
XS
.
.
.
.
.
.
.
.
.
10 20
30 40
60 80
100
120
140
160
5S
10S
.
.
.
.
.
.
.
.
.
.
.188
.218
.250
.375
.500
.594
.812
1.031
1.281
1.500
1.750
1.969
19.624
19.564
19.500
19.250
19.000
18.812
18.376
17.938
17.438
17.000
16.500
16.062
22 22.00
.
.
.
STD
XS
.
.
.
.
.
.
.
.
10 20
30 60
80 100
120
140
160
5S
10S
.
.
.
.
.
.
.
.
.
.188
.218
.250
.375
.500
.875
1.125
1.375
1.625
1.875
2.125
21.624
21.564
21.500
21.250
21.000
20.250
19.75 19.25
18.75 18.25
17.75 24 24.00
.
.
STD
XS
.
.
.
.
.
.
.
.
.
10 20
.
30 40
60 80
100
120
140
160
5S
10S
.
.
.
.
.
.
.
.
.
.
.218
.250
.375
.500
.562
.688
.969
1.219
1.531
1.812
2.062
2.344
23.564
23.500
23.250
23.000
22.876
22.624
22.062
21.562
20.938
20.376
19.876
19.312
26 26.00 .
STD
10 .
.
.
.312
.375
25.376
25.250
677
STAINLESS STEEL PIPE 40 0523 - 7
B810 ADELANTO WWTP IMPROVEMENT PLAN
Pipe Size
(inches)
Outside
Diameter
(inches)
Identification
Wall
Thickness
- t -
(inches)
Inside
Diameter
- d -
(inches)
Steel
Stainless Steel
Iron Pipe Size Schedule No. Schedule No.
XS 20 . .500 25.000
28 28.00
.
STD
XS
.
10 .
20 30
.
.
.
.
.312
.375
.500
.625
27.376
27.250
27.000
26.750
30 30.00
.
.
STD
XS
.
.
10 .
20 30
5S
10S
.
.
.
.250
.312
.375
.500
.625
29.500
29.376
29.250
29.000
28.750
32 32.00
.
STD
XS
.
.
10 .
20 30
40 .
.
.
.
.
.312
.375
.500
.625
.688
31.376
31.250
31.000
30.750
30.624
34 34.00
.
STD
XS
.
.
10 .
20 30
40 .
.
.
.
.
.344
.375
.500
.625
.688
33.312
33.250
33.000
32.750
32.624
36 36.00
.
STD
XS
.
.
10 .
20 30
40 .
.
.
.
.
.312
.375
.500
.625
.750
35.376
35.250
35.000
34.750
34.500
42 42.00
STD
XS
.
.
.
20 30
40 .
.
.
.
.375
.500
.625
.750
41.250
41.000
40.720
40.500
Standard wall - STD
Extra strong wall - XS
Double extra strong wall - XXS
B. Fittings shall be butt weld type manufactured in accordance with ASTM A774 of the same raw material and in the same thicknesses as the pipe. Long radius elbows up to 24 inches diameter shall 678
STAINLESS STEEL PIPE 40 0523 - 8
B810 ADELANTO WWTP IMPROVEMENT PLAN
be smoothflow; i.e., centerline to end of elbow equals 1.5 times the nominal pipe size. All short radius, special radius, and reducing elbows and long radius elbows greater than 24 inches diameter shall be of mitered construction with at least five (5) mitered sections for 90-degree bends, three (3) mitered sections for 45- to 60-degree bends, and two (2) mitered sections for 30-degree and smaller bends. Reducers shall be straight tapered, cone type. Tees, crosses, laterals, and wyes shall be shop fabricated from pipe.
C. The finish on the raw material, manufactured to ASTM A240 will be No. 1, HRAP (hot rolled annealed and pickled) or better. The finish on the completed pipe and fittings shall be as specified in ASTM A778 and A774, respectively. See PART 3 of this Specification for pickling and passivation requirements on piping fabrications.
2.2 FLANGES
A. Flanged pipe ends shall be made up of type (304L or 316L) stainless steel slip-on type rolled angle face rings drilled to ANSI 16.1 class 125 standard. The angle face ring thickness shall be equal to or greater than the wall of the pipe or fitting to which it is welded and it shall be continuously welded on both sides to the pipe or fitting. The angle leg shall not interfere with the flange bolt holes.
2.3 COUPLINGS
A. The piping will be shop prepared for pipe couplings where shown on the drawings or specified herein.
1. Sleeve type couplings shall be of standard steel construction. Pipe shall be plain end with external weld beads ground smooth to insure proper gasket seating. For pressure pipe lines, sleeve coupling joints will be restrained by the use of harness rods connecting across the joint to flange lugs on adjacent flange joints. Where no adjacent flange joints exist, stainless steel harness lugs shall be welded to the pipe to receive the harness rods. All sleeve couplings, flange lugs, harness rods and hardware shall be provided.
2. Arched band type couplings shall be stainless steel of equal of superior alloy and wall thickness as the pipe and will be Depend-O-Lok type as manufactured by Brico or ENGINEER-approved equal. Couplings will be Fixed – FxF, Expansion – ExE, of Fixed by Expansion – FxE as noted on the drawings or as required. The pipe shall be plain end with external weld beads ground smooth and with S.S. restraining rings shop welded to the piping for fixed type couplings.
3. Split type couplings shall be malleable iron or ductile iron. Gaskets shall be suitable for the service conditions. The pipe ends shall be roll grooved to the coupling manufacturers specifications. Where roll grooving is impractical, the pipe shall have heavy wall machine grooved pipe nipples or machined ring collars fully welded to the pipe or fitting. Nipples shall be taper or bored to the I.D. of the adjoining pipe to allow full weld penetration. Collars shall be welded on both sides to the piping.
4. Expansion couplings shall be the flanged rubber arch type. Pipe flanges shall be provided for these couplings where shown on the drawing.
2.4 THREADED CONNECTIONS
A. Threaded pipe, gauge or instrument connections shall be made using stainless steel 150-pound threaded half couplings conforming to ASTM A182 or ASTM A276, shop welded to the pipe at the locations shown on the drawings.
2.5 JOINTS
A. Flanges shall be provided as a minimum at all flanged valves, meters, couplings, and other equipment. Couplings will be provided as shown on the drawings.
B. Pipe and fitting spools shall be shop fabricated to the fullest extent possible in 40’0” maximum lengths with 7’6” maximum widths for efficient commercial transport to the project site. Spools with fitting may exceed 40 feet so long as length allows commercial transport. Smaller pipe spools 679
STAINLESS STEEL PIPE 40 0523 - 9
B810 ADELANTO WWTP IMPROVEMENT PLAN
shall be provided with joints as shown on the drawings for special handling, installation and/or disassembly requirements.
C. All other joints required for shipping, handling and installation of the piping spools shall be (filed welds, flange joints, sleeve couplings, band couplings, or split couplings.)
2.6 BOLTING
A. The CONTRACTOR shall supply and install flange bolting.
PART 3 – EXECUTION
A. Welding of pipe spools shall be performed using welders and procedures qualified in accordance with ASME Section IX. Piping with wall thicknesses up to and including 11 gauge (0.125”) shall be welded with the TIG (GTAW) process. Heavier walls shall be beveled according to procedure, root pas welded with TIG (GTAW), and have subsequent weld passes performed using the TIG (GTAW), or Metallic Arc (SMAW) process. Filler metal of equal or superior ELC grades only shall be added to all welds to provide a cross-section at the weld equal to or greater than the parent metal. Weld deposit shall be smooth and evenly distributed, weld reinforcement shall be as follows:
Wall Thickness Weld Reinforcement (Max)
I.D. O.D.
Up to 12 Ga. (0.109”) 1/16” 3/32”
11 Ga. (0.125”) to 3.16” PI. 3/32” 1/8”
1/4” Plate & Larger 1/8” 3/16”
Concavity, undercut, cracks or crevices shall not be allowed. Butt welds shall have full penetration to the interior surface, and inert argon gas shielding shall be provided to the interior and exterior of the joint. Angle face rings shall be continuously welded on both sides to pipe or fitting. Exterior welds, such as the back side of face rings or flanges and structural attachments, may be welded by the MIG (GMAW) or Metallic Arc (SMAW) process; however, care must be taken to avoid melting through to the interior surface on very light walls. Excessive weld deposits, slag, splatter and projections shall be removed by grinding. Welds on gasket surfaces shall be ground smooth.
B. Spools shall be fabricated to the “Pipe Fabrication Institute” fabricating tolerances ES-3 (1981).
C. After shop fabrication into pipe spools, exterior welds shall be manually scrubbed or brushed win non-metallic pads or stainless steel wire brushes to remove weld discoloration, rinsed with clean water and allowed to air dry. The finish on the completed piping shall have a glass bead blasted surface, surface preparation SSPC-SP5/NACE-1. Pickle and passivate by complete immersion (15 minutes minimum) in a citric acid- or nitric acid-based solution, heated to the correct temperature. Material to be rinsed in a neutralizing bath and air dried. Use of stainless steel pipe/fittings received Full Immersion Pickling and Passivation at the time of manufacture, followed by field cleaning weld effected areas with “Wonder Gel” (or ENGINEER-approved equal) on the O.D. and I.D., per the manufacturer’s listed procedure, is acceptable.
D. All fabricated piping shall have openings plugged and flanges secured for storage and/or transport after fabrication. All fabricated piping shall be piece marked with identifying number or codes which correspond to the layout and installation drawings. The marks will be located on the spools at opposite ends and 180 degrees apart.
680
STAINLESS STEEL PIPE 40 0523 - 10
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E. Use extreme care to avoid the contact of any ferrous materials with the stainless steel piping. All saws, drills, files, wire brushes, etc., shall be used for stainless steel piping only. Pipe storage and fabrication racks shall be non-ferrous or stainless steel or rubber lined. Nylon slings or straps, or ally chains or cable shall be used for handling stainless steel piping. After installation, wash and rinse all foreign matter from the piping surface. If rusting of embedded iron occurs, pickle the affected surface with Oakite Deoxidizer SS, Wonder Gel, or ENGINEER-approved equal, scrub with stainless steel brushes and rinse clean.
F. Supply and install the stainless steel piping with a consistently clean surface. After installation, identifying spool piece marks shall be removed with paint thinner or solvents and the entire stainless steel surface shall be washed with detergent and rinsed clean. Final marking of the pipeline will be in accordance with Section 40 0553 – Identification for Process Piping.
G. After installation, the piping system shall be tested according to Section 40 0553 – Piping, General.
END OF SECTION 40 0523
681
THERMOPLASTIC PROCESS PIPE AND TUBING 40 0531 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 40 0531 – THERMOPLASTIC PROCESS PIPE AND TUBING PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Furnish and install polyvinyl chloride, chlorinated polyvinyl chloride, polyethylene, and polypropylene pipe, tubing, and fittings in accordance with the Contract Documents.
1.2 PIPE/TUBE DESIGNATIONS: The following plastic pipe and tube designations are defined:
Designation Definition
PVC Polyvinyl Chloride
CPVC Chlorinated polyvinyl chloride
PE Polyethylene
PFA Perfluoroalkoxy alkane
1.3 RELATED WORK SPECFIED ELSEWHERE
A. Related Sections:
1. Section 31 0000 – Earthwork
2. Section 40 0553 – Piping, General
3. Section 40 0507 – Hangers and Supports for Process Piping
4. Section 40 0554 – Valves, General
1.4 SUBMITTALS
A. Submittals shall be furnished in accordance with Section 01 3300 – Submittal Procedures.
B. Submit materials list and catalogue data sheets naming each product to be used identified by manufacturer and type number.
1.5 QUALITY ASSURANCE REFERENCES
A. This Section contains references to some or all of the following documents, most recent edition.
They are a part of this Section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. ASTM STANDARDS:
D1248 Polyetheylene Plastics Molding and Extrusion Materials D1784 Rigid Polyvinyl Chloride (PVC) Compounds and Chlorinated Poly Vinyl Chloride (CPVC) Compounds
D1785 Polyvinyl Chloride (PVC) Plastic Pipe, Schedules 40, 80, and 120 D2241 Polyvinyl Chloride (PVC) Pressure-Rated Pipe (SDR series) D2464 Threaded Polyvinyl Chloride (PVC) Plastic Pipe Fittings, Schedule 80 D2466 Polyvinyl Chloride (PVC) Plastic Pipe Fittings, Schedule 40 D2467 Socket-Type Polyvinyl Chloride (PVC) Plastic Pipe Fittings, Schedule 80 D2564 Solvent Cements for Polyvinyl Chloride (PVC) Plastic Pipe and Fittings D3034 Type PSM Polyvinyl Chloride (PVC) Sewer Pipe and Fittings D4101 Propylene Plastic Injection and Extrusion Materials F402 Safe Handling of Solvent Cements and Primers used for Joining Thermoplastic Pipe and Fittings
F437 Threaded Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 80 F438 Socket-Type Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 40 682
THERMOPLASTIC PROCESS PIPE AND TUBING 40 0531 - 2
B810 ADELANTO WWTP IMPROVEMENT PLAN
F439 Socket-Type Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe Fittings, Schedule 80 F441 Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe, Schedules 40 and 80 F477 Elastomeric Seals (Gaskets) for Joining Plastic Pipe F493 Solvent Cements for Chlorinated Polyvinyl Chloride (CPVC) Plastic Pipe and Fittings PART 2 - PRODUCTS
2.1 PVC PIPE
A. General: PVC materials for pipe and fittings shall conform to ASTM D1784, Cell Classification 12454-B. Pipe and fitting materials shall be specially formulated with sufficient UV protection additives to provide for long term outdoor exposure with no deleterious effects. Flanges shall be one-piece solid design or two-part van stone type which utilize the tapered, serrated face and full face gasket technique for joining and are compatible with ANSIN16.5 Class 150 metal flanges.
Unions shall be the O-ring type having interchangeable components with true union valves for maximum system versatility. All reclaimed buried plastic piping shall be purple Pantone 522; see Section 40 0553 for paint color of exposed piping.
B. Schedule 40, 80, and 120: Pipe in accordance with ASTM D1785. Schedule 80 PVC socket type fittings shall conform to ASTM D2467. Schedule 40 PVC fittings shall conform to ASTM D2466.
PVC solvent weld cement for socket connections shall meet the requirement of ASTM D2564/ Schedule 80 PVC threaded fittings shall conform to ASTM D2464.
C. C900: Pipe shall meet the requirements of AWWA C900, “Polyvinyl Chloride (PVC) Pressure Pipe.” AllC900 pipe shall meet the requirements of DR 25, with the exception that the intrafacility reuse recycled water system shall be DR14. All pipe shall be suitable for use as pressure conduit.
Provisions must be made for expansion and contraction as each joint with an elastomeric ring. The bell shall consist of an integral wall section with a locked-in, solid cross-section elastomeric ring which meets the requirements of ASTM F477. The bell section shall be designed to be at least as hydrostatically strong as the pipe wall and meet the requirements of AWWA C900. Fittings shall be ductile iron, push-on or mechanical joint.
D. C905: Pipe shall meet the requirements of AWWA C905, “Polyvinyl Chloride (PVC) Water Transmission Pipe” Class 165. Pipe shall meet the requirements of DR 25. All pipe shall be suitable for use as pressure conduit and shall be cast iron pipe o.d. Provisions must be made for expansion and contraction at each joint with an elastomeric ring. The bell shall consist of an integral wall section with a locked-in, solid cross-section elastomeric ring which meets the requirements of ASTM F477. The bell section shall be designed to be at least as hydrostatically strong as the pipe wall. Fittings shall be ductile iron, push-on or mechanical joint, as specified in AWWA C907 PVC fittings.
E. Clear UV Resistant PVC Pipe meeting the requirements of ASTM D1784 shall be used with indicated on plans, drawings, and P&ID.
2.2 CPVC PIPE
A. General: CPVC materials for pipe and fittings shall conform to ASTM F441 and ASTM F441M.
Pipe and fitting materials shall be specially formulated with sufficient UV protection additives to provide for long term outdoor exposure with no deleterious effects. Flanges shall be one-piece solid design or two-part van stone type which utilize the tapered, serrated face and full-face gasket technique for joining and are compatible with ANSIN16.5 Class 150 metal flanges. Unions shall be the O-ring type having interchangeable components with true union valves for maximum system versatility.
B. Flanged Fittings: Shall comply with ASME B16.1 and B16.5; Class 125.
C. Socket Welded: Shall Comply with ASTM F438, Sch 40 and F439, Sch 80 D. Threaded: Shall Comply with ASTM F437 and ASME B1.20.1 and B1.20.2M 683
THERMOPLASTIC PROCESS PIPE AND TUBING 40 0531 - 3
B810 ADELANTO WWTP IMPROVEMENT PLAN
2.3 POLYETHYLENE TUBING
A. Polyethylene tubing shall be extruded from high molecular weight resins and conform with ASTM D148 Type 1, Class A, Category 4, Grade E5. Stress crack resistance shall be per ASTM D1693.
Tubing shall have a minimum working pressure of 120 psi. Fittings shall be polyethylene construction. All connections shall be leak proof. Where indicated on plans tubing shall be PTFE lined.
2.4 POLYTETRAFLUOROETHYLENE TUBING
A. Polytetrafluoroethylene tubing shall be formulated of Polytetrafluoroethylene conforming to ASTM D3295. The nominal inside diameter shall be per plans. Tubing shall be rated for a rated working pressure of 140 psi, and 0° to 200°F temperature.
2.5 PERFLUOROALKOXY (PFA) TUBING
A. Perfluoroalkoxy (PFA) tubing in accordance with ASTM D6867 for diluted chemical solutions, resistant to UV, chemicals and solvents. The nominal inside diameter shall be per plans. Tubing shall be rated for a rated working pressure of 140 psi, and 0° to 200°F temperature.
PART 3 - EXECUTION
3.1 INSTALLATION OF PIPE AND FITTINGS
A. General: In accordance with manufacturer’s recommendations and Section 40 0553 – Piping, General, whichever is more stringent.
B. Pipe and fittings shall be of the sizes indicated. Clean pipe interior of all foreign matter before installing. Pipe shall be square cut with fine tooth saw or other cutter or knife designed for use with plastic pipe. Remove burrs by smoothing edges with a knife, file, or sandpaper. Replace any section of pipe found to be defective or damaged with new acceptable pipe. Handle pipe carefully to prevent gouging or scratching. Any length of pipe have a gouge, scratch, or other permanent indentation more than 10 percent of the wall thickness in depth shall be rejected.
3.2 INSTALLATION OF SOLVENT WELD JOINT TYPE PIPE
A. In accordance with the recommendations of the pipe manufacturer and the following supplementary requirements:
1. Do not solvent weld joints if it is raining, if atmospheric temperature is below 40°F or above 90°F, if the pipe is exposed to direct sunlight.
2. Test fit dry pipe and fittings before applying cement. Pipe should enter socket without forcing at least one-third but not more than two-thirds the depth of socket. Fittings that are looser or tighter shall not be used. Thoroughly clean and dry the pipe end and socket of fitting with methyl, ethyl, ketone, acetone, or similar cleaner. Apply cement evenly to outside surface and end of pipe and inside surface of socket. Avoid excess application of cement but insure complete coverage of all bonding surfaces. Mark depth of socket on pipe to guide application of cement and insure full insertion of pipe. Insert pipe in socket, twisting pipe or fitting approximately ½ turn as pipe is being seated in socket. Make sure pipe is fully seated providing a bond between end of pipe and shoulder of socket. Immediately wipe excess cement from pipe leaving no more than a 1/8-inch fillet at fitting end. Hold assembled joint in place for approximately 15 seconds and allow to set for 30 minutes before moving. Avoid rough handling for 48 hours. Longer periods may be required in cold or wet weather.
3.3 INSTALLATION OF PUSH-ON JOINT TYPE PIPE
A. Clean gaskets and seats of foreign materials prior to joint assembly. Apply lubricant as recommended by the pipe manufacturer. Carefully insert the spigot end into the bell to prevent entry of dirt and incorrect entry angle. With suitable fork tool, crowbar, or by hand, make the joint to the insertion depth recommended by the manufacturer. When the selected pipe uses joints not 684
THERMOPLASTIC PROCESS PIPE AND TUBING 40 0531 - 4
B810 ADELANTO WWTP IMPROVEMENT PLAN
designed for full depth insertion, prevent further closure of previously completed joints by restraining movement of the installed line while making succeeding joints.
3.4 INSTALLATION OF TUBING
A. Carefully slip tubing inside of CPVC conduits without kinking or damaging the tubing. Tubing shall be continuous between boxes and equipment. No joints shall be allowed in conduits. Tubing shall be tested as specified in Section 40 0553 – Piping, General for 72 hours with no visible leaks.
3.5 TESTING
A. In accordance with Section 40 0553 – Piping, General.
END OF SECTION 40 0531
685
VALVES, GENERAL 40 0554 - 1
B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 40 0554 – VALVES, GENERAL
PART 1 - GENERAL
1.01 THE REQUIREMENT
A. Furnish and install all valves, actuators, and appurtenances, complete and operable, in accordance with the Contract Documents. These specifications shall not apply to valves, actuators, and appurtenances to be provided by process equipment vendors as part of process systems or equipment already approved by the OWNER.
B. The provisions of this Section shall apply to all valves and valve actuators except where otherwise indicated. Valves and actuators in particular locations may require a combination of units, sensors, limit switches, and controls indicated in other Sections of the Specifications.
C. Where a valve is to be supported by means other than the piping to which it is attached, the CONTRACTOR shall obtain from the valve manufacturer a design for support and foundation that satisfies the criteria in Section 46 0000. The design, including drawings and calculations sealed by a Professional Engineer, shall be submitted with the Shop Drawings. When the design is approved, the support shall be provided.
D. Unit Responsibility: A single manufacturer shall be made responsible for coordination of design, assembly, testing, and furnishing of each valve; however, the CONTRACTOR shall be responsible for compliance with the requirements of each valve section. Unless indicated otherwise, the responsible manufacturer shall be the manufacturer of the valve.
E. Single Manufacturer: Where two or more valves of the same type and size are required, the valves shall be furnished by the same manufacturer.
1.02 SUBMITTALS
A. General: Submittals shall be furnished in accordance with Section 01 3300 – Submittal Procedures B. Shop Drawings: Shop Drawings shall contain the following information:
1. Valve name, size, Cv factor, pressure rating, and identification number (if any).
2. Complete information on valve actuator, including size, Manufacturer, model number, limit switches, and mounting.
3. Cavitation limits for all control valves.
4. Assembly drawings showing part nomenclature, materials, dimensions, weights, and relationships of valve handles, handwheels, position indicators, limit switches, integral control systems, needle valves, and control systems.
C. Technical Manual: The Technical Manual shall contain the required information for each valve.
D. Spare Parts List: A Spare Parts List shall contain the required information for each valve assembly, where indicated.
1.03 QUALITY ASSURANCE
A. Valve manufacturer and model shall be as described in the Drawings or ENGINEER-approved equal.
1.04 SPARE PARTS
A. The CONTRACTOR shall furnish the required spare parts suitably packaged and labeled with the valve name, location, and identification number. The CONTRACTOR shall also furnish the name, address, and telephone number of the nearest distributor for the spare parts of each valve. Spare parts are intended for use by the OWNER after expiration of the correction of defects period. 686
VALVES, GENERAL 40 0554 - 2
B810 ADELANTO WWTP IMPROVEMENT PLAN
PART 2 - PRODUCTS
2.01 PRODUCTS
A. General: Valves and gates shall be new and of current manufacture. Shut-off valves 6-inches and larger shall have actuators with position indicators. Buried valves shall be provided with valve boxes and covers containing position indicators and valve extensions. Manual shut-off valves mounted higher than 7 feet above working level shall be provided with chain actuators. Valves with no clear way to determine position shall be provided with position indicators. Stem extensions shall be provided on valves where operation of the valve cannot be easily accomplished from ground level.
B. Valve Actuators: Unless otherwise indicated, valve actuators shall be in accordance with Section 40 9213- Primary Control Vales and Section 40 9243 - Electric Actuators.
C. Valve Labeling: A label shall be provided on all shut-off valves and control valves except for hose bibs. The label shall be of 1/16-inch plastic or steel, minimum 2 inches by 4 inches in size, as indicated in Section 40 0553.10 – Identification for Process Piping and shall by permanently attached to the valve or on the wall adjacent to the valve.
D. Valve Testing: As a minimum, unless otherwise indicated, valves 3 inches in diameter and smaller shall be tested in accordance with manufacturer's standard and 4 inches in diameter and larger shall be factory tested as follows:
1. Hydrostatic Testing: Valve bodies shall be subjected to internal hydrostatic pressure equivalent to twice the water rated pressure of the valve. Metallic valves rating pressures shall be at 100°F and plastic valves shall be 73°, or at higher temperature according to type of material. During the hydrostatic test, there shall be no leakage through the valve body, end joints, or shaft seals, nor shall any part of the valve be permanently deformed. The duration shall be sufficient time to allow visual examination for leakage. Test duration shall be at least 10 minutes.
2. Seat Testing: Valves shall be tested for leaks in the closed position with the pressure differential across the seat equal to the water rated pressure of the valve. The duration of test shall be sufficient time to allow visual examination for leakage. Test duration shall be at least 10 minutes. Leakage past the closed valve shall not exceed 1 fluid ounce per hour per inch diameter for metal seated valves and drop-tight for resilient seated valves.
3. Performance Testing: All valves shall be shop operated from fully closed to fully open position and reverse under no-flow conditions in order to demonstrate the valve assembly operates properly.
E. Valve Marking: Valve bodies shall be permanently marked in accordance with MSS SP25 - Standard Marking Systems for Valves, Fittings, Flanges, and Unions.
2.02 MATERIALS
A. General: Materials shall be suitable for the intended application. Materials not indicated shall be high-grade standard commercial quality, free from defects and imperfections that might affect the serviceability of the product for the purpose for which it is intended. Unless otherwise indicated, valve and actuator bodies shall conform to the following requirements:
1. Cast Iron: Close-grained gray cast iron, conforming to ASTM A48 - Gray Iron Castings, Class 30, or to ASTM A126 - Gray Iron Castings for Valves, Flanges and Pipe Fittings.
2. Ductile Iron: ASTM A536 - Ductile Iron Castings, or to ASTM A395 - Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures.
3. Steel: ASTM A216 - Steel Castings, Carbon Suitable for Fusion Welding for HighTemperature Service, or to ASTM A515 - Pressure Vessel Plates, Carbon Steel, for Intermediate- and Higher-Temperature Service.
4. Bronze: ASTM B62 - Composition Bronze or Ounce Metal Castings, and valve stems not subject to dezincification shall conform to ASTM B584 - Copper Alloy Sand Castings for General Applications.
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5. Stainless Steel: Stainless steel valve and operator bodies and trim shall conform to ASTM A351 - Steel Castings, Austenitic, for High-Temperature Service, Grade CF8M, or shall be Type 304 or 316 stainless steel.
6. PVC: Poly Vinyl Chloride materials for valve body, flanges, and cover shall conform to Cell Classification 12454.
7. CPVC: Chlorinated Poly Vinyl Chloride materials for valve body, flanges, and cover shall conform to Cell Classification 23447.
8. NSF Standard 14 and 61: All materials shall be listed for use in contact with potable water, where applicable.
B. Bodies: Valve bodies shall be cast, molded (in the case of plastic valves), forged, or welded of the materials indicated, with smooth interior passages. Wall thicknesses shall be uniform in agreement with the applicable standards for each type of valve, without casting defects, pinholes, or other defects that could weaken the body. Welds on welded bodies shall be done by certified welders and shall be ground smooth. Valve ends shall be as indicated, and be rated for the maximum temperature and pressure to which the valve will be subjected.
C. Bonnets: Valve bonnets shall be clamped, screwed, or flanged to the body and shall be of the same material, temperature, and pressure rating as the body. The bonnets shall have provision for the stem seal with the necessary glands, packing nuts, or yokes. Below grade valves with above grade worm gear drives/handwheels or electric actuators shall include extended bonnets for mating up to the worm gear drives/handwheel or electric actuators.
D. Stems: Valve stems shall be of the materials indicated, or, if not indicated, of the best commercial material for the specific service, with variable stem packing, O-rings, Chevron V-type packing, or other suitable seal. Where subject to dezincification, bronze valve stems shall conform to ASTM B62, containing not more than 5 percent of zinc or more than 2 percent of aluminum, with a minimum tensile strength of 30,000 psi, a minimum yield strength of 14,000 psi, and an elongation of at least 10 percent in 2 inches. Where dezincification is not a problem, bronze conforming to ASTM B584 may be used, except that zinc content shall not exceed 16 percent.
E. Stem Guides: Stem guides shall be provided, spaced 10 feet on centers unless the manufacturer can demonstrate by calculation that a different spacing is acceptable. Submerged stem guides shall be 304 stainless steel.
F. Internal Parts: Internal parts and valve trim shall be as indicated for each individual valve. Where not indicated, valve trim shall be of Type 316 stainless steel or other best suited material.
G. Nuts and Bolts: Nuts and bolts on valve flanges and supports shall be in accordance with Section 05 5000 – Metal Fabrications.
H. Coatings: Valve coatings shall be in accordance with Section 09 9700 - Special Coatings or as recommended by the valve manufacturer.
I. Environment: Submerged valves shall be of stainless steel construction as recommended by the valve manufacturer or as an ENGINEER-approved equal.
2.03 VALVE ACCESSORIES
A. Valves shall be furnished complete with the accessories required to provide a functional system.
PART 3 - EXECUTION
3.01 VALVE INSTALLATION
A. General: Valves, actuating units, stem extensions, valve boxes, and accessories shall be installed in accordance with the Manufacturer's written instructions and as indicated. Gates shall be adequately braced to prevent warpage and bending under the intended use. Valves shall be firmly supported to avoid undue stresses on the pipe.
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B. Access: Valves shall be installed with easy access for actuation, removal, and maintenance and to avoid interference between valve actuators and structural members, handrails, or other equipment.
C. Valve Accessories: Where combinations of valves, sensors, switches, and controls are indicated, the CONTRACTOR shall properly assemble and install such items so that systems are compatible and operating properly. The relationship between interrelated items shall be clearly noted on Shop Drawing submittals.
END OF SECTION 40 0554
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SECTION 40 0556 – MISCELLANEOUS VALVES
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide all miscellaneous valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 40 0554 – Valves, General, apply to this Section.
1.2 SUBMITTALS
A. Furnish submittals in accordance with Section 01 3300 – Submittal Procedures.
B. Complete Shop Drawings
C. Drawings valves and actuators
D. Drawings showing valve port diameters complete with dimensions, part numbers and materials of construction
1.3 OPERATION AND MAINTENANCE MANUAL
A. Operation and Maintenance Manual shall be furnished in accordance with the requirements of the General Section.
1.4 QUALITY ASSURANCE
A. Manufacturer and model shall be described on the Drawings, as specified herein, or ENGINEERapproved equal.
B. The manufacturer shall provide a 2-year equipment warranty.
C. If required: AIS Step Certification Process shall be used to ensure that producers adhere to the American Iron and Steel (AIS) requirement and verify that products comply with the AIS requirement. The AIS Step Certification Process shall require that certification for each handler (supplier, fabricator, manufacturer, processor, etc.) of the iron and steel products certifies that their step in the process was domestically performed. Each time a step in the manufacturing process takes place, the manufacturer shall deliver its work along with a certification of its origin. The certification must include at a minimum the name of the manufacturer, the location of the manufacturing facility where the product or process took place (not its headquarters), a description of the product or item being delivered, and a signature by a manufacturer’s responsible party. These step certifications shall be collected and maintained by the final manufacturer, vendor, or representative that delivers the iron or steel product to the worksite, and shall provide a final certification asserting that all manufacturing processes occurred in the US.
1.5 SPARE PARTS
A. Spares shall be as requested by the OWNER. Payment for spares shall be made in accordance with the General Conditions.
B. A list of spare parts for each piece of equipment shall be obtained from the manufacturer and submitted at the same time as Shop Drawings. The name, address, and telephone number of the nearest distributor for each piece of equipment shall be furnished. 690
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PART 2 - PRODUCTS
2.1 PRESSURE RELIEF/SUSTAINING VALVES
A. Quality Assurance: The valve manufacturer shall warrant the valve to be free of defects in material and workmanship for a period of three years from date of shipment, provided the valve is installed and used in accordance with all applicable instructions. Electrical components shall have a oneyear warranty. Valves shall be subjected to performance, leakage, and hydrostatic tests in accordance with procedures and acceptance criteria established by AWWA C530.
B. General: The pressure sustaining valve shall maintain a constant upstream and/or downstream pressure regardless of changing flow rate and/or inlet pressure. Valve shall be NSF 61 certified.
C. Main Valve: The valve shall be hydraulically operated, single diaphragm-actuated, globe pattern.
The valve shall consist of three major components: the body, cover, and diaphragm assembly. The diaphragm shall be the only moving part and shall form a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure. Packing glands and/or stuffing boxes are not permitted and there shall be no pistons operating the main valve or pilot controls.
D. Body: Valve body shall be ductile iron construction. Valve body shall be cast as one piece. No fabrication or welding shall be used in manufacturing.
E. Disc: The valve shall contain a resilient, synthetic rubber disc, with a rectangular cross-section contained on three and one-half sides by a disc retainer and forming a tight seal against a single removable seat insert. No O-ring type discs (circular, square, or quad type) shall be permitted as the seating surface. The disc guide shall be of the contoured type to permit smooth transition of flow and shall hold the disc firmly in place. The disc retainer shall be of a sturdy one-piece design capable of withstanding opening and closing shocks. It must have straight edge sides and a radius at the top edge to prevent excessive diaphragm wear as the diaphragm flexes across this surface.
No hourglass-shaped disc retainers shall be permitted and no V-type or slotted type disc guides shall be used.
F. Diaphragm: The diaphragm assembly containing a non-magnetic 303 stainless steel stem with sufficient diameter to withstand high hydraulic pressures shall be fully guided at both ends by a bearing in the valve cover and an integral bearing in the valve seat. No center guides shall be permitted. The stem shall be drilled and tapped in the cover end to receive and affix such accessories as may be deemed necessary. The diaphragm assembly shall be the only moving part and shall form a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure.
G. The flexible, non-wicking, FDA-approved diaphragm shall consist of nylon fabric bonded with synthetic rubber compatible with the operating fluid. The center hole for the main valve stem must be sealed by the vulcanized process or a rubber grommet sealing the center stem hole from the operating pressure. The diaphragm must withstand a Mullins Burst Test of a minimum of 600 psi per layer of nylon fabric and shall be cycle tested 100,000 times to insure longevity. The diaphragm shall not be used as the seating surface. The diaphragm shall be fully supported in the valve body and cover by machined surfaces which support no less than one-half of the total surface area of the diaphragm in either the fully opened or fully closed position.
H. Seat & Stem: The main valve seat and the stem bearing in the valve cover shall be removable. The lower bearing of the valve stem shall be contained concentrically within the seat and shall be exposed to the flow on all sides to avoid deposits. To ensure proper alignment of the valve stem, the valve body and cover shall be machined with a locating lip. No “pinned” covers to the valve body shall be permitted. Cover bearing, disc retainer, and seat shall be made of the same material.
All necessary repairs and/or modifications other than replacement of the main valve body shall be possible without removing the valve from the pipeline. Packing glands and/or stuffing boxes shall not be permitted and components including cast material shall be of North American manufacture.
I. Pilot System: Pilot tubing shall be 316 stainless steel construction. The pressure reducing pilot control shall be a direct-acting, adjustable, spring-loaded, normally open, diaphragm valve 691
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designed to permit flow when controlled pressure is less than the spring setting. The pilot control is held open by the force of the compression on the spring above the diaphragm, and it closes when the delivery pressure acting on the underside of the diaphragm exceeds the spring setting. The pilot control system shall include a fixed orifice. No variable orifices shall be permitted. The pilot system shall include an opening speed control on all valves. The pilot control shall have a second downstream sensing port which can be utilized to install a pressure gauge. A full range of spring settings shall be available in ranges of 0 to 450 psi.
J. Valve Position Indicator: As required by the project documents, each pressure relief/sustaining valve shall be provided with a dependable positive acting limit switch tied to the position of the valve when it is open or closed. Switch contacts shall be 24 VDC rated if wired directly to a PLC or 120 VAC in all other applications.
K. The valve manufacturer shall also provide a computerized cavitation chart which show flow rate, differential pressure, percentage of valve opening, Cv factor, system velocity, and if there will be cavitation damage.
L. Manufacturers, or ENGINEER-approved equal: Valve manufacturer and model shall be CLAVAL, or ENGINEER-approved equal.
2.2 BACKFLOW PREVENTER
A. General: Backflow preventers shall be a double check valve or reduce pressure principle type backflow preventer unit and associated components shall be equal in quality and performance to a “Foundation for Cross-Connection Control and Hydraulic Research”. Backflow preventers shall be Febco, Watts, Wilkins, or ENGINEER-approved equal. All backflow preventers shall be submitted for approval by the OWNER regardless of make or model.
2.3 TELESCOPING VALVE
A. General: Furnish and install manually-operated telescoping valves, complete and operable, as shown and specified, including appurtenances, operators, supports and accessories, in accordance with the requirements of the Contract Documents.
B. Valve Assembly: The telescoping valve assembly shall be of the rack and pinion type, of the size shown. The travel range shall be at least the amount shown. Assemblies shall consist of a handwheel pedestal (with offset if required) with handwheel operator, a rising stem, slip tube with flat weir crest skimming funnels, a tube guide collar with companion flange and gasket and a mounting bracket.
1. Slip Tube: The slip tube and skimming funnel shall be of Type 316, Schedule 40 stainless steel, with a seal to prevent leakage at the seam.
2. Stem: The stem shall be minimum 3/4-inch, Type 316 stainless steel, with a travel and height indicating device calibrated in 1-inch increments. A suitable stem lock shall be provided for holding the stem at the desired level.
3. Guide Collar: Guide collar shall include a neoprene gasket and stainless steel companion flange for securing to the receiving pipe as shown.
4. Mounting Bracket: A cast iron bracket shall be provided for mounting the operator pedestal with stainless steel anchor bolts.
5. Fastening Hardware: All nuts and bolts and other fastening hardware shall be Type 316 stainless steel.
6. Coating: Coating of all ferrous surfaces, except stainless steel, shall be in accordance with Section 09 9100, Painting (Process) and 09 9700 Special Coatings.
7. Lifts shall be hand wheel type with UHMW polyethylene thrust bearings along with a stub acme threaded type 316 stainless steel stem to provide automatic self-locking. Handwheels shall be a minimum of 12” in diameter and shall include a clear plastic Butyrate stem cover with a mylar strip type position indicator, calibrated in ¼”-increments to illustrate valve position.
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C. Valve shall be Troy Valve, Waterman, or ENGINEER-approved equal.
2.4 ACCESSORIES
A. Calibration Column:
1. Calibration column shall be provided for each chemical pump group. The calibration column shall be sized for the max flow of the chemical pump and shall be manufactured by Koflo Corporation or ENGINEER-approved equal.
B. Pulsation Dampeners:
1. Shall be of the single diaphragm design, capable of arresting water hammer in the pump discharge lines created by the metering pumps.
2. Materials of construction of diaphragm and body shall be CPVC and corrosion resistant to the chemical fluid pumped.
3. Provide one dampener on the discharge side of each metering pump.
4. Each pulsation dampener shall include an integral pressure gauge.
5. Pulsation dampeners shall be sized appropriately for each pump to remove a minimum of 95% of the pulsations. The manufacturer shall provide calculations to verify sizing if requested by the OWNER.
C. Pressure Relief, Pressure Sustaining Valve:
1. Adjustable diaphragm pressure relief, pressure sustaining type valve installed on pump discharge header and set at location according to Mechanical and P&ID Plans.
2. Materials of construction of body shall be CPVC and corrosion resistant to the chemical fluid pumped. Diaphragm shall be PTFE.
3. Valve shall be true-union connection.
4. Valve shall have capability of adjustable pressure setting.
E. Pressure Gauge and Diaphragm Isolators:
1. Piping shall be Schedule 80 CPVC.
2. True-union CPVC ball valves shall be provided for isolation of major equipment.
3. Seals shall be compatible with the chemical being pumped.
2.5 PRESSURE REDUCING VALVES
A. General: Furnish and install pressure reducing control valves in accordance with the project documents. The pressure reducing control valve shall automatically throttle to reduce a higher incoming pressure and maintain an accurate and constant lower downstream pressure regardless of changing flow rate and/or inlet pressure. If downstream pressure increases above the pilot spring setting, the valve shall close. When the outlet pressure is greater than the inlet pressure, the valve shall be provided with a check feature allowing the outlet pressure to be admitted into the main valve cover chamber closing the valve and preventing return flow.
B. Materials specification for the pressure reducing control valves shall be as follows:
Component Material
Body and Cover Ductile Iron-ASTM A536
Main Valve Trim Stainless Steel
Seat Stainless Steel
Stem, Nut and Spring Stainless Steel
Seal Disc Buna-N Rubber
Diaphragm Nylon Reinforced Buna-N Rubber
Internal Trim Parts Stainless Steel
End Detail Flanged
Pressure Rating AWWA Class D Flanges (pressure class 150) 693
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Temperature Range Water up to 180°F
Any other wetted metallic parts Stainless Steel
Coating NSF 61 Certified Fusion bonded epoxy coating (interior and exterior)
Accessories Position Indicator, opening speed controls (through pilot system, isolation valves for pilot system, inlet and outlet pressure gauges.
C. The main valve shall be hydraulically operated, single diaphragm actuated, globe pattern. The valve shall consist of three major components; the body with seat installed, the cover with bearing installed and the diaphragm assembly. The diaphragm assembly shall be the only moving part and shall form a sealed chamber in the upper portion of the valve, separating the operating pressure from line pressure. Packing glands, stuffing boxes and or rolling diaphragm technology will not be permitted and there shall be no pistons operating the main valve or pilot controls. No fabrication or welding shall be used in the manufacturing process. Y-pattern valves shall not be permitted.
The main valve shall comply with NSF/ANSI standard 61 and certified lead free to NSF/ASNI 372 as a safe drinking water system component.
D. The diaphragm assembly containing a non-magnetic stainless-steel stem; of sufficient diameter to withstand high hydraulic pressures and shall be fully guided at both ends by a bearing in the main valve cover and an integral bearing in the valve seat. The valve seat shall be a solid, one-piece design and shall have a minimum five-degree taper on the seating surface for a positive, drip-tight shut off. No center guides shall be permitted. The stem shall be drilled and tapped in the cover end to receive and affix such accessories as may be deemed necessary. The diaphragm assembly shall be the only moving part and shall form a sealed chamber in the upper portion of the valve, separating the operating pressure from the line pressure. No bolts or cap screws shall be permitted for use in the construction of the diaphragm assembly.
E. The flexible, non-wicking, FDA approved diaphragm shall consist of nylon fabric bonded with synthetic rubber compatible with the operating fluid. The diaphragm’s center hole for the main valve stem must be sealed by the vulcanized process or a rubber grommet sealing the center stem hole from the operating pressure. The diaphragm must withstand a Mullins Burst Test of a minimum of 600 X per layer of nylon fabric and shall be cycled tested 100,000 times to insure longevity. The diaphragm shall not be used as the seating surface. The diaphragm shall be fully supported in the valve body and cover by machined surfaces which support no less than one-half of the total surface area of the diaphragm in either the fully opened or fully closed position.
Bellofram type rolling diaphragms shall not be permitted.
F. The main valve seat and stem bearing in the valve cover shall be removable. The main valve seat shall be retained by flat head machine screws for ease of maintenance. The lower bearing of the valve stem shall be contained concentrically within the seat and shall be exposed to the flow on all sides to avoid deposits. To ensure proper alignment of the valve stem, the valve body and cover shall be machined with a locating lip. No “pinned” covers to the valve body shall be permitted.
Cover bearing, disc retainer and seat shall be made of the same material. All necessary repairs and/or modifications other than replacement of the main valve body shall be possible without removing the valve from the pipeline. The valve shall be designed such that both the cover assembly and internal diaphragm assembly can be disassembled and lifted vertically straight up from the top of a narrow opening/vault. Y- pattern valves shall not be permitted. The seat shall be of the solid one-piece design. Two piece seats or seat inserts shall not be permitted. Packing glands and/or stuffing boxes shall not be permitted.
G. Pilot Control System: The pressure reducing pilot control shall be a direct-acting, adjustable, spring-loaded, normally open, diaphragm valve designed to permit flow when controlled pressure is less than the spring setting. The pilot control is held open by the force of the compression on the spring above the diaphragm and it closes when the delivery pressure acting on the underside of the 694
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diaphragm exceeds the spring setting. The pilot control system shall include a strainer and a fixed orifice closing speed. No variable orifices shall be permitted. The pilot system shall include an opening speed control on all valves sizes 3” and smaller as standard equipment. The pilot control shall have a second downstream sensing port which can be utilized to install a pressure gauge. A full range of spring settings shall be available in ranges of 0 to 400 psi. Pilot shall comply with NSF/ANSI 61 and certified lead free to NSF/ANSI 372 as a safe drinking water system component.
The pilot control system shall include a strainer and a fixed orifice closing speed. No variable orifices shall be permitted. The pilot system shall include an opening speed control on all valves sizes 3” and smaller as standard equipment. A full range of spring settings shall be available in ranges of 0 to 400 psi. Pilot to be manufactured by control valve manufacturer.
H. Materials specification for the pilot control shall be as follows:
Component Material
Body and Cover Bronze
Pilot Trim Stainless Steel 303
Rubber Buna-N
Connections FNPT
Pressure Rating 400 psi max
Temperature Range Water to 180°F Max
Control Tubing Stainless Steel
Control Fittings Stainless Steel
I. Each control valve shall be factory assembled, and the manufacturer shall make all necessary adjustments and correct any defects.
Each control valve shall be factory tested by the manufacturer in accordance with their requirements. At a minimum the tests shall include a valve body and cover, seat, and stroke leakage test. Control valves and pilot valves, in the partially open position, with both ends closed off with blind flanges (valves) and pipe plugs (pilots), shall be subject to an air test. The applied air pressure shall be 90 psi minimum. All air pressure tests shall be applied for a minimum of 15 minutes. No visible leakage is permitted through the valve seat, the pressure boundary walls of the valve body, valve cover, pilot body, pilot cover or the body-cover joint. A direct factory representative shall be made available by the equipment supplier for start-up service, inspection, and necessary adjustments.
2.6 MUD VALVES
A. The Mud Valve shall be of the heavy duty flanged type designed to provide a positive seal under both seating and unseating head conditions. The valves shall be (non-rising, rising stem) stem style as detailed on the schedule or the plans. The frame, plug and yoke shall be cast iron (A126B) The valve operating stem and lift nut shall be bronze (B421) The seat ring shall be bronze (B62) with an accurately machined tapered seating face. The plug seat shall be a seamless molded, tapered resilient ring of BUNA-N designed to accurately mate with the seat ring for a positive seal.
B. Where required the manufacturer shall provide valve operating stems, Floor Stands and Stem Guides as specified in the valve schedule or plans.
C. The Mud Valves are to be coated using TNEMEC Pota Pox two-part epoxy, NSF approved coating.
D. Valves shall be manufactured by:
1. Troy Valve, Waterman
2. ENGINEER-approved Equal
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2.7 AIR-VACUUM AND AIR-RELEASE VALVES
A. Air and Vacuum Valves: Air and vacuum valves shall be capable of venting large quantities of air while pipelines are being filled, and allowing air to re-enter while pipelines are being drained. They shall be of the size indicated, with flanged or screwed ends to match piping. Bodies shall be of high-strength cast iron. The float, seat, and all moving parts shall be constructed of Type 316 stainless steel. Seat washers and gaskets shall be of a material insuring water tightness with a minimum of maintenance. Valves shall be designed for minimum 150 psi water-working pressure, unless otherwise indicated. Air-Release Valves: Air-release valves shall vent accumulating air while system is in service and under pressure and be of the size indicated and shall meet the same general requirements as indicated for air and vacuum valves except that the vacuum feature will not be required. Valves shall be designed for a minimum water-working pressure of 150 psi, unless otherwise indicated.
B. Combination Air Valves: Combination air valves shall combine the characteristics of air and vacuum valves and air release valves by exhausting accumulated air in systems under pressure and releasing or re-admitting large quantities of air while a system is being filled or drained, respectively. Valves shall have the same general requirements as indicated for air and vacuum valves.
C. Valves shall be manufactured by:
1. A.R.I.
2. Or ENGINEER-approved equal
2.8 FLAP VALVES
A. General: The flap valve shall be provided with a hinged flap/door to close round-, square-, or rectangular-shaped openings. The singe/ on-seating tightening shall be affected by means of a special EPDM spherical/lip shaped rubber profile placed around the opening in the door. After installation the flap valve shall be watertight on one side (on-seating) up to a continuous pressure of 20 feet of water column above the invert of the pipe the flap valve is connected without any visible deformation or leakage.
B. Application: a non-return flap valve is for installation that is permanently below the waterline. It shall regulate water flow in one direction and preventing back flow.
C. Construction and Materials: Unless otherwise indicated, all materials of construction shall be suitable for the service, whether water or air. The seats shall be positively clamped or bonded into the disc or body of the valve. The hinge construction for the flap valve will be of the “confined closed hinge” type. The confined closed hinge consists of two side segments and a cover plate.
Description Material Standards (may differ for service application – water/air)
Valve Bodies High Density Poly-Ethylene (HDPE)
Valve Hinge High Density Poly-Ethylene (HDPE)
Valve Hinge Axes Stainless Steel AISI 316L
Valve flap High Density Poly-Ethylene (HDPE)
Connection and Anchor Bolts Stainless Steel AISI 316
Painting and coating Refer to Section 09 9700 – Special Coatings D. Manufacturers, or ENGINEER-approved equal:
1. RW Gate Company
2. Or ENGINEER-approved Equal
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EXECUTION
3.1 INSTALLATION
A. Valves shall be installed in accordance with the manufacturer's printed recommendations, and with provisions of Section 40 0554 – Valves, General.
B. Vented Ball valves shall be installed with off gassing chemicals and in accordance with the provisions of Section 40 0554 – Valves, General. Care shall be taken that valves in plastic lines are well supported at each end of the valve.
C. The flap valve shall be mounted perpendicularly and free of tension. Valve connection is specified per plans and anchor and mounting bolts shall be of stainless steel AISI 316. Between the moving HDPE parts will be stainless steel AISI 316L. The valve flap shall be provided with ballast to prevent the door from floating in the water and ensure complete closing of the door under the water line. The ballast applied on the door ensure that the specific weight of the door is being increased to 1100 kg/ M3 ensuring full closing of the door below water level and yet maintains differential opening pressures of less than 10 mm water column when completely submerged.
END OF SECTION 40 0556
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SECTION 40 0557 – ACTUATORS FOR PROCESS VALVES AND GATES PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Provide all valve and gate actuators and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all valves and gates, except where otherwise indicated in the Contract Documents.
C. Single Manufacturer: Where two or more valve or gate actuators of the same type or size are required, the actuators shall all be produced by the same Manufacturer.
1.2 SUBMITTALS
A. General: Submittals shall be furnished in accordance with Section 01 3300 – Submittal Procedures.
The shop drawing shall substantiate compliance with the Contract Documents requirements.
B. Shop Drawings: Shop Drawings of all actuators shall be submitted together with the valve and gate submittals as a complete package.
PART 2 – PRODUCTS
2.1 GENERAL
A. General: Unless otherwise indicated, all shut-off and throttling valves, and externally actuated valves and gates, shall be provided with manual or power actuators. All actuators shall be complete and operable with mounting hardware, motors, gears, controls, wiring, solenoids, hand wheels, levers, chains, and extensions, as applicable. All actuators shall be capable of holding the valve in any intermediate position between fully open and fully closed without creeping or fluttering.
B. Manufacturers: Where indicated, certain valves and gates may be provided with actuators manufactured by the valve or gate Manufacturer. Where actuators are furnished by different manufacturers, coordinate selection to have the fewest number of manufacturers possible.
C. Materials: All actuators shall be current models of the best commercial quality materials and liberally sized for the maximum expected torque. All materials shall be suitable for the environment in which the valve or gate is to be installed.
D. Mounting: All actuators shall be securely mounted by means of brackets or hardware specially designed and sized for this purpose and of ample strength. The word "open" shall be cast on each valve or actuator with an arrow indicating the direction to open in the counter-clockwise direction.
All gear and power actuators shall be equipped with position indicators. Where possible, manual actuators shall be located between 48 and 60 inches above the floor or the permanent working platform.
E Standard: Unless otherwise indicated and where applicable, all actuators shall be in accordance with ANSI/AWWA C 540 - AWWA Standard for Power-Actuating Devices for Valves and Sluice Gates.
F. Functionality: Electric, pneumatic, and hydraulic actuators shall be coordinated with the power requirements of Division 26 and instrumentation equipment requirements indicated in Division 40.
2.2 MANUAL ACTUATORS
A. General: Unless otherwise indicated, all valves and gates shall be furnished with manual actuators.
Valves in sizes up to and including 8 inches shall have direct acting lever or handwheel actuators of the Manufacturer's best standard design. Larger valves and gates shall have gear-assisted manual actuators, with an operating pull of maximum 60 pounds on the rim of the handwheel. All buried 698
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and submerged gear-assisted valves, all gates, all gear-assisted valves for pressures higher than 250 psi, all valves 30 inches in diameter and larger, and valves where the operating pull exceeds a maximum of 60 pounds on the handwheel, and where so indicated, shall have worm-gear actuators, hermetically-sealed and grease-packed, where buried or submerged.
B. Buried Valves: Unless otherwise indicated, all buried valves shall have extension stems (or bonnets where shown on the plans) to grade, with square nuts or floor stands, position indicators, and castiron or steel pipe extensions with valve boxes, covers and operating keys. Where so indicated, buried valves shall be in cast-iron, concrete, or similar valve boxes with covers of ample size to allow operation of the valve actuators. Covers of valve boxes shall be permanently labeled as requested by the authority having jurisdiction, or the ENGINEER. Wrench-nuts shall comply with AWWA C500 - Metal - Seated Gate Valves for Water Supply Service, and a minimum of 2 operating keys, or one key per 10 valves, whichever is greater, shall be furnished.
C. Buried and Submerged Actuators: Buried and submerged valve actuators and gear assemblies shall be provided with Type 304 and/or 316 stainless steel bolting and trim, and shall be rated for continuous submerged service. If buried, the valve actuator shall be suitable for a submerged service at a water depth of 10 feet (minimum). If submerged, the actuator shall be suitable for a submerged service at a water depth of 30 feet (minimum).
2.3 ELECTRIC ACTUATORS (Section 40 9243)
2.4 CHAINWHEEL ACTUATORS
A. In locations where the valve is installed 6 feet or higher from the finished grade/floor/working platform, the CONTRACTOR shall provide a chainwheel actuator with a chain of sufficient length to allow for the valve to be actuated from the finished grade/floor/working platform. Bevel and/or gear offsets shall be provided by the CONTRACTOR as needed to allow for the chainwheel to be actuated from the finished grade/floor/working platform.
PART 3 – EXECUTION
3.1 SERVICES OF MANUFACTURER
A. Field Adjustments: Field representatives of manufacturers of valves or gates with pneumatic, hydraulic, or electric actuators shall adjust actuator controls and limit-switches in the field for the required function.
3.2 INSTALLATION
A. All valve and gate actuators and accessories shall be installed in accordance with Section 40 0523 – Common Work Results for Process Valves. Actuators shall be located to be readily accessible for operation and maintenance, without obstructing walkways. Actuators shall not be mounted where shock or vibrations will impair their operation, nor shall the support systems be attached to handrails, process piping, or mechanical equipment.
B. Inspection, Startup, and Field Adjustment: An authorized representative of the Manufacturer shall visit the site and witness the following:
1. Installation of the equipment for not less than 1 day.
2. Inspection, checking, and adjusting the equipment for not less than 1 day.
3. Startup and field-testing for proper operation for not less than 1 day.
END OF SECTION 40 0557
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SECTION 40 0560 – STAINLESS STEEL SLIDE AND WEIR GATES
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes: Stainless steel slide gates.
B. Related Requirements:
1. Section 40 0557 – Actuators for Process Valves and Gates
1.2 DEFINITIONS
A. Operating Head: Distance from centerline of gate to maximum water level of channel.
B. Design Head: The maximum differential head that will be applied on the gate under worst case conditions, measured from the gate invert.
C. Seating Head: Head applied on a wall mounted gate, in the direction that pushes the gate against the wall it is installed on.
D. Unseating Head: Head applied on a wall mounted gate in the direction pulling the gate away from the wall it is installed on.
E. Operating Head: The highest differential head that is to be applied on the gate when it needs to be operated, measured from the gate invert.
1.3 REFERENCE STANDARDS
A. American Water Works Association:
AWWA C541 Hydraulic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates
AWWA C542 Electric Motor Actuators for Valves and Slide Gates AWWA C561 Fabricated Stainless-Steel Slide Gates
ASTM
A240/A240M
Chromium and Chromium Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels and for General Applications
ASTM A276 Stainless Steel Bars and Shapes
ASTM
A582/A582M
Free-Machining Stainless Steel Bars
ASTM
A790/790M
Seamless and Welded Ferritic / Austenitic Stainless-Steel Pipe ASTM B179 Aluminum Alloys in Ingot and Molten Forms for Castings from All Casting Processes
ASTM B584 Copper Alloy Sand Castings for General Applications ASTM D2000 Rubber Products in Automotive Applications
ASTM D4020 Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials ASTM F593 Stainless Steel Bolts, Hex Cap Screws, and Studs B. NSF International:
1. NSF Standard 61 - Drinking Water System Components - Health Effects
2. NSF Standard 372 - Drinking Water System Components - Lead Content
1.4 PREINSTALLATION MEETINGS
A. Section 01 3000 – Administrative Requirements
B. Convene minimum one week prior to commencing WORK of this Section.
1.5 SUBMITTALS
A. Section 01 3300 – Submittal Procedures
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B. Product Data: Submit manufacturer information for system materials and component equipment.
C. Shop Drawings:
1. Indicate system materials and component equipment.
2. Submit installation and anchoring requirements, fasteners, and other details.
3. Indicate gate identification number, location, service, type, size, design pressure, operator details, stem details, and loads.
D. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.
E. Delegated Design Submittals: Submit signed and sealed Shop Drawings with design calculations and assumptions for seating/unseating pressure.
F. Manufacturer Instructions: Submit detailed instructions on installation requirements, including storage and handling procedures.
G. Source Quality-Control Submittals: Indicate results of shop/factory tests and inspections.
H. Field Quality-Control Submittals: Indicate results of furnished tests and inspections.
I. Manufacturer Reports:
1. Certify that equipment has been installed according to manufacturer instructions.
2. Indicate activities on Site, adverse findings, and recommendations.
J. Qualifications Statements:
1. Submit qualifications for manufacturer, installer, and licensed professional.
2. Submit manufacturer's approval of installer.
1.6 CLOSEOUT SUBMITTALS
A. Section 01 7000 – Execution and Closeout Requirements B. Project Record Documents: Provide record of the actual locations of installed slide gates and components.
1.7 QUALITY ASSURANCE
A. Materials in Contact with Potable Water: Certified to NSF Standard 61 and NSF Standard 372.
B. Perform Work according to all requirements of the latest edition of ANSI/AWWA C561. The slide gate manufacturer must maintain an ISO-9001 certification and also a company certification for its welding operations from the CWB or AWS. standards.
C. Maintain 2 copies of each standard affecting WORK of this Section on Site.
1.8 QUALIFICATIONS
A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum three years' documented experience.
B. Installer: Company specializing in performing Work of this Section with minimum three years' documented experience and approved by the manufacturer.
C. Licensed Professional: Professional Engineer experienced in design of specified Work and licensed in the State of Arizona.
1.9 DELIVERY, STORAGE, AND HANDLING
A. Section 01 6000 – Product Requirements: Requirements for transporting, handling, storing, and protecting products.
B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage.
C. Store materials according to manufacturer instructions.
D. Protection:
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1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas.
2. Provide additional protection according to manufacturer instructions.
1.10 EXISTING CONDITIONS
A. Field Measurements:
1. Verify field measurements prior to fabrication.
2. Indicate field measurements on Shop Drawings.
1.11 WARRANTY
A. Section 01 7000 – Execution and Closeout Requirements: Requirements for warranties.
B. Furnish three-year manufacturer's warranty for slide gates.
C. Furnish five-year manufacturer's warranty that clear plastic stem covers will not crack, discolor, or become opaque.
PART 2 - PRODUCTS
2.1 PERFORMANCE AND DESIGN CRITERIA
A. Seating/Unseating Head:
1. See Gate Schedule for Seating/Unseating.
2. Measurement: From maximum water surface to bottom of gate.
B. Minimum Vertical Loading: 50 percent of force on the gate from operating head acting on horizontal centerline of gate, multiplied by effective gate area, plus weight of slide and stem.
C. Gate Reinforcement: As required for deflection not greater than 1/720 of span or 1/16 in whichever is less and with stresses in the slide limited to 25% of the ultimate tensile, compressive, and shear strength and 50% of the yield strength, whichever is less.
D. Operating Head:
1. Safety Factor: Design gate to operate under specified operating head with safety factor of five.
2.2 STAINLESS STEEL SLIDE GATES
A. Manufacturers/Model:
1. 304 SS FONTAINE-AQUANOX Series 20 Slide and Sluice Gates
2. 304 SS FONTAINE-AQUANOX Series 40 Weir Gates
3. MPI Waterman Stop Gates
4. Or ENGINEER-approved Equal
B. Gates:
1. Material:
a. Type 304 stainless steel.
2. Minimum Thickness: 1/4 inch or 6 mm.
3. Size: As indicated on Drawings or gate list.
4. Configuration: Removable.
C. Yokes:
1. Material: Structural Steel
2. Mounting: Bolted to gate frame.
3. Yoke shall consist of a beam made of formed plates or structural members mounted on top of the frame to permit mounting of the actuator with proper stem alignment by the use of slotted holes in both directions. The yoke shall be sized to limit deflection under the design load to a maximum of 1/360 of the gate opening width or ¼ in (6mm) whichever is less. The 702
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yoke design load must be considered as the vertical thrust generated by an 80 lbs. (356 N) force on the crank or handwheel (for a manual actuator) or by the actuator in locked rotor condition (for an electric actuator). Per the latest edition of AWWA C561, the stresses in the yoke generated by the design load shall not exceed (for a manual actuator) 25% of the ultimate tensile, compressive, and shear strength and 50% of the yield strength, whichever is less, or (for an electric actuator) 2/3 of the yield strength.
D. Seating and Guiding:
1. Impacted into dovetail slots and held in position without use of screws or other fasteners.
2. Maximum Clearance between Seating Faces: 0.004 inch when gate is fully closed.
3. The slide shall seat and travel on guides made of ultra-high molecular weight polyethylene (UHMWPE) designed to perform for the life of the slide gate without replacement. The slide shall be kept in positive contact with the guides on both its upstream and downstream faces, all along its travel in the gate clear opening by an elastomeric cord. Above the gate clear opening, the guides shall extend high enough to ensure that the slide is supported on a minimum of 1/2 of its height when fully opened. The low friction guides shall be secured to the frame by bolted retainers allowing factory adjustment of the contact pressure with the slide. The surface of contact on the side seats shall be large enough to limit the stress under the design head to 600 psi (4137 KPa) without considering the top and bottom seats as load bearing.
E. Wedges:
1. Description: Machined brass blocks with angled faces and secured with a stud bolt to prevent slippage during operation.
2. Furnish side, top, and bottom wedges.
F. Frames:
1. Configuration: One piece.
2. Material: Type 304 stainless steel.
3. Minimum Thickness: 1/4 inch.
4. Mounting: As indicated on Drawings or gate list.
5. Furnish continuous as indicated on Drawings or gate list.
6. Seats: UHMW polymer.
7. Bottom Flush Closure: Resilient seal securely attached to frame along invert.
8. The gate frame shall be made of formed plates or structural members creating the clear opening of the specified dimensions in a rigid one-piece unit. The mounting and bolting flange of the frame to the wall shall be separate and independent from the seating and sealing plane of the slide. The bottom of the frame will be of the flush invert type. Stresses in the frame under design head shall not exceed 25% of the ultimate tensile, compressive, and shear strength and 50% of the yield strength, whichever is less.
G. Lifting Devices:
1. Manual actuator of the proper type and mounting location, as listed in the gate schedule or shown on the drawings, shall be provided by the gate manufacturer. Shall include stem, lifting nut, supports, bushings, stem cover, and position indicator. The effort required on the manual device to operate the gates shall not exceed 40 lbs (178N), while to start the gate in motion from the fully closed position with the design pressure, the required effort shall not exceed 60 lbs (267N). Indication of the opening direction of rotation shall be clearly marked in a permanent manner on the handwheel or crank.
2. Handwheels: The handwheel shall be removable and have a minimum diameter of 16” (406 mm). It shall drive the lift nut directly or via the extension pipe of self-contained gates or it shall engage the input shaft of the gearbox, when specified. Locate center 36 inches above operating floor.
3. Crank Operated Gearboxes: The gearbox, comprising a lift nut and thrust bearing assembly (as described below), shall be fully enclosed in a casted housing with seals around the lift nut 703
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and around the input pinion shaft. The input pinion shaft shall be supported on ball or tapered roller bearings. The removable crank, equipped with a revolving grip shall engage on the input shaft of the gearbox and have a minimum radius of 12” (305 mm).
4. Square Nut Actuator: The square nut shall be 2” x 2” (50mm x 50mm) designed for mounting in the floor box supplied by the contractor and designed to accommodate a standard T-wrench. T-wrench shall be supplied by the gate manufacturer in the quantity required by the gate schedule.
5. Actuator Lift Nut and Thrust Bearings: All gates shall include a thrust bearing assembly comprising a threaded bronze lift nut to engage the operating stem. This assembly must be enclosed in a machined stainless-steel housing or be an integral part of the gearbox when supplied. Needle roller thrust bearings shall be provided above and below the lift nut to support the operating efforts in closing and opening the gate. The length of thread engagement shall be sufficient to ensure that the maximum pressure on the projected area of thread contact does not exceed 2000 psi (13,8 MPa) at normal maximum operating load and that the PV (pressure velocity) factor does not exceed 30,000. The PV factor is calculated by multiplying the pressure on the projected area of thread contact in psi by the surface velocity in ft/min at the pitch diameter of the threads. For non-rising stem gates, the actuator lift nut shall be keyed to prevent rotation relative to the threaded stem.
6. Mounting: Fabricated-steel pedestal. The thrust bearing assembly or the gearbox shall be mounted on the yoke of the gate for all gates specified as self-contained or on a pedestal for gates specified as non-self-contained. Pedestal height shall be such that the handwheel or input shaft of the gearbox is located approximately 36” (900mm) above the operating floor.
Where shown on the drawings or when specified, a wall bracket shall be supplied to support the pedestal. The pedestal wall bracket shall be designed and supplied by the gate manufacturer to ensure that it can resist to all operating efforts of the gate based on the same design calculation criteria used for the yoke.
7. Powered Lift Devices:
a. When required by the gate schedule or the drawings, motorized actuators shall be supplied as specified in Section 40 0557 – Actuators for Process Valves and Gates.
Comply with AWWA C541 and AWWA C542. Actuators shall be Rotork IQ3 or Auma SA series, for ON/OFF (or modulating control as indicated in the plans) duty and have the characteristics indicated in the schedule shown below in this section. 1) Anchor Bolts
a) The quantity, size and location of anchor bolts shall be determined by the gate manufacturer and shown on the submittal drawings. The minimum required load capacity of the anchors used for design must also be indicated on the drawings.
2) Materials
Slide, Frame and Yoke Stainless Steel ASTM A240, grade 316L or 304L Side Seal/Guides and Top Seal Ultra High Molecular Weight Polyethylene (UHMWPE)
ASTM D4020
Flush Invert Bottom Seal Ethylene Propylene (EPDM) ASTM D2000 Compression Cord Ethylene Propylene (EPDM) ASTM D2000
Wall Gasket Ethylene Propylene (EPDM) ASTM D2000
Bolts and Hardware Stainless Steel ASTM F593, grade 316 Stem Stainless Steel ASTM A582, grade 316 or 304
Thrust Nut and Lift Nut Aluminum Bronze or
Manganese Bronze
ASTM B505, C95800
ASTM B584, C86300
Stem Couplings Stainless Steel ASTM A582, grade 316
Stem Guide Bracket Stainless Steel ASTM A582, grade 316 Stem Guide Bushing Ultra High Molecular Weight
Polyethylene (UHMWPE)
ASTM D4020
Handwheel Cast Aluminum ASTM B179
Crank Aluminum ASTM B209, 6061-T6
Pedestal Stainless Steel ASTM F593, grade 316
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Gearbox Housing Cast Iron ASTM A48 35B/40B
Square Nut Cast Aluminum ASTM B179
Stem Cover Clear PVC
Stem Cover Cap PVC
8. Hand-Lifted Gates: Furnish stainless steel lifting handle.
H. Lifting Nut:
1. Material: Brass.
2. Furnish grease fitting.
3. Furnish polymer bearing pads above and below lifting nut.
I. Lifting Stem:
1. Material: Type 304 or 316 stainless steel.
2. Configuration:
a. Rising or Non-rising as indicated in drawings or gate list. b. Removable.
3. Thread:
a. Type: Acme, double lead.
b. Cut threads are not acceptable.
4. Diameter: 1-1/8 inch
5. Fully lubricated.
6. Maximum Number of Turns: 16 per foot of travel.
7. Stem Guides will be provided as required to meet the stem buckling design criteria and positioned per the manufacturer’s recommendations to ensure that the length to radius of gyration ratio (l/r) does not exceed 200. The guides shall incorporate a UHMWPE bushing supported by a stainless-steel wall bracket adjustable in both horizontal directions
8. Stem Covers:
a. Material: Clear polycarbonate.
b. Configuration: Capped and vented.
c. Length: As required to allow full travel of gate.
d. All rising stem gates, weather manual or motorized shall be equipped with a clear stem cover with a closed top and ventilation hole. The cover shall bear graduation in both inches and centimeters to indicate the position of the gate.
J. Couplings:
1. The required stem extensions shall be joined together or to the threaded stem by means of a bolted connection, passing through both pipe and stem.
2.3 FINISHES
A. Stainless Steel Surfaces: Mill finish.
2.4 ACCESSORIES
A. Hardware: Type 316 stainless steel.
2.5 SOURCE QUALITY CONTROL
A. Section 01 4000 – Quality Requirements
B. Inspection and Testing:
1. Provide shop inspection and testing of completed assemblies.
2. Comply with AWWA C561.
C. Owner Inspection:
1. Make completed slide gate assembly available for inspection at manufacturer's factory prior to packaging for shipment.
2. Notify Owner at least seven days before inspection is allowed. 705
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D. Owner Witnessing:
1. Allow witnessing of factory inspections and test at manufacturer's test facility.
2. Notify Owner at least seven days before inspections and tests are scheduled.
E. Certificate of Compliance:
1. If manufacturer is approved by authorities having jurisdiction, submit certificate of compliance indicating Work performed at manufacturer's facility conforms to Contract Documents.
2. Specified shop tests are not required for Work performed by approved manufacturer.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Section 01 7000 - Execution and Closeout Requirements B. Verify that facilities are ready to receive slide gates.
3.2 PREPARATION
A. Section 01 7000 – Execution and Closeout Requirements B. Clean surfaces according to manufacturer instructions.
3.3 INSTALLATION
A. According to manufacturer instructions.
B. Ensure that products are installed plumb, true, and free of warp or twist.
C. Locate operators to avoid interference with handrails and other Work.
D. Guides:
1. Surface and Flange Mounting:
a. Install guides with expansion anchors.
b. Position guides at elevation as indicated on Drawings.
2. Recess Mounting:
a. Cut slot in concrete to receive guides.
b. Position guides at elevation as indicated on Drawings. c. Grout guides in place according to manufacturer instructions.
E. Sealing:
1. The guides combined with the elastomeric cord will provide sealing on both sides of the opening. Sealing at the top section of the gate will also be achieved with a UHMWPE seat maintained in contact by an elastomeric cord. At the gate invert, the slide shall close on a flush invert rubber seat/seal secured in the bottom member of the gate frame. Under the design seating or unseating head specified in the gate schedule, the slide gates shall restrict leakage to a maximum of 0.04 gpm/ft (0.5 l/min/m) of clear opening perimeter.
Manufacturer shall be able to demonstrate that the sealing system will retain its performance even after 25,000 operating cycles.
F. Lubricants: Provide oil and grease as required for initial operation.
3.4 FIELD QUALITY CONTROL
A. Section 01 4000 – Quality Requirements.
B. Section 01 7000 –- Execution and Closeout Requirements balancing. 706
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C. Inspection:
1. Verify alignment of gate and components.
2. Verify that gate operates smoothly and does not bind or scrape.
D. Testing:
1. Comply with AWWA C561.
2. Leakage: Not exceeding 0.1 gpm/ftof seating perimeter under 20 feet of seating head and not exceeding 0.21 gpm/ft. under 20 feet of unseating head.
3. Leakage shall be measured at the unseating design pressure. Operating force shall be measured with and without the design pressure. Factory test reports shall be available on request for all gates supplied.
E. Installation:
1. It is the responsibility of the Contractor to handle, store and install the gates in strict accordance with the manufacturer’s instructions and recommendations. The Contractor shall review the installation drawings and instructions before proceeding to the installation of the gates.
2. The gate assemblies must be installed on a true vertical plane, square and plumb. The operating stem shall be accurately aligned with the gate guides and properly greased.
F. Field Testing:
1. After installation, the gates must be field tested by the subcontractor, in the presence of the ENGINEER and Owner, to ensure compliance with the requirements of these specifications.
Each gate shall be operated on its complete open-close cycle to confirm operation without binding, scraping, or distorting. Operating effort on the crank, handwheel or T-wrench shall be observed or measured. In the case of motorized actuators, the operating torque shall be noted, and the initial set-up of each actuator shall be done in accordance with the instructions in the manual.
2. Each gate shall be water tested by the Contractor and sealing performance shall be observed.
3. The CONTRACTOR shall supply a detailed report of the field tests for review.
G. Equipment Acceptance:
1. Adjust, repair, modify, or replace components failing to perform as specified and re-inspect.
2. Make final adjustments to equipment under direction of manufacturer's representative.
H. Furnish installation certificate from equipment manufacturer's representative attesting that equipment has been properly installed and is ready for startup and testing.
3.5 ADJUSTING
A. Section 01 7000 – Execution and Closeout Requirements B. Adjust slide gates to provide smooth operation.
3.6 DEMONSTRATION
A. Section 01 7000 – Execution and Closeout Requirements B. Demonstrate equipment operation, routine maintenance, and emergency repair procedures to Owner's personnel.
END OF SECTION 40 0560
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SECTION 40 0562 – PLUG VALVES
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide plug valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 40 0554 - Valves, General apply.
1.2 SUBMITTALS
A. Furnish submittals in accordance with Section 01 3300 – Submittal Procedures.
1.3 OPERATION AND MAINTENANCE MANUAL
A. The requirements of 01 7823 – Operation and Maintenance Data apply.
1.4 QUALITY ASSURANCE
A. The manufacturer shall provide a minimum 2-year equipment warranty.
1.5 SPARE PARTS
A. Spares shall be as requested by the OWNER. Payment for spares shall be made in accordance with the General Conditions.
B. A list of spare parts for each piece of equipment shall be obtained from the manufacturer and submitted at the same time as Shop Drawings. The name, address, and telephone number of the nearest distributor for each piece of equipment shall be furnished.
PART 2 - PRODUCTS
2.1 ECCENTRIC PLUG VALVES
A. General: Plug valves shall be of the quarter-turn, non-lubricated, eccentric type with resilient faced plug. Plug valves shall be designed for a working pressure of 175 psi for valves 12” and smaller, 150 psi for valves 14” and larger. Valves shall provide tight shut-off at rated pressure. Valves 20” and smaller shall have round port design. 24” and larger valves shall have rectangular port design.
Minimum port area for all valves shall be 80% of corresponding pipe area.
B. Valve Body: The plug valve body shall be cast iron ASTM A126 Class B with welded-in overlay of greater than 90% nickel alloy content on all surfaces contacting the face of the plug. Sprayed, plated, nickel welded rings or seats screwed into the body are not acceptable. All cover bolts shall be corrosion resistant. The “SEAT END” of the valve shall be designated on the valve body.
C. Coating: Plug valves shall be coated in accordance with Section 09 9700 – Special Coating D. Valve Plug: The valve plug shall be cast iron ASTM A126 Class B, with Buna N resilient seating surface to mate with the body seat.
E. Valve Connections: Flanged valves shall be drilled in compliance with ANSI B16.1, Class 125.
Mechanical joint valves shall comply with AWWA C111. Threaded valves shall have NPT full size inlets with hexagonal wrench connection.
F. Valve Bearings: Plug valves shall be furnished with permanently lubricated sleeve type bearings conforming to AWWA C504. Bearings shall be of sintered, oil impregnated type 316 stainless steel ASTM A743 Grade CF-8M or bronze ASTM B127.
G. Valve Bonnet: Refer to Section 40 0554 – Valves, General.
H. Valve Shaft Seals: Valve shaft seals shall be of the “U” cup type, in accordance with AWWA C504. Seals shall be self-adjusting and repackable without removing the bonnet from the valve. 708
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I. Valve Actuators: Valves 2.5” and smaller shall be provided with a hand lever. Valves 3” and larger shall be specified as equipped with either a handwheel or 2” square nut for direct quarterturn operation.
J. Where specified, a totally enclosed and sealed worm gear actuator with position indicator and externally adjustable open and closed stops shall also be included. The worm segment gear shall be ASTM A536 Grade 65-45-12 ductile iron with precision bore and keyway for connection to the valve shaft. All buried valves shall be provided with worm and gear actuators suited for the intended service. All gear actuators shall be designed to withstand, without damage, a rim pull of 200 lbs for handwheels and an input torque of 300 ft-lbs for nuts.
K. Buried service actuators shall be packed with grease and sealed for temporary submergences to 20 feet of water. Exposed worm shafts shall be stainless steel.
L. Electric Actuators: When specified, electric actuators shall be in accordance with Section 40 9243 – Electric Actuators.
M. Manufacturers:
1. Val-Matic
2. Dezurik
3. or ENGINEER-approved equal
PART 3 - EXECUTION
3.1 GENERAL
A. Valves shall be installed in accordance with provisions of Section 40 0554 – Valves, General.
END OF SECTION 40 0562
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SECTION 40 0563 – BALL VALVES
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide ball valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 40 0554 – Valves, General apply.
C. The requirements of Section 40 9243 – Electric Actuators apply.
D. The requirements of Section 40 9213 – Primary Control Valves apply.
1.2 SUBMITTALS
A. Furnish submittals in accordance with Section 01 3300 – Submittal Procedures.
PART 2 - PRODUCTS
2.1 GENERAL
A. The ball valve type and its actuator shall be as indicated in the Contract Documents.
2.2 BALL VALVES (3- TO 12-INCH)
A. Construction: Ball valves shall be full bore with a design working pressure of 150 psig. Valve construction shall conform to the following:
1. Top Flange shall be design for direct mounting of actuator and gear operators. Top flange shall provide easy access for adjustment of gland bolts. Design shall conform to EN ISO 5211.
2. Valve Design shall conform to ASME B16.34-2004/ API 6D / BS EN ISO 17292 Class 150
3. Valve end-to-end dimensions shall be per ASME b16.10 / API 6D.
4. Valve Body shall be flanged, two-piece design in cast construction and shall be coated with two-coat zinc rich epoxy paint.
5. Ball shall be floating design, stainless steel with superior finish and sphericity to ensure extended seat life and low operating torque.
6. Stem shall be stainless steel, heavy duty construction with double “D” (sizes up to 4”) and round and keyed (sizes 6” and greater) configurations.
7. Seat shall be contoured and be reinforced with PTFE seat.
8. Body joint bolting shall conform to ASTM A193 B7/ ASTM A194 2H for carbon steel bodies and ASTM A193 GR.B8/ ASTM A194 GR.8 for stainless steel bodies.
B. Actuators: Unless otherwise indicated, ball valves shall have manual hand lever or wheel actuators.
C. Manufacturers:
1. Apollo
2. Nibco
3. Valtorc
4. or ENGINEER-approved equal
2.3 BALL VALVES (SMALLER THAN 3-INCH)
A. Construction: Ball valves, smaller than 3-inch, for general purpose use, shall be heavy-duty type for industrial service, with butt weld, grooved, threaded, or soldered ends to match the piping. The bodies shall be cast red bronze conforming to ASTM B584. The ball and threaded pack gland shall be brass with a reinforced PTFE seat ring. The stem shall be of silicon bronze. All valves shall have a pressure rating of minimum 125 psi steam, and 200 psi coldwater, unless otherwise indicated. 710
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B. Construction (Thermoplastic Ball Valves): PVC and CPVC ball valves, smaller than 3-inch, for general purpose use, shall be heavy-duty type for industrial service, with butt socket, threaded, or flanged ends to match the piping. The ball valves shall be true union type constructed from PVC Type I, ASTM D1784, or CPVC Type IV, ASTM D1784. All O-rings shall be EPDM or Viton. All ½” to 2” valves shall be pressure rated at 235 psi and all 2-1/2” to 3” valves shall be pressure rated at 150 psi, unless otherwise indicated.
C. Manufacturers, or ENGINEER-approved equal:
1. Nibco;
2. Apollo;
3. Asahi;
4. Spears;
2.4 BALL VALVES (SMALLER THAN 3-INCH AND USED W/CHEMICALS) A. Construction (Thermoplastic Ball Valves): Ball valves shall be constructed in accordance with AWWA C521. CPVC ball valves, smaller than 3-inch, for chemical use, shall be heavy-duty type for industrial service. The ball valves shall be true union type constructed from CPVC Type IV, ASTM D1784. All O-rings shall be Viton. All ½” to 2” valves shall be pressure rated at 235 psi and all 2-1/2” to 3” valves shall be pressure rated at 150 psi, unless otherwise indicated. Ball vales shall be vented for use with off gassing chemicals.
B. Manufacturers, or ENGINEER-approved equal:
1. Asahi
2. Spears
PART 3 - EXECUTION
3.1 GENERAL
A. Ball valves shall be installed in accordance with the provisions of Section 40 0554 – Valves, General. Care shall be taken that valves in plastic lines are well supported at each end of the valve.
END OF SECTION 40 0563
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SECTION 40 0564 – BUTTERFLY VALVES
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide butterfly valves and appurtenances, (air and water service) complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 40 0554 - Valves, General apply.
C. The requirements of Section 40 9213 – Primary Control Valves apply.
1.2 SUBMITTALS
A. Furnish submittals in accordance with Section 01 3300 – Submittal Procedures.
B. Complete Shop Drawings:
C. Drawings of butterfly valves and actuators.
D. Drawings showing valve port diameter complete with dimensions, part numbers and materials of construction.
1.3 QUALITY ASSURANCE
A. Valves shall be subjected to performance, leakage, and hydrostatic tests in accordance with procedures and acceptance criteria established by AWWA C504.
PART 2 - PRODUCTS
2.1 RESILIENT SEATED BUTTERFLY VALVES
A. General: Butterfly valves steady-state water working pressures and steady-state differential pressure shall be as indicated on the plans.
B. Valves shall be of the body type, pressure class, end joint, and actuator type indicated.
C. Construction: Unless otherwise indicated, all materials of construction shall be suitable for the service, whether water or air. The seats shall be positively clamped or bonded into the disc or body of the valve.
Description Material Standards (may differ for service application – water/air) Valve Bodies Cast Iron ASTM A126 Class B
Valve Stem Stainless Steel 416
Valve discs Aluminum or Bronze
Painting and coating Refer to Section 09 9700 – Special Coatings D. Manufacturers, or equal:
1. Val-Matic
2. Dezurik
3. Bray
4. Or ENGINEER-approved equal
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PART 3 - EXECUTION
3.1 INSTALLATION
A. All exposed butterfly valves shall be installed with a means of removing the complete valve assembly without dismantling the valve or operator. The installation shall be in accordance with Section 40 0554 – Valves, General.
END OF SECTION 40 0564
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SECTION 40 0565 – CHECK VALVES
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. Provide check valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 40 0554 - Valves, General apply to this Section.
1.2 SUBMITTALS
A. Furnish submittals in accordance with Section 01 3300 - Submittals.
PART 2 - PRODUCTS
2.1 SWING FLEX CHECK VALVES (3-INCH AND LARGER)
A. General: Swing check valves for water and wastewater service shall be a full body flange type, with a domed access cover and resilient disc. The valves shall meet ANSI/AWWA C 508 - SwingCheck Valves for Waterworks Service, 3 in. through 24 in. NPS, unless otherwise indicated, and shall be with full-opening passages and designed for a water-working pressure of 250 psi.
B. Body: The valve body and cover shall be of cast iron conforming to ASTM A536 Grade 65-45-12 with flow area equal to the nominal pipe inside diameter throughout the valve. Seat shall be constructed on a 45-degree angle to reduce disc travel. The seat and internal body shall be fully coated with a two part thermosetting epoxy suitable for use in both potable water and wastewater applications.
C. Disc: The resilient disc shall feature a fully encapsulated steel pressure plate with integral molded O-ring on the face of the elastomer. Nylon reinforcements shall be provided in the flexible hinge area of the disc assembly.
D. Backflow Actuator: If required, check valves shall be provided with a screw-type backflow actuator to allow for the opening of the valve during no flow conditions. The backflow shall be a risingstem type to indicate position. A stainless steel T-handle shall be provided for ease of operations.
E. Position Indicator: Check valves shall be provided with a mechanical position indicator to indicate disc position.
F. Valve manufacturer shall be Val-Matic, or ENGINEER-approved equal.
2.2 SWING CHECK VALVES (2-1/2-INCH AND SMALLER)
A. General: Swing check valves for steam, water, oil, or gas in sizes 2-1/2-inch and smaller shall be suitable for a steam pressure of 150 psi and a cold water pressure of 300 psi. They shall have screwed ends, unless otherwise indicated, and screwed caps.
B. Body: The valve body and cap shall be of bronze conforming to ASTM B61 - Steam or Valve Bronze Castings, or ASTM B62 with threaded ends conforming to ANSI/ASME B1.20.1 - Pipe Threads, General Purpose (inch).
C. Disc: Valves for steam service shall have bronze or brass discs conforming to ASTM B16 - FreeCutting Brass Rod, Bar, and Shapes for Use in Screw Machines, and for cold water, oil, and gas service replaceable composition discs.
D. Hinge Pin: The hinge pins shall be of bronze or stainless steel.
E. Position Indicator: Valves shall be provided with mechanical position (open/closed) indicators.
F. Valve manufacturer shall be as shown on the Drawings or ENGINEER-approved equal. 714
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2.3 DUCKBILL ELASTOMERIC CHECK VALVES
A. Check Valves are to be all rubber of the flow operated check type with a slip-on or flanged connection.
B. For slip-on connection, the Check Valve is designed to slip over the specified pipe outside diameter and attached by means of vendor furnished stainless steel clamps. The port area shall contour down to a duckbill, which shall allow passage of flow in one direction while preventing reverse flow.
The valve shall be one piece rubber construction with nylon reinforcement. In sizes 20” and larger, the bill portion shall be thinner and more flexible than the valve body, and formed into a curve of 180°.
C. For flange end connection, Check Valves are to be all rubber and the flow operated check type with a flanged end connection. The port area shall contour down to a duckbill which shall allow passage of flow in one direction while preventing reverse flow. The flange and flexible duckbill sleeve shall be one piece rubber construction with nylon reinforcement. The bill portion shall be thinner and more flexible than the valve body, and formed into a curve of 180°. The flange drilling shall conform to ANSI B16.1 Class 125/ANSI B16.5, Class 150 standards. The valve shall be furnished with steel back-up rings for installation.
D. Elastomeric duckbill check valve shall be manufactured in the United States of America. A single manufacturer shall provide all elastomer duckbill check valves.
E. MANUFACTURER. All valves shall be Tideflex, Onyx, or ENGINEER-approved equal.
PART 3 - EXECUTION
3.1 GENERAL
A. Valves shall be installed in accordance with provisions of Section 40 0554 - Valves, General.
END OF SECTION 40 0565
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SECTION 40 4200 – PROCESS PIPING AND EQUIPMENT INSULATION PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall furnish and install all pipe and equipment insulation, complete and operable, in accordance with the requirements of the Contract Documents. In addition to the insulation shown and specified, the CONTRACTOR shall insulate any cold or hot piping and exhausts that could be hazardous to plant personnel upon contact.
B. All steam and hot or chilled water piping shall be insulated with fiberglass metal jacketed insulation to form a watertight and weatherproof system.
C. Exposed process piping shall be heat taped and insulation against freezing as shown per the Contract Documents.
D. All air process piping within the blower building which passes through spaces above finished ceilings, or are suspended over equipment, electrical panels, or cabinets shall be insulated. Refer to the plans for insulation locations and requirements for air process piping.
E. All unions, flanges, mechanical joints, valves, strainers, steam traps, and other devices in insulated piping systems shall be insulated in the same manner as the adjacent piping. Operators, instruments, and other features requiring routine access shall not be covered. Insulation over removable devices shall be easily removable and replaceable.
F. Insulation on buried piping need not be jacketed.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Section 09 9700 – Special Coating
B. Section 40 – Process interconnections as applicable
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Comply with the reference specifications of the General Requirements.
B. Comply with the current provisions of the following Codes and Standards.
1. Federal Specifications:
a. HH-1-558B Insulation Blocks, Boards, Blankets, Felts, Sleeving (Pipe and Tube Covering), and Pipe Fitting Covering, Thermal (Mineral Fiber, Industrial Type)
2. Commercial Standards:
a. ASTM C547 Specification for Mineral Fiber Preformed Pipe Insulation b. ASTM E84 Test Method for Surface Burning Characteristics of Building Materials
1.4 SUBMITTALS
A. Shop Drawings: Shop drawings shall be submitted in accordance with Section 013300 – Submittal Procedures.
1. The following submittals and specific information shall be provided. a. The CONTRACTOR shall submit complete shop drawings showing locations of placement of all thermal insulation, with manufacturer's data on materials, covering, jackets, and finish.
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PART 2 - PRODUCTS
2.1 INSULATION
A. All components of the insulation, including covering, mastics and adhesives shall have a flamespread rating of not over 25, and a smoke development rating of not over 50. Ratings shall be as established by tests in accordance with ASTM E84 and Federal Specification standards. The integrated insulation assemblies shall also conform to the above specifications. Insulation shall be applied in strict accordance with the manufacturer's instructions.
B. Materials
1. Standard Insulation: This type of insulation shall be employed for process, cold-and hot water, steam, and condensate piping and equipment with surface temperatures up to 850°F.
Pipe insulation shall be molded-type pipe covering, made of fibrous glass with a minimum k-factor of 0.23 at 75°F mean temperature. The insulation shall be oversized for installation over electric heating cable. Unless otherwise specified, the insulation thickness shall be as follows:
2. Pipe Insulation:
Minimum Thickness of Insulation
(Inches)
Hot and cold water (domestic) –
6-inches and smaller 1
Hot and chilled water process -
6-inches and smaller
8-inches and large
1-1/2
2 Low pressure steam (50 psi and less) –
8-inches and less 2
Condensate, boiler blowdown, and boiler feed -
8-inches and less 1-1/2
Heated sludge and process piping -
6-inches and smaller
8-inches and larger
1 1-1/2
Heat traced piping -
3-inches and smaller
4-inches and larger
1 1-1/2
Equipment and Tanks:
Boilers, heaters, and manufactured equipment as recommended by manufacturer Heat exchangers, tanks, and vessels 3
3. Vapor barrier: Insulation shall have a factory-applied white fire-retardant vapor-barrier jacket of kraft paper and aluminum foil laminated together and reinforced with fiberglass yarn.
4. Insulation at Supports: Insulation shall be coordinated with the pipe hangers and supports and where insulation protection shields are provided the top half section of pipe insulation at support locations shall be of the same specified density, and the bottom half insulation segments provided between the pipe and the insulation protection shields shall have a density of not less than 6 lb/cu ft.
C. Manufacturers or ENGINEER-approved equal: Manville, Micro-Loc AP-T; Owens-Corning Fiber Glas Corp., Kaylo
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1. High Temperature Insulation: This type of insulation shall be employed for engine exhaust pipes, flues, and similar pipes and equipment with surface temperatures up to 1200°F. The high temperature insulation shall consist of 4-inch thick calcium silicate or similar premolded blocks with a minimum k-factor of 0.14, in two layers of 2-inch thickness, each, with staggered joints, all applied over a 3/4-inch high metal rib lath. The inner layer shall be suitable for 1200°F, and the second layer for 1000°F. All bends, voids, joints, fittings, and other parts of the piping system shall be filled with insulating cement. Aluminum lagging with preformed aluminum fittings shall be banded to the insulation in a similar fashion as specified for standard insulation. Allowance shall be made for thermal expansion.
D. Metal Jacketing: General: All insulation shall be covered with smooth aluminum weatherproof jacketing with a factory-attached moisture barrier.
1. The jacket for the fittings shall consist of precision-formed smooth-sided sections and shall be sized to cover and protect the insulated fitting. Each section shall be manufactured from aluminum, and all joints shall be sealed with silicon mastic, to provide a continuous, air and weathertight joint. Strapping shall be 1/2-inch wide, Type 3003 aluminum or Type 304 stainless steel.
2. The jacket at insulated valves shall fit over the removable insulation and be easily removed and re-installed. It shall be held in place by adjustable stainless steel hose clamps.
3. Metal jacketing shall be 0.016-inch thick, smooth finish aluminum sheet conforming to ASTM B209, alloy 5005, temper H16, with integral vapor barrier. Sheet metal screws shall be aluminum or stainless steel. Jackets shall be secured with 0.020 by ¾-inch Type 304 stainless steel expansion bands.
2.2 HEAT CABLE
A. Heating cable shall be self-regulating through the use of a thermostat for freeze protection. Heating cable shall be applicable to the type of pipe material being protected.
B. Heating cable shall utilize 120 VAC and provide heating power of minimum of 5 watt/ft @ 50°F.
PART 3 - EXECUTION
3.1 INSTALLATION
A. All insulation and heat cables shall be installed by a qualified insulation CONTRACTOR in strict accordance with the manufacturer's recommendations and the requirements of these specifications.
B. Insulation shall be installed over heat cable where required.
C. Piping shall be tested and shall be approved by the DESIGN/BUILDER prior to insulation installation.
D. All end joints of insulation shall be tightly butted.
E. All seams and joints shall be held by manufacturer's standard adhesive.
F. Jacket laps shall be neatly pasted in place.
G. All joints shall be pointed with insulating cement.
H. Fittings and valves shall be covered with the same material as the pipe, cut in segments to fit snugly without open spaces, held in place with copper wire or cement, and then covered with the same jacketing material as the pipe.
I. Insulation at valves and other devices shall be formed into two halves, easily removable for valve maintenance. The halves shall be constructed from segments cemented together to fit the valve and to extend over the adjacent piping insulation.
J. Insulated fittings adjacent to vapor-barrier insulation shall be sealed with acceptable vapor-barrier cement before installation of the finish jacket.
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K. Pipe insulation and vapor-barrier shall be continuous through hangers and supports. Hangers shall permit insulation to pass through. Suitable saddles shall be provided to prevent the weight of the piping from being supported by the insulation.
END OF SECTION 40 4200
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SECTION 40 6000 CONTROL DESCRIPTIONS & PROGRAM MODIFICATIONS PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The CONTRACTOR shall provide the services of an I&C CONTRACTOR who is skilled and versed in the supply, configuration, installation, programming, commissioning and integration of water and wastewater field instrumentation, electro-mechanical actuators, Programmable Logic Controllers (PLCs), Remote Input Output (RIO) devices, Human Machine Interface (HMI) devices and central Supervisory Control And Data Acquisition (SCADA) systems.
B. The CONTRACTOR shall submit the qualifications of the proposed I&C CONTRACTOR to the OWNER for review and approval, prior to commencement of the work. In general, the I&C CONTRACTOR shall have the following minimum qualifications:
1. Shall have completed a minimum of five (5) water / wastewater integration projects of equal or greater scope using Allen Bradley CompactLogix PLCs and Flex I/O with programming services using the Studio5000 platform.
2. Shall have completed a minimum of five (5) water / wastewater integration projects of equal or greater scope using Wonderware Archestra SCADA platform and Allen Bradley PanelView 6 or greater HMI platforms.
3. Shall have supplied, configured, calibrated field instruments and field controllers similar to those specified in the Project Documents.
4. Shall have experience configuring and testing fiber optic, CAT 5/6 and RS485 serial industrial network systems using Allen Bradley Ethernet /IP and Modbus RTU protocols.
C. This specification includes the general system overview and description of logic modifications for each unit process or piece of equipment being controlled by the central control system. Other sections of Division 40 shall supplement this Section as necessary.
D. The intent of this section is to provide guidance to the I&C CONTRACTOR in the programmable logic function for various I/O signals indicated on the Drawings. The control and monitoring functions described herein cover the basic logic to be performed with each I/O signal. These control descriptions are not intended to cover every possible scenario or describe every possible timer, interlock, safety shutdown, etc. that may be necessary for a complete operational system. The primary function of these control descriptions is to provide the I&C CONTRACTOR with information that cannot be indicated in electrical schematic diagrams such as logic performed by PLC's and/or operator interface software. A brief description of signals to be provided to/from PLC and RIO control panels has also been provided herein.
E. An attempt has been made on the Drawings and in these Specifications to describe system logic and functionality as well as show signals, interlocks, and devices necessary for proper operation of the control and monitoring systems. However, if a particular signal, device, sensor, interposing control relay, signal converter, control logic, interlock (hardware or software), etc., is required to meet the intent or operational requirements and is not indicated, the I&C CONTRACTOR shall furnish and install this piece of equipment with no extra compensation.
F. The I&C CONTRACTOR shall provide a minimum of forty (40) hours of programming/operator interface configuration time for additional modifications or changes in the system logic, operator interface screens and/or SCADA system as requested by the OWNER, OPERATOR or ENGINEER. This additional programming and/or configuration time will take place only after the system has been programmed and tested for proper operation as described herein and will be billed at the I&C CONTRACTOR’s standard rates for a Not to Exceed Value, as included in the Project Bid and Project Contract.
G. All alarm conditions shall be maintained until manually reset and/or acknowledged unless otherwise indicated herein or on the Drawings.
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PART 2 - PRODUCTS (NOT USED - SEE SPECIFICATION SECTIONS 40 9000 & 40 9010) PART 3 - EXECUTION
3.1 EXISTING PLANT CONTROL SYSTEM DESCRIPTION
The existing plant control system consists of several Allen Bradley ControLogix PLCs, with associated Remote I/O cabinets, using Allen Bradley Flex IO hardware. A majority of the plant is controlled either directly (from PLCs) or indirectly (via RIOs) or local operator stations with signalization to the PLC and RIO panels. The PLCs are connected via a central network system, consisting of both CAT 5e and Point-to-Point Fiber Optic cables. A Wonderware central SCADA system is located in the Operations Building and is connected to the central network system at the Main Control Panel PLC, located in the electrical room of the Operations Building.
3.2 MODIFICATIONS TO EXISTING PLANT CONTROL SYSTEMS
A. Documentation of the existing PLC and OIT programs is available from the OWNER and will be available for the I&C CONTRACTOR’s use in completing the Project. The I&C CONTRACTOR is responsible for verifying the program information supplied with the current operating field program files. The I&C CONTRACTOR shall be fully responsible for the proper operation of all control equipment (existing and proposed) and documentation of all modifications made to programs at Project Completion. If, in the event existing documented programs are not correct or available, the I&C CONTRACTOR shall work with the CONTRACTOR and the OWNER to determine the best, most cost effective approach to achieving the project control objectives contained here-in.
B. Allen Bradley CompactLogix – The existing Allen Bradley hardware and programming is to remain intact, with only minor modifications to the network configuration and hardware in the PLCs and RIOs to account for the addition of required I/O and remote devices. Modifications to the existing ladder logic programming are anticipated to be implemented as additional sub-routine programs, with only minor modifications to existing ladder logic when appropriate.
C. Innotech Maxium III (Not in use but present) – The existing Innotech PLC hardware and programming, where encountered, is to remain intact with no modifications to the PLC hardware or ladder programming.
D. Existing SCADA system – The I&C CONTRACTOR shall modify the existing central SCADA system and develop new screens to incorporate all new components, processes, and set-points, which are being added to the facility as part of this Project.
E. Existing HMI systems - The I&C CONTRACTOR shall modify existing Local HMI systems and develop new screens to incorporate all new components, processes, and set-points, which are being added to the associated processes of the facility as part of this Project.
3.3 MODIFICATIONS TO EXISTING PLCs and RIOs
A. The I&C CONTRACTOR shall supply, install, configure, and commission all hardware and software required by the Project Plans and Specifications. Supply of new PLC and RIO hardware shall conform to Specification Sections 40 9000 and 40 9010 contained here-in.
3.4 MODIFICATIONS TO EXISTING PLC PROGRAMMING & CONFIGURATION A. Influent Lift Station Pump Control:
The existing Lift Station PLC program currently provides On/Off control for four (4) pumps (P1- P4), based on level set points, as compared to an analog level signal from the Influent Wet Well.
P1 and P2 are small flow pumps. P3 and P4 are large flow pumps. The I&C CONTRACTOR shall modify the existing influent lift station PLC program to add an additional large pump (P5) to the control sequence. P5 controls shall be a duplicate of the operational, monitoring and alarm sequences of pumps P3 and P4.
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B. Aeration Blower Control:
The existing Aeration Blower PLC program currently provides On/Off and variable capacity / speed control to three (3) equal capacity blowers (B1 – B3) and the Open/Closed position of Aeration Valves V1 and V2. The blowers are arranged such that B1 is dedicated to the North Biolac Aeration Basin, B3 is Dedicated to the South Biolac Aeration Basin and B2 is a redundant blower, which can feed either Biolac Aeration Basin, based on the Open/Closed position of Aeration Valves V1 (to North Biolac Aeration Basin) and V2 (to South Biolac Aeration Basin). The capacity / speed command to the blowers is determined by the Biolac Control Panel PLC which determines a calculated air demand for each Biolac Aeration Basin. This value is sent to the Aeration Blower Control Panel, which intern, adjusts the capacity / speed control of the operating blower for that basin. The CONTRACTOR will be relocating the modulating actuators on V1 and V2 to new 16” control valves, which will be installed on the dedicated feed pipes to each Biolac Aeration Basin. Additionally, the CONTRACTOR will be installing a fourth equal-capacity blower (B4) on the existing discharge manifold. In this configuration, all four (4) blowers will discharge into a common discharge manifold, which can supply either Biolac Aeration Basin.
Therefore, the I&C Contractor shall modify the existing Aeration Blower Control PLC program to add an additional blower (B4) to the control sequence. B4 controls shall be a duplicate of the operational, monitoring and alarm sequences of blowers B1- B3. Additionally, the I&C CONTRACTOR shall modify the programming to control the number of operating blowers based on the sum of the air demands, as transmitted by the Biolac Control Panel PLC. The program shall stage blowers On/Off as Lead, Lag, Lag1 and Lag 2, based individual On/Off Airflow Set Points for each designation. Additionally, the program shall automatically alternate Lead, Lag, Lag1 and Lag2 based on a 168-hour (1 week) timer and a Rotation Time set point. The rotation shall be fixed such that the Lead becomes Lag2, Lag2 becomes Lag1, Lag1 becomes Lag and Lag becomes Lead.
If, during operation, any of the blowers fails to operate when its position is called to run or the machine is otherwise out of service, the program shall automatic call the next successive position to operate in its place.
The I&C CONTRACTOR shall also provide additional programming to control the relocated modulating air supply valve actuators to deliver the correct air flow to each Biolac Aeration Basin, based on the air demand for that basin, as transmitted from the Biolac Control Panel PLC to the Aeration Blower Control PLC. The valve control shall use a Most Open Valve (MOV) control strategy to reduce excess backpressure on the blowers, which translates in to additional wasted energy. Using the existing FCI Air Flow Meters on each Biolac Aeration Basin supply pipe, the control shall maintain the valve associated with the basin with the highest air demand in the maximum open position and modulate the valve associated with the basin with the lowest air demand as needed to maintain the transmitted air flow set point. If a Biolac Aeration Basin is taken out of service, its associated air control valve shall automatically move to the Closed position and the remaining basin air control valve shall move to the Maximum Open position. If both basins are taken out of service, both air control valves shall close and all blowers shall be set to the Off condition.
C. Biolac Aeration Basin Control:
The existing Biolac Control Panel PLC provides Open/Closed control of eleven (11) individual air supply valves on each basin, via a dedicated Modbus RTU network to the valve actuators. The valves are selected to be in one of four (4) groups. Open Group, Closed Group, A Group, B Group. In the Open Group, the associated valve is always Open. In the Closed Group, the associated valve is always Closed. When selected to be in either A or B Group, the Open/Closed position of the valve is determined by a flip-flop timer set point in which, Group A is Open for a period of time while Group B is Closed. At the pre-determined time set point, Group B Opens and Group A Closes. This repeats on a continuous loop basis so long as the basin is in service. In addition to valve control, each Biolac Aeration Basin has a Dissolved Oxygen (DO) probe, which is installed at the end outlet structure of the basin. The DO probe sends information back to the Biolac Control Panel PLC, which uses this information to calculate the air demand set point for 722
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that basin. The CONTRACTOR will be installing two (2) additional DO probes in each Biolac Aeration Basin at the 1/3 basin length locations as shown on the Project Plans. Additionally, the CONTRACTOR will be installing a new Multi-parameter probe unit at the location of the existing DO probes. The new DO probes provide additional DO signals and the Multi-parameter probe provides DO, pH, ORP, NO3 and Temperature readings via the existing Modbus RTU network for the associated basin.
Therefore, the I&C CONTRACTOR shall provide programming and configuration to the existing Biolac Control Panel PLC, which adds these new devices to the existing control tags and displays the values on the local HMI and central SCADA system. In addition, the I&C CONTRACTOR shall provide an additional sub-routine program which allows the operator to Enable / Disable Nitrate Trim of the existing air demand set point, based on feedback from the Multi-parameter NO3 reading. Additionally, the I&C CONTRACTOR shall change the existing DO control feedback value from the existing DO probe to the new Multi-parameter probe DO reading for standard Biolac DO control. The program shall continuously monitor the NO3 in the associated basin and provide a rolling 30-minute average value (mg/l), based on a sampling frequency of 10 seconds. When Enabled, the Nitrate Trim will add XXX CFM to the standard DO-based calculated air flow set point if the rolling average NO3 is below the Low NO3 set point, based on an interval timer set point of between 0 and 30 minutes. If the rolling average NO3 is above the High NO3 set point, the Nitrate Trim will subtract XXX CFM from the calculated air flow set point, based on the same interval timer set point time.
D. Secondary Clarifier RAS/WAS Control:
The existing RAS/WAS pump system consists of three (3) equal-capacity pumps (P1-P3), which remove settled / thickened sludge from the bottom of two (2) existing secondary clarifiers. The pumps convey the sludge, by common manifold, to either the RAS return line or the WAS waste line. The pumps are supplied with On/Off and speed control from the Main Control Panel PLC located in the electrical room of the Operations Building. There are currently several modes of RAS operation, which can be selected by the operator. These consist of Constant Speed Set Point Control, Constant Flow Rate Set Point Control and Flow Ratio Control (Ratio of Influent Flow Rate to RAS Flow Rate). The CONTRACTOR will be installing new Sludge Blanket Level Sensors in each clarifier and new suspended solids meters on the MLSS inlet feed box to the clarifiers and the RAS/WAS discharge manifold of the RAS/WAS pump station. Additionally, the CONTRACTOR will be installed modulating valve actuators on the manual underflow plug valves, feeding the suction manifold of the RAS/WAS pump station.
The I&C CONTRACTOR shall provide new configuration and tagging to add these devices to the existing control system and central SCADA system. Additionally, the I&C CONTRACTOR shall provide new programming, using a Most Open Valve (MOV) strategy, to modulate the new underflow valve actuators to balance the outflow from each clarifier evenly, based on flow rate feedback from the existing RAS and WAS Flow Meters and the existing Underflow Flow Meters on each clarifier. I.E. with both clarifiers in service, RAS + WAS = Underflow 1 + Underflow 2 with modulation to maintain Underflow 1 = Underflow 2. If either clarifier is out of service, its associated valve shall automatically move to full Closed position. The program shall also allow the operator to select Full Open, Full Closed, % Position and Auto modes of operation for each underflow valve actuator.
The I&C CONTRACTOR shall provide new programming, which adds an additional RAS Sludge Level Control mode to the existing RAS operating modes. This mode of operation will seek to maintain a Sludge Blanket Level Set Point in each operating clarifier, by operating in the existing Flow Control Mode, buy adjusting the existing Flow Rate Set Point automatically, based on feedback from the new Sludge Blanket Level Sensors. When both clarifiers are in operation, the control shall use the average level reading of both Sludge Blanket Level Sensors. When only one clarifier is in operation, the control shall only use the associated Sludge Blanket Level Sensor.
The I&C CONTRACTOR shall provide additional programming, which adds an additional WAS 723
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mode to the existing WAS control program. The new Mass Solids WAS mode shall use the existing WAS flow meter and the new RAS/WAS solids meter to calculate the total pounds of solids wasted each day. In this mode, the operator shall be able to enter the Total Pounds/Day to be wasted and the control will operate the WAS control valve to Open (based on the current programming time scheduler) and stay Open until the Total Pounds/Day set point is met; at which time the valve will close for that day.
E. Secondary Clarifier Polymer Addition Control:
The CONTRACTOR will be installing two new polymer injection systems in a new building adjacent to the existing RAS/WAS pump station. The polymer systems will be used to mix and inject emulsion polymer into the existing feed splitter box of the secondary clarifiers. The new polymer systems (Poly1 and Poly2) have limited control and signalization, which will be connected to the existing Clarifier RIO Control Panel. Each polymer system has a 4-20mA analog input, which controls the speed of the polymer dosing pump; a dilution water solenoid valve, which controls the supply of dilution water into the polymer system; and two (2) digital output signals for “Running” and “Fault” conditions.
Therefore, the I&C CONTRACTOR shall provide new configuration and programming in the Main Control Panel PLC, which will utilize the new RIO hardware installed in the Clarifier RIO Control Panel to control the new polymer systems. The polymer systems will be installed as Lead and Standby, with selection of the Lead unit made by the operator from the central SCADA system and/or the Clarifier HMI. Each polymer system shall have a virtual Hand-Off-Auto selector on the SCADA system and/or Clarifier HMI. In Hand, the associated polymer system will be called to operate and will be run at a fixed speed as entered by the operator (0-100%). In Off, the associated polymer system will not operate. In Auto, the associated polymer system will be called to operate when selected as the Lead, or when the Lead system fails to operate, and will be controlled using an operator selectable Flow-paced Control mode or Solids-paced Control mode. In either mode, the polymer system will not operate until the combined MLSS Feed Flow Rate from the North and South Biolac Aeration Basins exceeds the Enable Polymer Flow Rate Set Point. When this occurs, the Lead polymer unit will activate and its associated dilution water solenoid valve will open. In Flow-paced mode, the speed command of the operating polymer system will be continuously adjusted to maintain a constant dose set point ratio (# Polymer / MGD flow), under varying combine MLSS Feed Flow Rates. In solids-paced control mode, the speed command of the operating polymer system will be continuously adjusted to maintain a constant dose set point ratio (# Polymer / # Dry Solids), under varying combined MLSS Feed Flow Rates and varying RAS/WAS solids concentration as read from the new RAS/WAS solids meter.
3.5 PLANT ALARMS
A. Plant alarms shall be provided for each piece of new process equipment with at least a Fault alarm.
Plant alarms shall be provided for each field instrument with High and Low Alarm Set Points.
Alarms will follow the existing alarm strategy and be categorized into three alarm levels as follows:
1. Level 3 alarms will be displayed on the SCADA System and at each operator interface.
The alarm will remain displayed on each operator interface until the operator acknowledges and resets the alarm at the operator interface.
2. Level 2 alarms will also be displayed on the SCADA system and each operator interface, but will activate an external alarm horn & beacon after a 10-minute time delay. The alarm will remain activated until the operator acknowledges and resets the alarm at an operator interface.
3. Level 1 alarms will be displayed on the SCADA system and each operator interface, activate the external alarm horn/beacon, after 10 minutes and initiate an auto dial alarm system to call offsite operators. The alarm will remain activated until the operator acknowledges and resets the alarm at an operator interface. The auto dial alarm system can be reset from a touch-tone telephone or operator remote intervention via SCADA.
END OF SECTION 40 6000
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SECTION 40 9000 – INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS PART 1 – GENERAL
1.1 REQUIREMENT
A. This section includes the general requirements for furnishing and installing the Instrumentation, Control and Monitoring equipment as indicated on the Drawings and specified in Division 40 – Process Integration of these Specifications. Other instrumentation and control sections of this Division shall supplement this Section as necessary.
B. The intent of the instrumentation and control sections of Division 40 – Process Integration is to require that all instrumentation as indicated, specified and/or required, shall be furnished by a single competent, qualified Instrumentation and Control Integrator (hereinafter referred to as the I&C INTEGRATOR) to assure system compatibility and coordination with all other subsystems.
C. Labor, materials, apparatus, and components essential to the complete functioning of systems described and indicated herein, or which may be reasonably implied as essential, whether mentioned in the Contract Documents or not, shall be furnished and installed by the I&C INTEGRATOR. In case of doubt as to the work intended, or in the event of need for explanation thereof the I&C INTEGRATOR shall refer to the OWNER for supplemental instructions.
D. All items not specifically mentioned in these specifications or noted on the Drawings, or on shop drawings, but which are necessary to make a complete and satisfactory, working electrical/instrumentation installation, shall be deemed to be included herein. The Construction Documents are not intended to show every fitting, junction, or component nor every difficulty that may be encountered during installation or coordination with different equipment manufacturers.
The I&C INTEGRATOR shall refer to related data in all Contract Documents and shall verify this information on site.
E. Unless otherwise indicated, all equipment and components shall' be rated for use in the environment installed. Outdoor equipment shall be weatherproof or rated for outdoor use. Equipment installed in corrosive areas shall be rated for that environment. Equipment installed in a hazardous area shall be explosion-proof. In case of doubt as to the area classification, or need for explanation thereof, or discrepancies noted between components specified and the environment installed the I&C INTEGRATOR shall refer to the OWNER or supplemental instructions.
1.2 REFERENCES
A. The specifications reference known standards and codes. Each such standard referenced shall be considered a part of the Specifications to the same extent as if reproduced therein in full. The following is a representative list of such Associations, Institutes and Societies, together with the acronym by which each is identified.
AIEE American Institute of Electrical Engineers
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
ICEA Insulated Cable Engineers Association
IEEE Institute of Electrical and Electronics Engineers
NEC National Electrical Code (2002)
NEMA National Electrical Manufacturers Association
NETA National Electrical Testing Association
NFPA National Fire Protection Association
UL Underwriter's Laboratories, Inc
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B. Every reference in the Specifications shall mean the latest printed edition of each in effect at the Contract date or latest edition as adopted by the local governing authority.
1.3 SUBMITTALS
A. Submittals shall be furnished in accordance with Section 01 3300 – Submittal Procedures.
1. Where applicable, provide complete manufacturer's part number, identifying scaling, operating range, housing and wetted parts materials, NEMA rating, product options, consumable materials, and other pertinent information.
2. Prior to Final Acceptance of the work, the I&C INTEGRATOR shall provide Operations and Maintenance Manuals, in accordance with the Contract Documents.
3. Descriptive Data: Submit copies of complete descriptive literature, performance data, physical dimensions, power and signal connections for each component and equipment to be furnished. Provide name of manufacturer, style, and complete model number. Listing items "as specified" without both make and model or type designation is not acceptable.
4. Important Notice:
a. After material or equipment has been submitted and approved, no substitutions will be allowed.
b. If I&C INTEGRATOR's submittal(s) depart from the Contract Documents, the I&C INTEGRATOR shall make specific mention thereof in his letter(s) of transmittal, otherwise review of such submittals by the ENGINEER shall not constitute review of such departure(s).
c. The I&C INTEGRATOR may be charged for costs incurred by the ENGINEER for third and subsequent submittal reviews. Cost for ENGINEER's review time shall be billed at the ENGINEER's standard hourly rates.
5. Control System Drawings: Submit 11" X 17" detailed shop drawings indicating dimensions, component layout, mounting details, wiring diagrams, nameplate legends and bill of materials for each control panel.
a. Wiring diagrams shall include all interconnections, inter-wiring and terminals between all electrical and/or instrumentation units. Wire numbers shall be continuous from start to finish. Wire numbers shall not change when going from one unit, cabinet, enclosure, terminal or any device to another.
b. Discrete control and power circuits: Submit ladder diagrams indicating all panel devices related to discrete functions mounted in or on control panel. c. Show unique rung numbers on left side of each rung. Label each wire, coil and terminal block. Show individual component terminal numbers.
d. Analog signals: Indicate the entire analog loop on the wiring diagram including all devices connected in series and location of each device. Indicate loop power supplies and individual component terminal numbers. Indicate wire and terminal numbers of each device in the loop.
e. Use different symbols for terminal blocks located in different pieces of equipment.
Label each terminal block and wire termination point.
f. Show each PLC / RIO I/O point rack, slot, terminal number and PLC configured address on each drawing.
6. Submit a complete PLC I/O listing including instrument tag numbers and descriptions. The I/O list shall contain the PLC rack, slot, terminal number and PLC address. Submit a complete PLC program database cross-reference list linking each database and internal register with its associated I/O point(s).
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1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this Section shall be the product of firms regularly engaged in the design and manufacture 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 I&C INTEGRATOR from responsibility for the proper installation and functioning of the work.
B. The manufacture shall provide a 2-year equipment warranty.
C. The I&C INTEGRATOR must have a minimum of three (3) years’ experience as a system integrator, panel fabricator and instrumentation supplier for other projects of similar type, size and requirements. The I&C INTEGRATOR must submit documentation from his selected panel fabricator verifying the experience and UL 508A file number.
D. See Addition Minimum Requirements for qualification as the I&C INTEGRATOR in Specification 40 6000.
E. All equipment furnished shall be new and of current design. Like equipment shall be of the same manufacturer.
1.5 SYSTEM RESPONSIBILITY
A. The I&C INTEGRATOR shall have total responsibility for the work as specified in the instrumentation and control specifications of this Division. This includes but is not necessarily limited to furnishing system components, system integration and design, wiring diagrams, loop drawings, programming, installation supervision, field instrument calibration, start-up, testing and operator training. The I&C INTEGRATOR is responsible to verify existing field conditions, including the functionality and capability of the existing PLC to be reprogrammed to incorporate any new process controls.
B. The I&C INTEGRATOR is a subcontractor. Therefore, references made to the responsibilities and requirements of the ENGINEER shall only mean that the responsibilities and requirements pass through the ENGINEER and that the final responsibility for all Control and Instrumentation systems rests with the I&C INTEGRATOR.
1.6 OPERATING AND MAINTENANCE MANUALS
A. Operating and Maintenance Manuals (O&M): The I&C INTEGRATOR shall provide O&M manuals for equipment and materials furnished under this contract. Submit number of copies as specified in Division 1 – General Requirements of these specifications (min 4). Assemble data in a single complete indexed volume and identify the size, model, and features indicated for each item.
Equipment O&M manuals shall include the following information as a minimum:
1. A neatly typewritten index near the front of the manual furnishing immediate information as to the location in the manual of emergency data regarding installation.
2. Installation requirements and procedures.
3. Complete instructions regarding the operation and maintenance of equipment involved.
Instructions and documentation not related to the equipment furnished must be removed or crossed out. O&M manuals must be individually tailored to the project and equipment as furnished.
4. Bill of Materials, component data sheets, descriptive literature, product specification sheets, wiring diagrams and calibration procedures. O&M manuals must be individually tailored to the project and equipment as furnished.
5. Complete nomenclature of replaceable parts, part numbers, current cost, name and address of nearest vendor of replacement parts. Information on equipment or components not related to equipment furnished must be removed or crossed out. O&M manuals must be individually tailored to the project and equipment as furnished
6. Copy of warranties issued on the installation, showing dates of expiration.
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B. Operator interface/PLC cross-reference table/interface list. The cross-reference list shall include all PLC registers linked to each operator interface display feature. The list shall include the operator interface tag, PLC address, I/O type and range of analog signals in engineering units.
C. Four (4) copies of the final PLC programs on 8-1/2" x 11" paper and two (2) copies on CDROM/ Flash Drive after final acceptance of the project. The electronic copies shall be a complete set of fully documented programming files as used by the I&C INTEGRATOR in programming all PLCs.
The programs (including electronic copies provided) shall be well documented with control descriptions.
D. Two (2) copies of all final operator interface configuration files on CDROM/ Flash Drive after final acceptance of the project.
1.7 RECORD DRAWINGS
A. Record Drawings: Upon completion of work, I&C INTEGRATOR shall furnish a complete set of Record Drawings and Shop Drawings which properly reflect final tested system, loop diagrams, PLC programs, etc., as actually installed. Drawings shall accurately record the final constructed system and shall be labeled as "RECORD".
1.8 COORDINATION
A. The I&C INTEGRATOR shall coordinate with all other equipment manufacturers to avoid conflicts and interferences. No extra compensation will be allowed for changes made necessary due to conflicts between various equipment.
B. Any discrepancies noted in these contract documents or discrepancies between Drawings and actual field conditions shall be promptly brought to the ENGINEER for a decision. No extra compensation will be allowed for changes made by the I&C INTEGRATOR without the ENGINEER’s consent.
C. The I&C INTEGRATOR shall be responsible for coordination of any control panel fabrication, testing and instrumentation system installation with configuration of both PLC's and operator interface's. Project completion will not be granted to the I&C INTEGRATOR until programming and configuration has been completed and complete automatic operation has been tested.
1.9 WARRANTY
A. In addition to specific warranties required by the Specifications, the I&C INTEGRATOR shall leave the entire installation in complete working order and free from defects in materials, workmanship or finish. I&C INTEGRATOR shall repair or replace at his own expense any part that may develop defects due to faulty material or workmanship during the tests and within a period of one year (minimum, or as indicated elsewhere) after substantial completion acceptance. The I&C INTEGRATOR shall repair or replace existing equipment and work that is damaged during the repair of defective apparatus, materials or workmanship at no cost to the OWNER.
B. All manufacturers’ warranties shall be filled out in their entirety by the I&C INTEGRATOR for the OWNER using the OWNER's name and address. Equipment warranty periods will commence on date of final acceptance.
PART 2 – PRODUCTS
2.1 STANDARD EQUIPMENT
A. Furnish and install equipment of the type specified which has been proven to operate successfully.
Material or equipment that has been specified or called out by manufacturer and/or model number is approved by the ENGINEER. All other equipment may be selected based on equal quality and performance. If the I&C INTEGRATOR wishes to use an alternate manufacturer to that indicated on the plans or specified herein, the I&C INTEGRATOR shall submit to the ENGINEER for approval, along with a written request stating the reason(s) for the substitution. The ENGINEER and the OWNER shall review such requests and have final approval prior to purchase or installation. The I&C INTEGRATOR shall be responsible for the design and installation 728
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requirements with no additional charge/fee to the OWNER.
B. All control panel components shall be UL recognized and ground fault protected per UL 508A fabrication standards. Each control panel assembly shall bear a serialized UL 508A label.
C. All instrumentation equipment and control panel components shall be capable of operating successfully at full-rated load, without failure, at an ambient air temperature of 50°C, and specifically rated for the altitude in which the equipment will be placed in service. If equipment cannot operate under the specified conditions or excessive heat build-up is expected to exceed component rating, the I&C INTEGRATOR shall supply heat mitigation measures to reduce the operating temperature within the control space to that specified by the manufacturer.
D. Instrument tubing shall be soft annealed, ASTM B280 copper with soldered connections. Tubing bends shall be made with a tubing bender. Tubing shall be run straight, vertical or horizontal and secured with straps or clamps.
PART 3 – EXECUTION
3.1 FACTORY ACCEPTANCE TEST
A. Prior to final acceptance of the work, the I&C INTEGRATOR shall certify the equipment and installation included under this Section to be free of defects, and suitable for trouble-free operation under the conditions set forth in these specifications. This requirement is in addition to the manufacture's guarantee.
B. Before delivering any control panels to the site, the I&C INTEGRATOR shall notify the ENGINEER in writing at least two weeks prior so that a factory acceptance test can be performed.
The test shall be conducted only after the I&C INTEGRATOR has performed his testing, calibrations and check-out of the system.
C. The PLC and operator interface programs shall be thoroughly tested. Each input and output signal shall be tested for proper indication and control function. The PLC control logic will be tested by using simulated inputs and tripping interlocks.
D. The factory acceptance test shall be conducted by the I&C INTEGRATOR. The test shall be witnessed by the ENGINEER.
E. A successful factory acceptance test only allows the I&C INTEGRATOR to ship the system to the site. It does not constitute final acceptance by the OWNER.
3.2 INSTALLATION
A. Equipment and materials specified in this Section shall be installed and connected as specified, and as shown on the Plans. The I&C INTEGRATOR shall coordinate the installation with the other trades, to insure proper installation of the control instrument, components and associated conduit and cables.
B. The I&C INTEGRATOR shall calibrate the instruments to the proper ranges, as required by the OWNER and the ENGINEER. Where analog signals are connected to local or remote monitoring equipment, the I&C INTEGRATOR shall verify that the calibrated ranges and scaling of the local and remote indicators are correct.
C. The I&C INTEGRATOR shall furnish the services of instrumentation technicians or control system engineers trained and experienced in the installation of the various instrument and control equipment being supplied. These services shall be utilized by the I&C INTEGRATOR as he deems necessary to supervise installation, calibrate, troubleshoot and put equipment into service.
3.3 INSTRUMENT CALIBRATION
A. The I&C INTEGRATOR shall provide the services of a factory representative with the proper tools and equipment to properly calibrate and adjust each instrument in the field. The ENGINEER shall be notified when the factory representative will be onsite to witness instrumentation calibration and 729
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setup. This site visit by the factory representative may also be utilized for the OWNER designated operator training as required below.
B. Each instrument shall be tested with certified test instruments simulating inputs at 0, 25, 50, 75, and 100 percent of the calibrated range. Ten (10) data points shall be recorded by ascending to 100 percent than descending back to O. Data shall be recorded on a prepared Instrument Calibration Report with the following information:
1. Instrument description
2. Type and location of service
3. Manufacturer, model and serial number of instruments
4. Scale range and engineering units
5. Testing method and description
6. Input values or settings
7. Output values (recorded data)
8. Calibrations notes or explanations
9. Technician's name, date and signature
10. Copy of the test instrument calibration report. Testing instrument must have been calibrated within one year prior to calibration date.
3.4 FINAL ACCEPTANCE
A. Upon completion of instrument calibration and system validation, all systems to be retested under process conditions. The OWNER, ENGINEER and I&C INTEGRATOR shall perform this test as a final acceptance test for each instrument or piece of equipment. The process variables will be pushed to their limit to verify accuracy, alarms and interlocks. Any defects or problems will be corrected immediately. Once all testing has been completed to the OWNER's satisfaction, the I&C INTEGRATOR shall submit a certified report with all substantiating data sheets indicating that the total instrumentation and control system meets the functional intent of the Contract Documents.
B. After installation of the system and checkout by the OWNER, ENGINEER and I&C INTEGRATOR, a performance test shall be performed per Section 01 7700 - Contract Closeout.
The test shall include an operational demonstration during which the system shall run continuously without loss of basic functions. The operational demonstration shall confirm that the status, alarm, and process variable signals are valid and are being updated appropriately. If additional time or tests are need due to improper function of the control system, the I&C INTEGRATOR shall perform the necessary work at no cost/fee to the OWNER.
3.5 SPARE PARTS
A. Provide the OWNER with a list of the manufacturers' recommended spare parts.
END OF SECTION 40 9000
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SECTION 40 9010 – PRIMARY SENSORS AND FIELD INSTRUMENTS PART 1 - GENERAL
1.1 DESCRIPTION
A. Scope:
1. Provide primary sensors and field instruments as required by the Contract Documents.
B. Related Sections:
1. Section 40 6300.13 – Instrumentation and Control for Process Systems.
1.2 QUALITY ASSURANCE
A. Acceptable Manufacturers:
1. Furnish primary process measurement devices by the named manufacturers or ENGINEERapproved equal equipment by other manufacturers.
2. The named manufacturers have been specified to establish the standard of quality and performance of the equipment to be supplied.
3. Obtain all sensors and field instruments of a given type from the same manufacturer.
B. Manufacturers' Responsibilities and Services:
1. Design, manufacturing, field supervision, inspection, start-up, and training in accordance with the requirements of Section 40 6300.13 – Instrumentation and Control for Process Systems.
1.3 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Comply with the requirements specified in Section 40 6300.13 – Instrumentation and Control for Process Systems.
B. Primary process measurement devices shall not be delivered to the Site until all product information and sensors and instrument submittals have been approved.
1.4 MATERIALS OF CONSTRUCTION FOR WETTABLE PARTS
A. Provide compatible materials of construction for primary sensors and field instrument (wetted) parts that come in contact with the process fluids shown on the drawings.
1.5 IDENTIFICATION TAGS
A. Performance Requirements:
1. Tag numbers of sensors and field instruments shall be in accordance with tag naming convention outlined on the instrumentation list. For items not shown or specifically tagged, the item tag number shall be established by the system supplier in accordance with tag naming convention. All instruments, whether field or panel mounted, shall have an identification tag.
2. Include the identifying tag number, manufacturer, model number, service, and range.
3. Fasten tags to the device with self-tapping stainless-steel screws. Where fastening with screws cannot be accomplished the tags shall be permanently attached to the device by a circlet of stranded stainless-steel wire rope and clamp.
4. All sensors and field instruments mounted on or within control panels and enclosures shall have the identification tag installed so that the engravings are easily visible to service personnel. Panel mounted devices shall have the tag attached to the rear of the device.
B. Construction Features:
1. Tags shall be engraved with 3/16-inch letters and constructed as follows. a. 3/32-inch-thick laminated phenolic for engraving composed of core, laminated on both sides with a matte (non-glare) finish cover sheet.
b. Core to be black; cover sheet to be white.
c. Mounting holes to be centered on width and 1/4-inch from each end. 731
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1.6 FILLING LIQUID
A. Use silicone except for process fluids containing chlorine. When the process fluid contains chlorine, the filling liquid shall be Halocarbon 63 or Flurolube 63.
PART 2 – PRODUCTS
2.1 INSTRUMENTATION
A. Provide instrumentation as noted on the Equipment List, P&ID, and drawings.
2.2 PROCESS TAPS, SENSING LINES AND ACCESSORIES
A. Water Pressure Sensing Lines and Accessories for Flow and Pressure Transmitters:
1. Material: Copper Water Tube, ASTM B88, Type L, drawn temper or annealed.
2. Pressure Rating: 150 psi.
3. Size: 1/2-inch O.D. for water.
4. Connections: Brass Compression Type, "Swagelok" by Crawford, or ENGINEER-approved equal.
5. Shut-Off Valves:
a. Type: Ball
b. Pressure Rating: 150 psi.
c. Body, Ball and Stem: Brass
d. Packing: High Density TFE
e. Handle: Nylon with metal travel stops
f. Support Rings: TFE coated brass
g. End Connections: Removable "Swagelok", or ENGINEER-approved equal h. Model: Whitey 45 Series for water, or ENGINEER-approved equal
6. Manifolds:
a. Type: 5-valve and 3-valve meter manifolds.
b. Materials: Type 316 stainless steel body, bonnets, and stems; Delrin seats; Teflon packing.
c. Products and Manufacturers:
1) Anderson-Greenwood
2) Or ENGINEER-approved equal
B. Pressure Tap Sensing Lines and Accessories for Pressure Gauges and Pressure Switches:
1. For Process Sensing Taps in Ductile Iron, Steel and Stainless-Steel Piping Systems:
a. Material and Fittings: Type 304 stainless steel pipe (ASTM A312) and threaded fittings and adapters (ASTM A403).
b. Sizes: 1/2-inch minimum for main sensing piping and 1/4-inch gauge and switch connections.
c. Pressure Rating: Equal to or greater than the applicable system pressure. d. Accessories:
1) For applications not requiring diaphragm seals, provide separate 1/2-inch Type 316 stainless steel threaded ball valve for each gauge and switch. 2) For applications requiring diaphragm seals, provide a separate 1/2-inch threaded Type 316 stainless steel ball valve for seal process side shutoff.
2. For Process Sensing Taps in Copper and Thermoplastic Piping Systems:
a. Pipe Material and Fittings: Use same type of pipe material and fittings as that used in the process piping system.
b. Sizes: 1/2-inch minimum for main process sensing piping and 1/4-inch for gauge and switch connections.
c. Accessories:
1) For copper piping system taps with or without seals, provide a separate 1/2-inch 732
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minimum threaded brass or bronze ball valve for each gauge and switch. 2) For PVC piping systems with or without diaphragm seals, provide a separate 1/2-inch threaded ball valve for process sensing line shutoff.
2.3 LEVEL SWITCH - FLOAT TYPE
A. Type: Direct acting, pear shaped, eccentric weighted, displacement type liquid level sensor.
B. Construction Features:
1. Float Body: Hollow hermetically sealed, rigidly molded of polypropylene containing mechanical switch and eccentric metal weight. The use of mercury floats is NOT acceptable.
2. Mechanical Switch: SPDT switch rated 10-16 amps resistive at 120 VAC and five amps resistive at 30 VDC.
3. Weight: Weight to cause sensor to hang straight down from cable when not immersed and only allow float to pivot when immersed in liquid.
4. Electrical Cable:
a. Heavy duty, three conductor, flexible and submersible cable, sheathed in PVC and connected to float and switch with watertight seal.
b. Cable Length: CONTRACTOR shall coordinate and confirm required cable length as required.
C. Products and Manufacturers:
1. Flygt, Model ENM-10
2. Conery, 2900 Series
3. Or ENGINEER-approved equal.
2.4 WET FLOOR/SUMP DETECTION LEVEL SWITCH
A. Type: Displacement Type Switch
B. Performance Requirements:
1. Magnetically actuated make and break
C. Construction Requirements:
1. Float Material: Stainless Steel
2. Cable Jacket Material: Neoprene
3. Slosh Shield Material: Lucite
4. Stem and Mounting Hardware: Stainless Steel
5. Mounting Bracket Hardware: Stainless Steel Strut
6. Hermetically Sealed N.C. Dry Reed Switch Rated at 50 V.
7. Waterproof, 2-Conductor 18/2 Cable, Six Feet Long with Waterproof Connection D. Accessories:
1. Cable Length: CONTRACTOR shall coordinate and confirm required cable length extension as required.
2. Slosh Shield
3. Wall Mounting Bracket
E. Products and Manufacturers:
1. Gems, LS-270 Series
2. Or ENGINEER-approved equal
2.5 PRESSURE TRANSMITTER
A. Type: Solid State two-wire, differential capacitance, or resonant wire type transmitter B. Function: Monitor system pressures. The transmitter shall display the monitored pressure value and shall output a 4 to 20 mADC signal proportional to the monitored pressure. 733
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C. Performance Requirements:
1. Positive Overrange Protection: At least 1.25 times the maximum span limit
2. Local Indication: Yes
3. Accuracy (includes combined effects of linearity, hysteresis, and repeatability): ±0.10 percent of calibrated span
4. Repeatability: 0.05 percent of calibrated span
5. Hysteresis: 0.05 percent of calibrated span
6. Stability (drift over a six-month period): Not more than ±0.25 percent of transmitters upper range limit
7. Power: Designated to operate on power from receiver or remote power supply, nominal 24 VDC
8. Supply Voltage Effect: Output change not greater than 0.005 percent of span for each one volt change in supply power
9. Output:
a. Isolated direct acting 4 to 20 mADC
b. Digital process variable signal superimposed on 4 to 20 mADC signal without compromising loop integrity
10. Ambient Temperature Limits: -20°F to +180°F
11. Ambient Temperature Effect (Total Error per 100°F change between the Ambient Temperature Limits): Not more than ±1.0 percent of the transmitters upper range limit (maximum span)
D. Construction Features:
1. Measuring elements protected by sealing diaphragm
2. Non-Wetted Parts:
a. Body and Process Connection Bolting: Type 316 stainless steel b. Housing and Cover: Die cast low copper aluminum alloy finished with epoxy paint system; covers shall be threaded and seated on Buna-N O-rings; NEMA 4 rating.
3. Process Wetted Parts: To be compatible with the process fluid.
4. Calibration Adjustments:
a. Zero: Adjustable in electronics compartment
b. Span: Coarse and fine adjustments in electronics compartment
5. Zero Elevation and Suppression: The extent that the amount of suppression plus the calibrated span does not exceed the upper range limits of the sensor.
6. Damping: Internal Adjustable
7. Built-in electrical surge and RFI protection
8. Provide a single shutoff valve at each process line tap to enable live process removal of transmitter.
9. Provide Type 316 stainless steel three valve manifold for shutoff and pressure equalization on differential pressure and flow measurement applications.
10. Electrical Conduit Connection: 1/2-inch NPT
11. Process Connection: 1/2-inch NPT
12. Stainless steel mounting bracket and hardware suitable for mounting transmitter on flat vertical surface or a 2-inch diameter pipe.
13. Indicator: Provide integral indicator with range in engineering units.
E. Accessories:
1. Valves: As Required by the Contract Documents.
2. Hand held interface with keyboard and LED display capable of easily configuring and testing the transmitter.
F. Products and Manufacturers:
1. Endress + Hauser, Cerabar S Model
2. Or ENGINEER-approved equal
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2.6 PRESSURE GAUGE
A. Type: Bourdon Tube Pressure Element Type, Liquid Filled Gauge (For Pressure Ranges of 15 psi and Greater and Vacuum Ranges to 30-inches Hg):
B. Performance Requirements:
1. Accuracy: ±0.5 percent of span (ANSI B40.1 Grade 2A).
C. Construction Features:
1. Case:
a. Solid front design constructed of glass filled polyester. b. Color: Black
2. Size: 4-1/2-inch
3. Ring: Threaded, glass filled polyester
4. Window: Glass
5. Dial: White with black markings
6. Filling Liquid: Glycerin
7. Overpressure protection: Full blowout back
8. Bourdon Tube and Socket:
a. Type 316 stainless steel
b. Heliarc welded, unless otherwise specified
9. Movement:
a. Type 300 series stainless steel
b. Rotary geared with Teflon S coating, or cam and roller type c. Built-in overload and underload movement stops
10. Connection: 1/4-inch male NPT, bottom
11. Mounting: Stem Mount
12. Calibration:
a. Adjustable pointer
b. Externally accessible zero adjustment
D. Accessories:
1. Pressure Snubber: Sintered stainless steel snubber threaded into gauge socket or in external stainless steel housing with 1/4-inch NPT male and female connections
2. Process Isolation: Provide ball valves for process isolation.
E. Products and Manufacturers:
1. Ashcroft, Duragage 1379 Series
2. Helicoid, Series 900
3. Wika EN 837
4. Or ENGINEER-approved equal
2.7 DIAPHRAGM SEAL
A. General:
1. Furnish diaphragm seals for pressure gauges and switches at locations shown and as specified.
2. The complete diaphragm seal assembly, including gauge, switch, or transmitter, shall be factory assembled, filled, and calibrated to the ranges and switch setpoints specified prior to shipment.
3. System Supplier Manufacturer shall be responsible for assuring that fill volumes and sensitivities of the supplied seals and diaphragms are suitable to provide the required gauge, switch, or transmitter accuracy over the specified measurement range or at switch setpoints.
4. Location and orientation of the gauges, switches and seal assemblies shall be coordinated with the actual piping and equipment installations so that gauges and indicators shall be easily read and accessed for maintenance by plant personnel. 735
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5. Where field mounting and orientation conflicts arise due to incomplete coordination with field changes in the process piping and equipment installation, assemblies shall be relocated, re-oriented, re-assembled and re-calibrated as directed by the ENGINEER.
B. Construction Features:
1. Instrument Connection: 1/4-inch NPT
2. Process Connection: 1/2-inch NPT
3. Flushing Connection: 1/4-inch NPT
4. Top Housing Materials: Type 316 stainless steel.
5. Process Side Housing Materials:
a. Type 316L stainless steel for metallic piping
b. PVC or CPVC to match non-metallic piping
6. Bolting Materials: Type 316 stainless steel
7. Diaphragm, O-Rings, and Gasket Materials: Teflon
C. Accessories:
1. Provide fill/bleed screw to permit filling of instrument and diaphragm seal.
2. Provide a clean-out ring which holds the diaphragm captive in the upper housing to allow the upper housing assembly to be removed for recalibration or cleaning of the process side housing without the loss of filling liquid or change in calibration.
D. Products and Manufacturers:
1. Helicoid, Type 100 HAC
2. Or ENGINEER-approved equal
2.8 MAGNETIC FLOWMETER AND TRANSMITTER
A. Type: Flowmeter with Pulsed DC Magnetic Flow Transmitter B. Function: Monitor liquid flows. The transmitter shall display the monitored flow value and shall output a 4 to 20 mADC signal proportional to the monitored flow.
C. Performance Requirements:
1. Accuracy (with analog output):
a. ±0.5 percent of flow rate, or better, over a range from 1 fps to 31 fps b. ±0.005 fps, or better, at flows below 1 fps
c. 0 Upstream/0 Downstream straight run options shall be provided as required for consistent and accurate measurement.
d. Accuracy unaffected by changes in fluid velocity, density, pressure, temperature, or conductivity (above minimum conductivity limits)
e. System accuracy shall be proven by submittal of flow test curves of the actual meters being furnished.
1) Test curves shall show a minimum of ten equally spaced flow points. Tests shall be performed using water and a weight or volume tank. A “master meter” used as a reference standard is not acceptable. The test setup shall be submitted and approved prior to testing.
2. Repeatability: ±0.15 percent of flow rate, or ±0.0015 fps, whichever is greater
3. Drift: Complete zero stability
4. Minimum Fluid Conductivity Limit: Five microsiemens per centimeter or less
5. Minimum Pre-Amp Input Impedance: 1012 ohms
6. Power:
a. 120 VAC ± 10 percent, 60 Hz, ±3 Hz power supply.
b. Power Consumption shall not exceed 50 watts for flowmeter and transmitter combined.
7. Output:
a. 4 to 20 mA DC, direct acting and isolated, into 0 to 1000 ohms 736
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b. High accuracy, field adjustable scaled pulse output (0.1 to 10 Hz or greater) to drive local totalizer
8. Operating Temperature: Suitable for operation with process fluid temperature from 0°F to 140°F
9. Flow Range: As Specified in the Contract Documents.
10. Pipeline Size: As Specified in the Contract Documents.
D. Construction Features
1. Flowmeter:
a. Type: Lined metal flowmeter
b. Interchangeability: Ratio of flow velocity to voltage reference signals generated identical for all meter sizes to permit interchangeability with transmitter without requiring circuit modifications.
c. Tube Material: Type 304 stainless steel
d. Electrode:
1) Conical or elliptical shaped.
2) Material: Compatible with the process fluid
e. Lining: Compatible with the process fluid
2. Enclosure:
a. Materials and Rating:
1) Cast low-copper aluminum alloy or fabricated sheet steel 2) NEMA 6 rated
3) Capable of withstanding accidental submergence in 30 feet of water for 48 hours b. Finish: Finish exterior, except for flange faces, with a high build epoxy paint c. End Connections: ANSI Class 150 suitable for mating with pipe specified d. Electrical Connections: 3/4-inch NPT tapped holes for power conduit fitting and signal conduit fittings
3. Pulsed DC Magnetic Flow Transmitter:
a. Materials and Rating:
1) Die cast, low-copper aluminum alloy
2) NEMA 4 rated
b. Solid state construction
c. Local Indication:
1) 3-1/2 digit minimum LCD meter with field selectable engineering units 2) Seven-digit electromechanical totalizer or eight-digit electronic LCD totalizer with reset and lithium battery backup. Totalizer shall be integral with transmitter and visible through viewing window or shall be externally mounted in a separate NEMA 4X enclosure or condulet with viewing window and installed adjacent to the transmitter. Totalizer shall read forward, reverse, and net flow. d. Pulse and analog outputs galvanically isolated from input and earth ground e. Automatic zeroing feature making it unnecessary to zero the instrument before or after placing it in operation
f. Pre-calibrated span adjustment providing continuous span adjustment over entire range.
g. Range Adjustment: Direct reading thumbwheel switches or calibrated potentiometer, continuously adjustable for full scale settings from 1 to 31 feet per second. h. Signal Conditioning: Adjustable damping circuit with response times of 1 to 25 seconds minimum.
i. Low Flow Cutoff: Provide automatic low flow cutoff circuitry to stop pulse output and local totalization when flow drops below 0.5 percent ± 0.2 percent of the calibrated upper range valve.
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E. Accessories:
1. Mounting:
a. Provide complete Type 316 stainless steel mounting hardware. b. Transmitter and driver electronics shall be mounted from the flow tubes at locations shown.
c. Type of mounting (wall, support frame or pipe stand) as required.
2. Shielded cable assemblies of sufficient length for connection between flowmeter and transmitter electronics.
3. Type 316 stainless steel grounding rings for flowmeter.
4. Type 316 stainless steel grounding straps.
5. NEMA 4X rated 120 VAC power on-off selector switch as specified in Article 2.2, above.
6. The CONTRACTOR shall provide a spare spool piece for replacement of each different size flow tube where no bypass piping is provided.
7. One calibrator suitable to calibrate all flow tubes provided.
F. Products and Manufacturers:
1. Toshiba, LF620F/LF622F
2. Endress + Hauser, Promag 400.
3. Or ENGINEER-approved equal.
2.9 AIR FLOW SWITCH
A. General:
1. Switches shall be capable of providing reliable monitoring of the movement of air produced within a system. The switch shall consist of a sensing element, such as a vane or paddle, positioned in the path of the air flow and mounted in an orientation that does not hinder the function of the sensing element. When the sensing element is actuated, it shall trigger a switch mechanism.
B. Performance: Requirements
1. Process Connection: ½” NPT Connection.
2. Switch Type: Normally Open (NO). Contact Closed with Air Flow
3. Setpoint: Single Setpoint, Adjustable Deadband
4. Switch Contacts: 120V or 24VDC per Contract Documents
5. Features/Ratings: As Required by Hazardous Classification
6. Mounting: Duct Mounted, Orientation as required by the Contract Documents C. Manufacturers
1. Larson Electronics
2. Or ENGINEER-approved equal.
2.10 DISSOLVED OXYGEN SYSTEM (Aqua Troll 500 or Approved Equal) A. Multiparameter controller display module with interchangeable sensors and wiper port
1. Parameters: Dissolved Oxygen, Nitrate, ORP, pH, Temperature and Level
2. Power: 24VDC
3. Communications: MODBUS
B. Dissolved Oxygen Sensor (RDO PRO-X or Approved Equal)
1. Range: 0 to 60 mg/L
2. Accuracy: ±0.1 mg/L (0 to 20 mg/L) and ±0.2 mg/L of reading (20 to 60 mg/L)
3. Resolution: 0.01 mg/L
4. Temperature Range: 0° to 50° C (32° to 122° F)
C. Nitrate Sensor (Temperature or Conductivity sensor needed)
1. Range: 0 to 40,000 mg/L as N
2. Accuracy: ±10% or ±2 mg/L
3. Resolution: 0.01 mg/L
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4. Temperature Range: 0° to 50° C (32° to 122° F)
D. Manufacturers
1. In-Situ
2. Or Equal.
2.11 SUSPENDED SOLIDS / SLUDGE BLANKET DEPTH SYSTEM (CM448 or Approved Equal) A. Multiparameter transmitter with 8 measuring channels
1. Power: 100 to 230 VAC, 50/60 Hz
2. Communications: Ethernet/IP
3. Features:
a. Six (6) Digital Sensors
b. Two (2) 4 to 20mA Output
c. Four (4) Relay Output
d. Two (2) Digital Output
e. Two (2) Digital Input
f. Two (2) 4 to 20mA Input
B. Suspended Solids Probe (Turbimax CUS51D or Approved Equal)
1. Material: Stainless Steel 316L
2. Process Connection: G1 and ¾” NPT Connection.
3. Range: 0 to 300 g/L
4. Temperature Range: -20° to 80° C (-4° to 176° F)
C. Ultrasonic Sludge Blanket Sensor (Turbimax CUS71D or Approved Equal)
1. Process Connection: G1 and ¾” NPT Connection.
2. Range: 0.3 to 10 m (1 to 32 ft)
3. Resolution: 0.01 mg/L
4. Temperature Range: 1° to 50° C (34° to 122° F)
D. Manufacturers
1. Endress + Hauser
2. Or ENGINEER-approved equal.
2.12 SPARE PARTS AND TEST EQUIPMENT
A. Furnish and deliver the spare parts and test equipment per manufacturer’s requirements.
B. Spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended.
C. All spare parts shall have been operated and tested in the factory as part of factory testing prior to shipment of the control system.
D. Furnish and deliver the spare parts and test equipment as outlined below, identical to and interchangeable with similar parts furnished under this Section.
E. For process sensors and all other analog instruments, the supplier shall submit a separate quotation for a recommended list of spare parts and test equipment. Each item recommended shall be listed and priced separately. The spare parts quotation shall contain a statement that the prices quoted are firm for a period of one year from the installation date of the equipment, and that the supplier understand that the OWNER reserves the right to purchase none, any, or all of the parts quoted.
The supplier is required to show that a stock of spare parts and test-equipment is obtainable within a 48-hour period.
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PART 3 - EXECUTION
3.1 INSTALLATION
A. Provide the services of qualified factory-trained servicemen to assist in the installation of the instrumentation and control system equipment.
B. Install each item in accordance with manufacturer's recommendations. Transmitters and instruments, which require access for periodic calibration or maintenance, shall be mounted so they are accessible while standing on the floor. Care shall be taken in the installation to ensure sufficient space is provided between instruments and other equipment or piping to allow for easy removal and servicing.
C. Mount and anchor items and instrument components using stainless steel hardware.
D. All field instruments shall be rigidly secured to walls, stands or brackets as required by the manufacturer.
E. Conform to all applicable provisions of the NEMA standards, NEC and local, State and Federal codes when installing the equipment and interconnecting wiring.
3.2 START-UP, CALIBRATION, TESTING, AND TRAINING
A. Provide manufacturer datasheet and field verification documentation that instruments have been installed per manufacturer’s instructions and recommendations.
B. Verify instrument range against manufacturer datasheet in the field.
C. Test instruments as part of facility testing for integration with the existing controls.
D. Train operators with a focus on instrument maintenance, cleaning, housekeeping, and field calibration/range verification.
END OF SECTION 40 9010
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SECTION 40 9213 PRIMARY CONTROL VALVES
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Provide all valve and gate actuators and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all valves and gates, except where otherwise indicated in the Contract Documents.
C. Single Manufacturer: Where two or more valve or gate actuators of the same type or size are required, the actuators shall all be produced by the same Manufacturer.
1.2 SUBMITTALS
A. General: Submittals shall be furnished in accordance with Section 01 3300 – Submittals and Section 40 0560 – Common Work Results for Process Valves. The shop drawing shall substantiate compliance with the Contract Documents requirements.
B. Shop Drawings: Shop Drawings of all actuators shall be submitted together with the valve and gate submittals as a complete package.
PART 2 – PRODUCTS
2.1 GENERAL
A. General: Unless otherwise indicated, all shut-off and throttling valves, and externally actuated valves and gates, shall be provided with manual or power actuators. All actuators shall be complete and operable with mounting hardware, motors, gears, controls, wiring, solenoids, hand wheels, levers, chains, and extensions, as applicable. All actuators shall be capable of holding the valve in any intermediate position between fully open and fully closed without creeping or fluttering.
B. Manufacturers: Where indicated, certain valves and gates may be provided with actuators manufactured by the valve or gate Manufacturer. Where actuators are furnished by different manufacturers, coordinate selection to have the fewest number of manufacturers possible.
C. Materials: All actuators shall be current models of the best commercial quality materials and liberally sized for the maximum expected torque. All materials shall be suitable for the environment in which the valve or gate is to be installed.
D. Mounting: All actuators shall be securely mounted by means of brackets or hardware specially designed and sized for this purpose and of ample strength. The word "open" shall be cast on each valve or actuator with an arrow indicating the direction to open in the counter-clockwise direction.
All gear and power actuators shall be equipped with position indicators. Where possible, manual actuators shall be located between 48 and 60 inches above the floor or the permanent working platform.
E. Standard: Unless otherwise indicated and where applicable, all actuators shall be in accordance with ANSI/AWWA C 540 - AWWA Standard for Power-Actuating Devices for Valves and Sluice Gates.
F. Functionality: Electric, pneumatic, and hydraulic actuators shall be coordinated with the power requirements of Division 26 - Electrical and instrumentation equipment requirements indicated in Division 40 – Process Integration.
2.2 MANUAL ACTUATORS
A. General: Unless otherwise indicated, all valves and gates shall be furnished with manual actuators.
Valves in sizes up to and including 8 inches shall have direct acting lever or handwheel actuators of the Manufacturer's best standard design. Larger valves and gates shall have gear-assisted manual 741
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actuators, with an operating pull of maximum 60 pounds on the rim of the handwheel. All buried and submerged gear-assisted valves, all gates, all gear-assisted valves for pressures higher than 250 psi, all valves 30 inches in diameter and larger, and where so indicated, shall have worm-gear actuators, hermetically-sealed and grease-packed, where buried or submerged. All other valves 10 inches to 24 inches in diameter may have traveling-nut actuators, worm-gear actuators, spur- or bevel-gear actuators, as appropriate for each valve.
G. Buried Valves: Unless otherwise indicated, all buried valves shall have extension stems (or bonnets where shown on the plans) to grade, with square nuts or floor stands, position indicators, and castiron or steel pipe extensions with valve boxes, covers and operating keys. Where so indicated, buried valves shall be in cast-iron, concrete, or similar valve boxes with covers of ample size to allow operation of the valve actuators. Covers of valve boxes shall be permanently labeled as requested by the OWNER, or the DESIGN/BUILDER. Wrench-nuts shall comply with AWWA C 500 – Metal-Seated Gate Valves for Water Supply Service, and a minimum of 2 operating keys, or one key per 10 valves, whichever is greater, shall be furnished.
H. Buried and Submerged Actuators: Buried and submerged valve actuators and gear assemblies shall be provided with Type 304 and/or 316 stainless steel bolting and trim, and shall be rated for continuous submerged service. If buried, the valve actuator shall be suitable for a submerged service at a water depth of 10 feet (minimum). If submerged, the actuator shall be suitable for a submerged service at a water depth of 30 feet (minimum).
PART 3 – EXECUTION
3.1 INSTALLATION
A. All valve and gate actuators and accessories shall be installed in accordance with Section 40 0560 – Common Work Results for Process Valves. Actuators shall be located to be readily accessible for operation and maintenance, without obstructing walkways. Actuators shall not be mounted where shock or vibrations will impair their operation, nor shall the support systems be attached to handrails, process piping, or mechanical equipment.
END OF SECTION 40 9213
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SECTION 40 9243 – ELECTRIC ACTUATORS
PART 1 – GENERAL
1.1 THE REQUIREMENT
A. Furnish and install electric actuators in accordance with the Contract Documents.
1.2 RELATED WORK SPECIFIC ELSEWHERE
A. Related Sections:
1. Division 26 – Electrical
1.3 SUBMITTALS
A. Submittals shall be furnished in accordance with the requirements of the General Section.
B. Submit complete manufacturer catalog information showing dimensions, electrical requirements, operating instructions, etc.
1.4 OPERATION & MAINTENANCE MANUALS
A. Operation and Maintenance Manual shall be furnished in accordance with the requirements of the General Section.
1.5 QUALITY ASSURANCE
A. The manufacturer shall provide a 2-year equipment warranty.
PART 2 – PRODUCTS
2.1 ELECTRIC ACTUATORS
A. General: The CONTRACTOR shall verify with the vendor/manufacturer that each electric actuator (supplied and installed) delivers the necessary torque requirements for opening and closing the corresponding valve that it is actuating, and provide supporting documentation to the DESIGN/BUILDER. Electric actuators shall be suitable as specified on the plans for use on 115 VAC, 1-phase, or 480 VAC, 3-phase, 60Hz power supply. The actuators shall incorporate motor, integral reversing starter, local control facilities and terminals for remote control and indication connections housed within a self contained, sealed enclosure.
1. In order to maintain the integrity of the enclosure, setting of the torque levels, position limits and configuration of the indication contacts, etc. shall be carried out without the removal of any actuator covers over an Infrared interface. Sufficient commissioning tools shall be provided with the actuators and must meet the enclosure protection and certification levels of the actuators. Commissioning tools shall not form an integral part of the actuator and must be removable for secure storage/authorized release. In addition, provision shall be made for the protection of configured actuator settings by a means independent of access to the commissioning tool.
2. The actuator shall include a device to ensure that the motor runs with the correct rotation for the required direction of valve travel irrespective of the connection sequence of the power supply.
B. Enclosure: Actuators shall be 0-ring sealed, watertight to /IP68 7m for 72hrs, NEMA 4, 6. The motor and all other internal electrical elements of the actuator shall be protected from ingress of moisture and dust when the terminal cover is removed for site for cabling. The terminal compartment shall have the same ingress protection rating as the actuator with the terminal cover removed. Enclosure must allow for temporary site storage without the need for electrical supply connection. The enclosure shall be acceptable for use in the following locations:
1. Non-hazardous indoor or outdoor location to protect against wind-blown dust and rain, splashing water and hose-directed water.
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2. Hazardous locations classified as Class I and II, Groups C, D, E, F, and G as defined in the National Electrical Code plus non-hazardous locations to protect against wind-blown dust and rain, splashing water and hose-directed water (i.e. CSA Enclosure 4 and 7 – Explosionproof and Weatherproof).
3. All external fasteners shall be zinc plated stainless steel. The use of unplated stainless steel or steel fasteners is not permitted.
C. Actuator Sizing: The actuator shall be sized to guarantee valve closure at the specified differential pressure and temperature. The safety margin of motor power available for seating and unseating the valve shall be sufficient to ensure torque switch trip at maximum valve torque with the supply voltage 10% below nominal. For linear operating valves, the operating speed shall be such as to give valve closing and opening at approximately 10-12 inches per minute unless otherwise noted.
For 90 valve types the operating time will be specified. Actuator manufacturer/vendor shall confirm appropriate opening and closing times for the valve the actuator is operating.
D. Environmental: Actuators shall be suitable for indoor and outdoor use. The actuator shall be capable of functioning in an ambient temperature ranging from -33°C (-27°F) to 70°C (158°F), up to 100% relative humidity. Actuators for hazardous area applications shall meet the area classification, gas group and surface temperature requirements specified in data sheet.
E. Motor: The motor shall be an integral part of the actuator, designed specifically for valve actuator applications. It shall be a low inertia high torque design, class F insulated with a class B temperature rise giving a time rating of 15 minutes at 40°C (104°F) at an average load of at least 33% of maximum valve torque. Temperature shall be limited by thermostats embedded in the motor end windings and integrated into its control. Electrical and mechanical disconnection of the motor should be possible without draining the lubricant from the actuator gear case.
F. Motor Protection: Protection shall be provided for the motor as follows:
1. Stall - the motor shall be de-energized within 8 seconds in the event of a stall when attempting to unseat a jammed valve.
2. Over temperature - thermostat will cause tripping of the motor. Auto-reset on cooling
3. Single phasing - lost phase protection.
4. Direction – phase rotation correction.
G. Gearing: The actuator gearing shall be totally enclosed in an oil-filled gear case suitable for operation at any angle. Grease lubrication is not permissible. All drive gearing and components must be of metal construction and incorporate a lost-motion hammerblow feature. For rising spindle valves the output shaft shall be hollow to accept a rising stem, and incorporate thrust bearings of the ball or roller type at the base of the actuator. The design should be such as to permit the opening of the gear case for inspection or disassembled without releasing the stem thrust or taking the valve out of service. For 90 operating type of valves, drive gearing shall be self-locking to prevent the valve backdriving the actuator.
H. Manual Operation: A hand wheel shall be provided for emergency operation, engaged when the motor is declutched by a lever or similar means, the drive being restored to power automatically by starting the motor. The hand wheel or selection lever shall not move on restoration of motor drive.
Provision shall be made for the hand/auto selection lever to be locked in both hand and auto positions. It should be possible to select hand operation while the actuator is running or start the actuator motor while the hand/auto selection lever is locked in hand without damage to the drive train. Clockwise operation of the hand wheel shall give closing movement of the valve unless otherwise noted. For linear valve types the actuator hand wheel drive must be mechanically independent of the motor drive and should be such as to permit valve operation in a reasonable time with a manual force not exceeding 400N through stroke and 800N for seating/unseating of the valve.
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I. Drive Bushing: The actuator shall be furnished with a drive bushing easily detachable for machining to suit the valve stem or gearbox input shaft. Normally the drive bush shall be positioned in a detachable base of the actuator. Thrust bearings, when housed in a separate thrust base should be of the sealed for life type.
J. Torque and Turns Limitation: Torque and turns limitation to be adjustable as follows:
1. Position setting range – multi-turn: 2.5 to 100,000 turns, with resolution to 15 deg. of actuator output.
2. Position setting range – direct drive part turn actuators: 90 +/-10, with resolution to 0.1 deg. of actuator output.
3. Torque setting: 40% to 100% rated torque.
4. Measurement of torque shall be from direct measurement of force at the output of the actuator. Methods of determining torque-using data derived from the motor such as motor speed, current, flux, etc. are not acceptable
5. A means for automatic “torque switch bypass” to inhibit torque off during valve unseating and “latching” to prevent torque switch hammer under maintained or repeated control signals shall be provided.
The electrical circuit diagram of the actuator should not vary with valve type remaining identical regardless of whether the valve is to open or close on torque or position limit.
K. Remote Valve Position/ Actuator Status Indication: Four contacts shall be provided which can be selected to indicate any position of the valve. Provision shall be made for the selection of a normally closed or open contact form. Contacts shall maintain and update position indication during hand wheel operation when all external power to the actuator is isolated.
1. The contacts shall be rated at 5A, 250 VAC, 30 VDC. As an alternative to providing valve position any of the four above contacts shall be selectable to signal one of the following:
a. Valve opening, closing or moving
b. Thermostat tripped, lost phase
c. Motor tripped on torque in mid travel, motor stalled d. Remote selected
e. Actuator being operated by hand wheel
2. Provision shall be made in the design for an additional 4 contacts having the same functionality. Provision shall be made in the design for the addition of a contactless transmitter to give a 4-20mA analogue signal corresponding to valve travel for remote indication when required. The transmitter will auto range to the set limits L. Local Position Indication: The actuator display shall include a dedicated numeric/symbol digital position indicator displaying valve position from fully open to fully closed in 1% increments. Valve closed and open positions shall be indicated by symbols showing valve position in relation to the pipe work to ensure that valve status is clearly interpreted. With main power on the display shall be backlit to enhance contrast at low light levels and shall be legible from a distance of at least 6 feet (2m).
1. Red, green, and yellow lights corresponding to open, closed, and intermediate valve positions shall be included on the actuator display when power is switched on. The digital display shall be maintained and updated during hand wheel operation when all power to the actuator is isolated.
2. In addition, the actuator display shall include a separate text display element with a minimum of 32 characters to display operational, alarm and configuration status. The text display shall be selectable between English and one of the following languages: Spanish, German, French, Italian, and Portuguese. Provision shall be made to upload a different language without removal of any covers or using specialized tools not provided as standard with the actuator.
Provision shall be made to orientate the actuator display through increments of 90°. 745
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M. Local Torque Indication: The digital display shall be capable of indicating real time torque and valve position simultaneously, both being displayed in 1% increments of valve position and actuator rated torque. In addition, torque shall also be displayed in horizontal bar graph form.
N. Integral Starter and Transformer: The reversing starter, control transformer and local controls shall be integral with the valve actuator suitably housed to prevent breathing and condensation. The starter shall be suitable for 60 starts per hour (for open/close operation) or 1,200 starts per hour, minimum (for modulating, or proportional control) and of rating appropriate to motor size. The controls supply transformer shall be fed from two of the incoming three phases and incorporate overload protection. It shall have the necessary tappings and be adequately rated to provide power for the following functions:
1. Energization of the contactor coils.
2. 24 VDC output for remote controls.
3. Supply for all the internal electrical circuits.
O. Local Controls: The actuator shall incorporate local controls for Open, Close and Stop and a Local/Stop/Remote mode selector switch lockable in any one of the following three positions: local control only, stop (no electrical operation), remote control plus local stop only. It shall be possible to select maintained or non-maintained local control. The local controls shall be arranged so that the direction of valve travel can be reversed without the necessity of stopping the actuator.
Provision shall be made to orientate the local controls through increments of 90°.
P. Control Facilities: The necessary control, wiring and terminals shall be provided in the actuator for the following functions:
1. Open and close external interlocks to inhibit local and remote valve opening and/or closing control. It shall be possible to configure the interlocks to be active in remote control only.
Remote controls fed from an internal 24 VDC supply and/or from an external supply between 20V and 120 VAC or 20 V and 60 VDC, to be suitable for any one or more of the following methods of control:
a. Open, Close, and Stop control.
b. Open and Close maintained or “push to run” (inching) control. c. Overriding Emergency Shut-down to Close (or Open) valve from a normally closed or open contact.
d. Two-wire control, energize to close (or open), de-energize to open (or close).
2. It shall be possible to reverse valve travel without the necessity of stopping the actuator. The motor starter shall be protected from excessive current surges during rapid travel reversal.
The internal circuits associated with the remote control and monitoring functions are to be designed to withstand simulated lightning impulses of up to 2kV.
3. In locations where the electric actuator is installed 6 feet above the finished grade/floor/working platform the Contractor shall provide a remote control station wired to the electric actuator to allow operation of the valve from the finished grade/floor/working platform.
Q. Monitoring Facilities: Facilities shall be provided for monitoring actuator operation and availability as follows:
1. Monitor (availability) relay, having one change-over contact, the relay being energized from the control transformer will de-energise under any one or more the following conditions:
a. Loss of main or customer 24 VDC power supply
b. Actuator control selected to local or stop
c. Motor thermostat tripped
d. Actuator internal fault
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2. Where specified, provision shall be made for contacts to provide discreet indication of one or more of the following:
a. Remote selected
1) Thermostat trip
2) Actuator fault
3. Actuator text display indication of the following status/alarms:
a. Closed Limit, open limit, moving open, moving closed, stopped b. Torque trip closing, torque trip opening, stalled
c. ESD active, interlock active
d. Thermostat trip, phase lost, 24V supply lost, Local control failure e. Configuration error, Position sensor failure, Torque sensor failure f. Battery low, power loss inhibit
4. Integral data logger to record and store the following operational data:
a. Opening last /average torque against position
b. Closing last /average torque against position
c. Opening motor starts against position
d. Closing motor starts against position
e. Total open/closed operations
f. Maximum recorded opening and closing torque values
g. Event recorder logging operational conditions (valve, control and actuator)
5. The data logger shall record relevant time and date information for stored data.
6. Data logger data is to be accessed via non-intrusive IrDA communication. Sufficient standard intrinsically safe tools shall be provided for downloading data logger and actuator configuration files from the actuators and subsequent uploading to a PC. The actuator manufacturer shall supply PC software to enable data logger files to be viewed and analyzed.
R. Wiring and Terminals: Internal wiring shall be tropical grade PVC insulated stranded cable of appropriate size for the control and 3-phase power. Each wire shall be clearly identified at each end. The terminals shall be embedded in a terminal block of high tracking resistance compound.
The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal and shall be provided with a minimum of 2 threaded cable entries with provision for a maximum of 4.
1. All wiring supplied as part of the actuator shall be contained within the main enclosure for physical and environmental protection. External conduit connections between components are not acceptable.
2. A durable terminal identification card showing plan of terminals shall be provided attached to the inside of the terminal box cover indicating:
a. Serial number
b. External voltage values
c. Wiring diagram number
d. Terminal layout
3. The code card shall be suitable for the CONTRACTOR to inscribe cable core identification alongside terminal numbers.
S. Manufacturers or ENGINEER-approved equal: Note: Models shall be based on specific application and whether that application requires modulating (or proportional control) or open/close only operation. CONTRACTOR shall supply submittals based upon the intended application.
1. Rotork Models IQT, or IQTM (for quarter-turn or modulating quarter turn actuated valves) and IQM (for linear/multi-turn actuated valves and gates). All actuators shall be supplied with required compatible communication protocol modules.
2. ENGINEER-approved equal
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PART 3 – EXECUTION
3.1 INSTALLATION
A. Install per manufacturer’s recommendations.
B. Each actuator shall be supplied with a start-up kit comprising installation instruction manual, electrical wiring diagram and cover seals to make good any site losses during the commissioning period. In addition, sufficient actuator commissioning tools shall be supplied to enable actuator set up and adjustment during valve/actuator testing and site installation commissioning C. Each actuator must be performance tested and individual test certificates shall be supplied free of charge. The test equipment should simulate a typical valve load, and the following parameters should be recorded.
1. Current at maximum torque setting
2. Torque at max. torque setting
3. Flash test voltage
4. Actuator output speed or operating time.
D. In addition, the test certificate should record details of specification such as gear ratios for both manual and automatic and second stage gearing if provided, drive closing direction, wiring diagram number.
END OF SECTION 40 9243
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IDENTIFICATION FOR WATER AND WASTEWATER EQUIPMENT 46 0553 - 1 B810 ADELANTO WWTP IMPROVEMENT PLAN
SECTION 46 0563 – IDENTIFICATION FOR WATER AND WASTEWATER EQUIPMENT PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Nameplates
2. Tags
3. Stencils
4. Labels
1.2 SUBMITTALS
A. Product Data: Submit manufacturers catalog literature for each product required.
B. Shop Drawings: Submit list of wording, symbols, letter size, and color coding for equipment identification and schedule, including equipment number, location, function, and manufacturer's name and model number.
C. Samples: Submit five nameplates, labels, and tags for each size used on Project.
D. Manufacturer's Installation Instructions: Indicate installation instructions, special procedures, and installation.
E. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.
F. Qualifications Statement:
1. Submit qualifications for manufacturer.
1.3 SUSTAINABLE DESIGN SUBMITTALS
A. Manufacturer's Certificate: Products meet or exceed specified sustainable design requirements.
B. Product Cost Data: Verify compliance with Project sustainable design requirements. Exclude cost of labor and equipment to install products.
1. Provide cost data for following products:
a. Salvaged, refurbished, and reused products
b. Products with recycled material content
c. Regional products
1.4 MAINTENANCE MATERIAL SUBMITTALS
A. Extra Stock Materials: Furnish four (4) containers of spray-on adhesive.
1.5 QUALITY ASSURANCE
A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum three years' experience.
PART 2 - PRODUCTS
2.1 NAMEPLATES
A. Manufacturers:
1. Craftmark Pipe Markers
2. Or ENGINEER-approved equal
B. Description: Laminated three-layer plastic with engraved black letters on light, contrasting background color.
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2.2 TAGS
A. Plastic Tags:
1. Manufacturers:
a. Brady ID
2. Or ENGINEER-approved equal
3. Description:
a. Laminated three-layer plastic with engraved black letters on light, contrasting background color.
B. Metal Tags:
1. Manufacturers:
a. Brady ID
b. Or ENGINEER-approved equal
2. Description:
a. Aluminum or Stainless steel construction; stamped letters.
C. Information Tags:
1. Manufacturers:
a. Brady ID
b. Or ENGINEER-approved equal
2. Description:
a. Clear plastic with printed DANGER, CAUTION, WARNING, and message. b. Furnish grommet and self-locking nylon ties.
2.3 STENCILS
A. Manufacturers:
1. Kolbi Pipe Marker Co.
2. Or ENGINEER-approved equal
B. Description:
1. Clean-cut symbols
C. Stencil Paint: As specified in Section 09 9000 - Painting and Coating; semigloss enamel.
2.4 LABELS
A. Manufacturers:
1. Brady ID
2. Or ENGINEER-approved equal
B. Description:
1. Aluminum, Polyester, or Laminated Mylar construction.
2. Adhesive backed, with printed identification
PART 3 - EXECUTION
3.1 PREPARATION
A. Degrease and clean surfaces to receive adhesive for identification materials.
B. Prepare surfaces as specified in Section 09 9000 - Painting and Coating for stencil painting.
3.2 INSTALLATION
A. Identify equipment with plastic nameplates or stencil painting.
B. Identify inline pumps and other small devices with tags.
C. Identify control panels and major control components outside panels with plastic nameplates. 750
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D. Apply stencil painting as specified in Section 09 9000 - Painting and Coating.
E. Install identifying devices after completion of coverings and painting.
F. Install plastic nameplates with corrosion-resistant mechanical fasteners or adhesive.
G. Labels:
1. Install labels with sufficient adhesive for permanent adhesion and seal with clear lacquer.
2. For unfinished covering, apply paint primer before applying labels.
H. Install tags using corrosion-resistant chain.
END OF SECTION 46 0553
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SECTION 46 0600 – SUBMERSIBLE WASTEWATER PUMPS (INFLUENT PUMPS) PART 1. GENERAL
1.1. SCOPE OF WORK
A. The work in this Section shall include furnishing and placing into operation the specified submersible pumps, with discharge connections, lifting chains and guide bars as specified herein and as indicated on the drawings.
1.2. REFERENCES
A. American Society for testing and material (ASTM) International
1. A48: Standard Specification for Gray Iron Castings.
2. A743: Standard Specification Iron-Chromium Nickel, Corrosion Resistant, B. American National Standards Institute (ANSI):
1. B16.1: Standard for Cast Iron Pipe Flanges and Flanged Fittings, 125 lb.
C. Hydraulic Institute: Current Standards.
1. HI 14.6: Hydrodynamic Pumps for Hydraulic Performance Acceptance Tests.
2. HI 11.6: Submersible Pump Tests
1.3. SUBMITTALS
A. Submittal data shall be provided to show compliance with these specifications, plans or other specifications that will influence the proper operation of the pumps.
B. Standard submittal data for approval must consist of:
1. Pump Performance Curves
2. Pump Outline Drawing
3. Station Drawing for Accessories supplied by the Pump Manufacture
4. Electrical Motor Data
5. Installation Instructions
6. Technical Manuals and Parts List
8. Printed Warranty
9. Management system certificate ISO 9001
10. Manufacturer's Equipment Storage Recommendations
11. Manufacturer's Standard Recommended Start-Up Report Form C. Lack of the above requested submittal data is cause for rejection.
1.4. QUALIFICATION REQUIREMENTS
A. The Pump Manufacturer shall provide data on the manufacturer's experience specific to the design, manufacturing, supply, commissioning, and service of solids handling non-clogging submersible sewer pumps. Only Manufacturers with 20 or more years of experience in all identified aspects of the Scope of Supply and who have furnished at least five (5) same / similar pumps in the last five (5) years shall be considered.
B. After installation, a pump system start-up shall be performed by the installing contractor, under the supervision of the Pump Manufacture’s factory authorized representative. 8 hours of field service shall be provided by an authorized, factory trained representative of the pump manufacturer.
Services shall include, but not be limited to, inspection of the completed pump system installation to ensure that it has been performed in accordance with the manufacturer’s instructions and recommendations, supervision of all field-testing and activation of the Pump Manufacturer’s Warranty. The test shall demonstrate to the satisfaction of the Owner and Engineer that the equipment meets all specified performance criteria, is properly installed and anchored, and operates smoothly without exceeding the full load amperage rating of the motor. Upon successful 752
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completion of the start-up services, the Pump Manufacture’s factory authorized representative shall finish a signed document indicated Manufacture’s Certification of Proper Operation.
C. The Pump Manufacturer’s representative and Contractor shall be responsible for coordinating the required field services with each other and the Owner and Engineer prior to scheduled start-up activities. The Contractor shall be responsible for including these activities in the overall project schedule and shall notify the Owner and Engineer two (2) weeks prior to the scheduled start-up activities so that they may be present to witness said activities.
1.5. DELIVERY, STORAGE AND HANDLING
A. The Manufacturer and Contractor shall coordinate delivery of the equipment to the site. The Contractor will be responsible for the proper storage and handling of products under provisions of Section 11000 and the Manufacturer’s requirements and recommendations.
1.6. OPERATIONAL REQUIREMENTS AND WARRANTY
A. The Manufacturer shall have Unitary Responsibility for the proper function of the pumping equipment supplied. The Contractor shall have Unitary Responsibility of the pumping system operation.
B. The pumps shall be provided with prorated 60 months (5 years) warranty against defects in materials and or workmanship. Unless otherwise specified, all other equipment shall be warrantied for 12 months (1 year). The warranty shall be in printed form and previously published as the manufacturer's standard warranty for all similar units manufactured, latest revision. Upon warranty occurrence, the manufacturer's authorized service center shall remove the pump, repair, reinstall and provide start up on the repaired pump. A detailed failure analysis shall be submitted to the Owner for their records summarizing corrective action taken.
C. The manufacturer shall guarantee clog-free operation for a period of 12 months from the date of start-up of the pumps by the local authorized factory representative. A certificate shall be provided to the Owner on the day of start up with the local contact information and effective date. If the impeller clogs with typical solids or modern trash debris normally found in domestic wastewater during this period, an authorized representative shall travel to the jobsite, remove the pump, clear the obstruction, and reinstall the pump at no cost for the Owner. A written report shall be provided to the Owner detailing the service call with pictures for verification purposes.
1.7. SPARE PARTS
A. Provide all spare parts anticipated to be required for the first 2 years of operation as recommended by the manufacturer. At a minimum this shall specifically include the following items.
1. 1 set of all Radial and Axial (Thrust Bearings)
2. Upper and Lower (Inner and Outer) Mechanical seals
3. Casing Seal Gaskets or O-Rings
PART 2. PRODUCTS
2.1. SUBMERSIBLE SEWAGE PUMPS
A. General Requirements
1. The Manufacturer shall supply the specified submersible sewage pump(s) complete; each with discharge connection, guide bars, cable holders, lifting chain and seal leak & thermal motor protection relay. The Contractor shall be responsible for supply of the “balance of system” and installation of all equipment and materials per the Manufacturer’s requirements and recommendations.
2. It shall be possible to lift and lower the pumps on parallel guide bars and connect them to wet well mounted discharge connection. There shall be no need for personal to enter the wet well when removing or reinstalling the pumps.
3. The pump housing shall be prepared for the assembling of a sump mixing valve. The 753
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discharge flange of the pump housing shall be as noted in the plans.
4. The Materials of construction shall be as follows:
a. Pump housing: ASTM A48, Class 35B
b. Impeller and insert ring: A532 ALLOY III A (25% Chrome) c. Cooling jacket: Stainless steel AISI 316
d. Stator housing: ASTM A48, Class 35B
e. Shaft: ASTM A479 S43100-T.
f. Shaft seal: Pump side: - Corrosion resistant Tungsten carbide WCCR g. Shaft seal Motor side: - Corrosion resistant Tungsten carbide WCCR
5. All castings must be blasted before coating. All wet surfaces are to be coated with two-pack oxyrane ester Duasolid 50. The total layer thickness should be at least 120 microns. Zink dust primer shall not be used.
6. Each pump supplied shall be capable of the following guaranteed duty points when supplied by a Variable Frequency Drive (VFD) motor controller:
Minimum Flow: 1,200 US GPM @ 40’ TDH
Design Flow: 2,800 US GPM @ 43’ TDH
Maximum Head: 2,400 US GPM @ 52’ TDH
7. The overall efficiency at these duty points shall be not less than 50% and evaluated and approved according HI 11.6:2012 Grade 2B.
8. Each completed and assembled pump/motor unit shall undergo the following factory tests at the manufacturer’s plant prior to shipment. The Manufacturer shall provide on demand a copy of his quality control plan for these tests and an ISO 9001 factory certificate:
a. Minimum 5-point hydraulic performance test, HI 2B.
b. No-Leak seal integrity test
c. Electrical integrity test
B. Motor Requirements:
1. Each pump shall be equipped with a high-efficiency submersible electric motor with an installed electrical supply cable which includes integral seal leak and thermal sensor leads, capable to operate on a 460 volt, 3 phase, 60 hertz power supplied from a 6-pulse Variable Frequency Drive motor controller.
2. The motor shall be equipped with screened cable suitable for submersible pump applications and of sufficient length as shown in the bid plans. The power cable shall be sized according to NEC and ICEA. The outer jacket of the cable shall be oil resistant chlorinated polyethylene rubber. The cable shall be capable of continuous submergence underwater without loss of watertight integrity to a depth of 65 feet.
3. The motor and fully assembled pump, including cables, shall be Explosion approved according FM CLASS 1 - DIV 1 "C" & "D".
4. The cable entry shall consist of dual cylindrical elastomer sleeves, flanked by washers, all having a close tolerance fit against the cable and the cable entry. Epoxies, silicones, or other secondary sealing systems shall not be considered acceptable.
5. The pump shaft shall rotate on two bearings. Motor bearings shall be permanently grease lubricated and have a nominal L10 lifetime of 50.000 hours. The upper bearing shall be a single deep groove ball bearing. The lower bearing shall be a two row angular contact bearing to compensate for axial thrust and radial forces. Single row lower bearings are not acceptable.
6. The required power input to the motor, at the guaranteed duty points, shall be less than 45 HP.
The motor speed shall be a maximum of 1175 rpm. A performance chart shall be provided upon request showing curves for torque, current, power factor, input/output HP and efficiency.
This chart shall also include data on starting and no-load characteristics 754
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7. The motor shall be provided with an integral motor cooling system. A stainless steel cooling jacket shall encircle the stator housing, providing for dissipation of motor heat regardless of the type of pump installation. An impeller, integral to the cooling system and driven by the pump shaft, shall provide the necessary circulation of the cooling liquid through the jacket. The cooling liquid shall pass about the stator housing in the closed loop system in turbulent flow providing for superior heat transfer. The cooling system shall have one fill port and one drain port integral to the cooling jacket.
8. The motor shall be protected by 3 thermal switches embedded in the stator set to open at 284°F (140°C) and one leakage sensor floating type located in a leakage chamber below the main bearing. The sensor and the switches shall be connected to the control panel which shall stop the motor and send an alarm when the sensors are activated.
9. The pump shall be capable of operating in a continuous condition in a liquid with a temperature up to 104°F even when the motor is not submerged.
10. The junction chamber containing the terminal board shall be hermetically sealed from the motor by an elastomeric compression seal. Connection between the cable conductors and stator leads shall be made with threaded compression type binding posts permanently affixed to a terminal board. The motor and the pump shall be produced by the same manufacturer.
11. The motor shall be capable of no less than 30 evenly spaced starts per hour and be able to operate throughout the entire pump performance curve from shut-off through run-out.
12. The stator windings shall be insulated with moisture resistant Class H insulation rated for 356°F.
C. Impeller Requirements:
1. The submersible pumps shall have a semi-open multi-vane self-cleaning impeller designed to transport wastewater with fibrous materials and municipal sludge with up to 8% Dry Solids content.
2. The impeller shall be wear-resistant against sand and grit, which are expected to be present in the pumped fluid. Impellers shall be made of high chromium cast iron with at least 24% chrome or have equal to or better hardness and wear resistance. Impellers that have surface hardening (by thermal, coating, etc.) will not be allowed.
3. The impeller blades shall be self-cleaning upon each rotation as they pass across a sharp relief groove in the Insert ring and shall keep the impeller blades clear of debris. The clearance between the insert ring and the impeller leading edges shall be adjustable.
4. The impeller shall be mounted on the motor shaft. Couplings shall not be accepted.
D. Mechanical Seal Requirements:
1. Each pump shall be provided with a positively driven dual, tandem mechanical shaft seal system consisting of two seal sets, each having an independent spring. The lower primary seal, located between the pump and seal chamber, shall contain one stationary and one positively driven rotating corrosion and abrasion resistant tungsten-carbide ring. The upper secondary seal, located between the seal chamber and the seal inspection chamber shall be a leakage-free seal. The upper seal shall contain one stationary and one positively driven rotating corrosion and abrasion resistant tungsten-carbide seal ring. The rotating seal ring shall have small backswept grooves laser inscribed upon its face to act as a pump as it rotates, returning any fluid that should enter the dry motor chamber back into the lubricant chamber. All seal rings shall be individual solid sintered rings. Each seal interface shall be held in place by its own spring system. The seals shall not depend upon direction of rotation for sealing. Mounting of the lower seal on the impeller hub is not acceptable. Shaft seals without positively driven rotating members or conventional double mechanical seals containing either a common single or double spring acting between the upper and lower seal faces are not acceptable. The seal springs shall be isolated from the pumped media to prevent materials from packing around them, limiting their performance. Any leakage passing the sealing shall not pass the bearings.
Before it reaches the bearings, the liquid shall create an alarm via the floating leakage sensor. 755
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2. Each pump shall be provided with a lubricant chamber for the shaft sealing system. The lubricant chamber shall be designed to prevent overfilling and to provide lubricant expansion capacity. The drain and inspection plug, with positive anti-leak seal shall be easily accessible from the outside. The seal system shall not rely upon the pumped media for lubrication. Seal lubricant shall be non-hazardous.
3. Where a seal cavity is present in the seal chamber, the area about the exterior of the lower mechanical seal in the cast iron housing shall have cast in an integral concentric spiral groove.
This groove shall protect the seals by causing abrasive particulate entering the seal cavity to be forced out away from the seal due to centrifugal action.
2.2. EQUIPMENT FOR WET WELL INSTALLATION
A. For each pump the Manufacturer shall supply and the Contractor shall install a discharge connection made of cast iron ASTM A48, Class 35B. Sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal to metal watertight contact. Sealing of the discharge interface with a diaphragm, O-ring or profile gasket will not be acceptable.
B. The outlet flange of the discharge connection shall be as required by the Project Plans and Specifications drilled according ANSI B16.1-89; tab.5.
C. The pump(s) shall be automatically and firmly connected to the discharge connection, guided by no less than two parallel guide bars extending from the top of the station to the wet well mounted discharge connection. The material of the guide bars shall Stainless steel AISI 316 and shall be nonsparking (spark resistant).
D. The length of the guide bars shall be as shown in the Project Plans and they shall be fastened at the top of the access hatch with a guide bar holder made of Stainless steel AISI 316.
E. For each pump the Manufacturer shall supply and the Contractor shall install a cable holder made with 4 hooks of Stainless steel AISI 316.
F. Upon completion of installation, there shall be no need for personnel to enter the wet-well to retrieve and service the submersible pump(s).
G. The sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal to metal contact. Sealing of the discharge interface with a diaphragm, O-ring or profile gasket will not be accepted. The entire weight of the pump/motor unit shall be borne by the pump discharge elbow. No portion of the pump/motor unit shall bear on the sump floor directly or on a sump floor mounted stand.
2.3. LIFTING EQUIPMENT FOR PUMPS
A. Each pump shall be fitted with a ANSI 316 stainless steel lifting chain of sufficient length to be 10% longer than the maximum dimension measured from the top of the motor to the bottom of the wet well hatch. The Contractor shall install ANSI 316 stainless steel lifting cable of sufficient length to extend up to 5’ above the finished floor, access hatch or tank wall when pulled taunt by a lifting device. The lifting cable shall be supplied and installed with removable ANSI 316 stainless steel shackles on each end. The working load of the lifting system shall be a minimum of 200% of the pump weight.
PART 3. PRODUCTS
3.1. INSTALLATION
A. CONTRACTOR shall install the equipment in accordance with the Project Plans and Specifications, installation requirements of Project Specification Section 11100 and per the Manufacturer’s written installation instructions and requirements.
END OF SECTION 46 0600
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SECTION 46 3333 – POLYMER BLENDING AND FEED EQUIPMENT
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Polymer blending units and feed systems
2. Chemical metering pumps
3. Skid-mounted supports, frames, and floor stands
4. Valves and piping appurtenances
5. Flow meters
6. System control panels
7. Control features
8. Mixing chamber
1.2 SUBMITTALS
A. Product Data: Manufacturer information, including system materials, component equipment, and performance characteristics
B. Shop Drawings:
1. Dimensional drawings and details
2. Schedule of equipment components
3. Materials of construction
4. Wiring and control diagrams
5. Installation and anchoring requirements, including fasteners and other details
6. Mounting details, and location and elevation of electrical controls and panels C. Manufacturer's Certificate: Products meet or exceed specified requirements.
D. Manufacturer Instructions: Installation requirements, including storage and handling procedures, special field procedures, anchoring, and layout.
E. Source Quality-Control Submittals: Indicate results of shop tests and inspections.
F. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections.
G. Manufacturer Reports: Indicate that equipment has been installed according to manufacturer instructions.
H. Qualifications Statements:
1. Qualifications for manufacturer and installer
2. Manufacturer's approval of installer
1.3 CLOSEOUT SUBMITTALS
A. Project Record Documents: Record installed locations and final orientation of equipment and accessories.
1.4 QUALITY ASSURANCE
A. Materials in Contact with Potable Water: Certified according to NSF 61 and 372.
B. Manufacturer: Company specializing in manufacturing products specified in this Section with three years' experience.
C. Installer: Company specializing in performing Work of this Section with three years' experience.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Store materials according to manufacturer instructions. 757
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B. Protection:
1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas.
2. Provide additional protection according to manufacturer instructions.
1.6 EXISTING CONDITIONS
A. Field Measurements:
1. Verify field measurements prior to fabrication.
2. Indicate field measurements on Shop Drawings.
1.7 WARRANTY
A. Furnish 2-year manufacturer's warranty for polymer blending and feed equipment.
PART 2 - PRODUCTS
2.1 POLYMER BLENDING AND FEED EQUIPMENT
A. Manufacturer/Model:
1. DynaBlend / Model L4S-1200 (OR ENGINEER-approved equal) B. Description:
1. Unit process capable of automatic metering, dilution, mixing, activation, and feeding of liquid polymer.
2. Materials of Construction:
a. Structural frame: 304 stainless steel
b. Plumbing: PVC, nylon, stainless steel
c. Mixing chamber: PVC, acrylic
3. Dimensions: Frame: 24” wide x 18” deep x 40” high
C. Components:
1. Neat Polymer Pump:
a. Type: Peristaltic Metering Pump
b. Drive: Automatic Variable Speed with Manual Override c. Motor shall be direct-coupled to a gear reducer.
d. Pump shall be direct-coupled to gear reducer.
e. Dilution Water Flow Rate: 120 to 1200 gph at 45 to 60 psig above pressure at point of use.
f. Polymer Flow Rate: 0.125 to 2.5 gph.
g. Operation: Manual and automatic, with 4-20 mA dc pacing signal. h. Pump shall include a leak detection system to detect leakage from the pump tubing or connections within the pump unit.
i. Rotor speed shall not exceed 500 rpm.
2. Water Flow Rate Measurement: Rotometer as specified in Section 40 7005 – Primary Sensors and Field Instruments
3. Needle Valve Assembly
4. Mixing Chamber
a. Polymer and water shall be mixed in a chamber designed to create sufficient mixing energy based on the dilution water flow and pressure.
b. Solution shall undergo a tapered mixing intensity as it exits the initial high sheer zone. c. Polymer activation efficiency shall be consistent over the dilution water range. d. The volume of the mixing chamber shall be sufficient to provide sufficient residence time for activating and disentangling polymer molecules. e. Mixing chamber shall include an injection check valve. 758
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5. Dilution Water Control
a. The primary water flow rate shall be manually adjustable through a precision throttling needle value prior to addition of chemical polymer and flow into the mixing chamber. b. Unit shall have an electric solenoid valve for on/off control of total dilution water flow.
Valve shall have brass body with NBR seals and NEMA 4X rated coil enclosure. c. A rotometer shall be provided for the measurement and indication of the dilution water stream.
d. Dilution water and solution output connections shall include PVC ball valves and unions in the piping to aid in servicing the polymer injection system.
6. Plumbing Connections:
a. Dilution water inlet, 1” FNPT
b. Neat polymer inlet, 3/8” OD Tube
c. Solution discharge, 1” FNPT
D. Operation:
1. Electrical Characteristics:
a. 0.5 hp
b. Voltage: 115 V, single phase, 60 Hz.
c. Electrical Connections:
1) Standard, grounded male plug: 120 / 1 / 60, 17 amps
2) Terminal blocks: 4-20 mA signal input
3) Terminal blocks: dry contact alarm output
4) Terminal blocks: dry contact run output
2. Control Panel/Controls:
a. Factory mounted.
b. NEMA 4X Enclosure
c. Single-point power connection and grounding via standard 120V/15A male receptacle plug.
d. Unit shall accept a 4-20 mA analog signal to pace the polymer metering pump. e. An integral timer shall monitor loss of flow and energize contacts indicating alarm after 15 seconds of continuous loss.
E. Materials:
1. Frame and Skid: Stainless Steel
2. Supports: Stainless Steel members
F. Finishes: According to manufacturer's recommended coating for service conditions.
G. Accessories:
1. Pressure-relief valve
2. Pressure Gages: As specified in Section 40 7313 - Pressure and Differential Pressure Gauges.
3. Static mixer
4. Calibration column
5. Piping Supports: As specified in Section 40 0507 - Hangers and Supports for Process Piping.
2.2 SOURCE QUALITY CONTROL
A. Provide shop inspection and testing of completed assembly.
B. Control Panel:
1. Perform a factory test of completed control panel by demonstrating operation of control functions, and provide certified test results.
2. Factory assemble and test each control and alarm function.
3. Test sequence of operation.
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C. Certificate of Compliance:
1. If fabricator is approved by authorities having jurisdiction, submit certificate of compliance indicating Work performed at fabricator's facility conforms to Contract Documents.
2. Specified shop tests are not required for Work performed by approved fabricator.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify that designated areas, clearances, structural requirements, piping, utility connections, and electronic signals are ready to receive equipment.
3.02 INSTALLATION
A. According to manufacturer instructions.
B. Piping:
1. Equipment Connections: Provide flexible connectors as specified in Section 40 0506 - Couplings, Adapters, and Specials for Process Piping.
2. Harness or anchor flexible connectors as necessary.
C. Base Pads:
1. Material: Concrete, as specified in Section 03 3000 - Cast-in-Place Concrete.
2. Minimum Size: As indicated in Drawings.
3. Using templates furnished with equipment, install anchor bolts and accessories for mounting and anchoring equipment.
D. Install insulation as indicated.
3.03 FIELD QUALITY CONTROL
A. Field Testing:
1. Test for proper alignment.
2. Demonstrate operation without undue noise, vibration, or overheating.
3. Owner will witness field testing.
B. Equipment Acceptance: Adjust, repair, modify, or replace components failing to perform as specified and rerun tests.
3.04 DEMONSTRATION
A. Demonstrate equipment startup, shutdown, routine maintenance, alarm condition responses, and emergency repair procedures to Owner's personnel.
END OF SECTION 46 3333
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SECTION 46 5100 – SINGLE-STAGE HIGH-SPEED CENTRIFUGAL TURBO BLOWERS PART 1 – GENERAL
3.1 SUMMARY
A. The OWNER currently owns and operates three (3) Aerzen High-speed Turbo Blowers at the project site. The existing blowers were designed and installed approximately 10 years ago with space and ancillary mechanical, electrical and control accommodations for the addition of a fourth blower unit of equal size. To maintain a high level of operability, reliability, compatibility, spare parts and technical knowledge of the facility operations staff, the equipment and materials specified in this section are to be supplied by Aerzen USA Corporation with no equal.
B. Furnish all labor, materials, equipment, and incidentals required and install complete, ready for operation and field-test one (1) new packaged high speed, air foil turbo blower system and appurtenances, as shown on the Drawings and as specified herein.
C. The entire blower package and its components shall comply with all applicable safety and environmental regulations.
D. The supplied blower system shall include blower, premium efficiency motor, variable frequency drive, control panel, CPU, inlet filter and silencer, blow off valve, blow off valve silencer, check valve, discharge isolation valve, expansion joint, connectors, and other appurtenances as shown on the Drawings and as specified herein for a complete and operational system.
3.2 DESIGN AND PERFORMANCE REQUIREMENTS
A. Design conditions and performance requirements are as indicated in the schedule provided below:
Total Number of Blowers 1
Method of Operation Continuous
Blower Type High Speed Turbo
Drive Type Direct
Design Ambient Barometric Pressure 13.23 psia
Design Relative Humidity 40%
Design Site Elevation 3,400 ft
Design Maximum Inlet Air Temperature 109°F
Design Minimum Inlet Air Temperature 32°F
Blower Inlet Pressure Loss (Ductwork and Filter) 0.2 PSI Design Blower Capacity 4,000 scfm
Minimum Required Blower Outlet Flowrate @ 109°F 1,490 scfm Design Discharge Pressure 7.2 psig
Discharge Flange (ANSI 150 lb bolt pattern) 10 inch
Primary Air Source Blower room
Maximum Motor Horsepower (VFD Rated) 200 Hp
Available Power Voltage 460 ± 10%
Available Power Phase 3 Phase
Maximum Noise at 3 Feet free field 80 decibels
Maximum Width of Enclosure 40 inches
Maximum Length of Enclosure 52 inches
Maximum Height of Enclosure (excluding appurtenances) 84 inches Maximum Weight of Unit 1,914 lbs
Allowable Vibration Level < 2 mm/sec
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3.3 SUBMITTALS
A. Submittals shall include at least the following information:
1. Tentative schedule and an outline of services to be performed by Manufacturer’s representative to meet the requirements described herein.
2. Product Data: The following shall be supplied by the Manufacturer:
a. General description of the blower with all performance data, blower curves and model. b. Mechanical drawings with general arrangement showing blower base dimensions, floor mounting, skid piping and overall weight.
c. Process and Instrumentation Diagrams
d. Control panel drawings to include the following:
1) Interconnects to all components outside the panel.
2) Sample operator interface screens for the local control panel. 3) Local Control Panel interconnect wiring.
4) CPU address points for remote monitoring and control. e. Preliminary input/output (I/O) listing
f. Detailed blower test plan with complete piping and instrumentation configuration diagram. Blower test plan shall include the following:
1) Quality control procedures
2) Test procedure and method of calculating results
3) Functional testing of entire package instrumentation, ancillary components, and the local control panels.
g. Surface preparation and shop paint specifications
3. Miscellaneous Technical Information including:
a. Safety precautions
b. Receiving and handling requirements
c. Storage requirements
d. Allowable load on compressor discharge flange
e. Suggested preventative maintenance
f. Blower Manufacturer’s service and spare parts capabilities g. Recommended spare parts
h. Installation list
i. Warranty
4. List of components with Manufacturer and model number information a. Mechanical and structural components
b. Instruments
c. Central Processing Unit (CPU)
d. Operator interface/machine monitors
5. Motor Data
a. Motor type
b. Input voltage rating
c. Service factor
d. Cooling system
e. Insulation class
f. Type of temperature protection
g. Environmental temperature range
B. Shop Test Reports
1. Reports shall be neatly bound and shall include a written test description, piping and instrumentation drawings, instrument descriptions, actual test data sheets, computation results and summary, photographs, and reports for functional, sound and vibration tests. 762
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C. The following reports shall be submitted prior to final equipment acceptance:
1. Shop Test Report
2. Initial Inspection and Startup Report
3. Performance Test Report
4. Dynamic Balance Test Report
D. Operation and Maintenance Manuals:
1. Manufacturer shall provide written instructions for operating the equipment furnished under this Section.
2. The instructions should be short, easy to understand directions describing the various possible methods of operating the equipment including tests which may be required to be made by the operator.
3. The instructions shall include starting and stopping sequence and precautions to be taken by operating personnel with the equipment.
4. Operation and Maintenance Manual shall include:
a. Unloading, handling, storage, and maintenance requirements b. Recommended spare parts list and list of spare parts supplied per specifications c. Troubleshooting guide
d. Suggested preventative maintenance schedule
e. Sample blower data log
E. Warranty
1. Blower Manufacturer shall furnish the OWNER with a written warranty covering the blower package including motors, VFDs and blower package control components against defects in workmanship and material for a period of thirty (42) months from shipment or twenty-four (36) months from date of start-up, whichever occurs first.
2. Manufacturer’s warranty shall be issued in the OWNER’s name.
3.4 Quality Control Procedures
A. Motor Tests:
1. Each motor/air end shall be factory tested as a complete assembly including permanent magnet motor, scrolls, impellers and radial and thrust bearings.
2. Each motor shall be tested at its nominal design point. Flow, Power, input voltage, current, core temperature, vibration, and speed shall be measured and recorded.
B. Package Testing:
1. Upon completion of assembly and before shipment, all blower packages shall be functionally tested at the place of assembly. All start/stop and running sequences and all safety and alarm systems shall be tested.
2. Each blower package shall be performance tested to demonstrate the wire to air power required to meet the specified design operating points. Each test point shall match similitude at the corresponding specified design condition by matching the inlet volumetric flow within +/-1%, the isentropic head within +1%/-0% and the specific volume ratio within +/- 5%. The minimum flow at the highest density operating conditions shall also be determined. The test points and acceptance criteria shall be confirmed in the submittal.
3. A calibrated power analyzer shall measure the total power input to the blower unit. Measured power shall include wire-to-air and all associated losses, including but not limited to the motor, inverter, bearings, controls, and cooling system, if used.
4. The flow rate shall be measured on the discharge side of the blower using an orifice plate as per ASME PTC19.5 The flow rate shall be converted to test inlet flow conditions for confirmation of similitude. The net delivered flow rate and discharge pressure shall be guaranteed with no negative tolerance. There shall be no tolerances or measuring uncertainties used in reporting test results (i.e., the tests shall be reported with ± zero percent tolerance using the measured values).
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5. Test ambient conditions, discharge pressure and temperature, flow and power shall be measured by instruments independent of the blower package. Measurement stations shall be configured as per ASME PTC 13. All test equipment shall be calibrated and certified by an independent test agency no more than 12 months prior to the test date.
6. Data shall be collected three times over a 15-minute period for each test point. The blower operation must remain stable during this period as defined per ASME PTC13.
7. The sound pressure level of each blower package shall be measured for each design point at locations 3 ft. above floor level and 3 ft. distance from the package at all four sides and at one location 3 ft. above the package. The sound pressure levels at each test point shall be averaged.
The highest average shall be converted to free field conditions by accounting for test room dimensions and acoustics.
8. The RMS vibration level of each blower package shall be measured at the motor in the Y and Z axis for each design point. The data shall be recorded in mm/sec or in/sec.
9. The blower test report shall provide a summary of results, a compilation of the test data converted to predicted performance at site conditions, performance curves showing inlet flow, discharge pressure, and wire to air power, all raw data, results of the functional, vibration and sound tests, and schematics and photographs of the test configuration.
PART 2 – PRODUCTS
2.1 GENERAL
A. The blower package shall be used for supplying a variable volume of air to the specified tanks.
B. All components of the blower package shall be new.
C. Both workmanship and materials shall be of the very best quality and shall conform to all applicable sections of these specifications.
D. The blowers shall be air bearing type, single stage turbo blowers for absolutely oil-free conveyance and compression of air. The turbo machines shall offer optimized performance at minimum loss of flow design. Magnetic bearing type turbo blowers shall not be acceptable.
E. The blower design shall be that of single stage compression, single impeller design directly driven from a permanent magnet motor. A geared coupling or induction motor design shall not be acceptable.
2.2 ACCEPTABLE MANUFACTURERS
A. Aerzen USA Corporation
2.3 COMPONENTS
A. Mechanical Requirements
1. The blower unit shall be vertically mounted and shall be connected to the conical diffuser and the blow off valve all of which shall be directly integrated into the acoustical hood supported by steel construction. External mounting of any of these components shall not be acceptable.
2. Impeller
a. Blower impeller shall be of the backswept design, cast from stainless steel X5CrNiCuNb16-4 (17-4 Stainless Steel).
b. Blower impeller shall be designed and developed using 3D CAD technology. c. The first lateral critical speed of the rotor system shall be at least 110% of the maximum allowable speed.
d. The impeller shall be statically and dynamically balanced to meet a balancing grade of G1.
3. Blower shall have a spiral casing (scroll) made of aluminum die casting. 764
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4. The blower unit shall be directly flanged to the motor housing. a. Shaft seal between the blower unit and the motor housing shall be of a labyrinth type design.
b. Motor housing shall be stainless steel.
c. Motor shaft shall be of an alloyed special steel (Inconel).
5. Bearings
a. Blower shall utilize radial bearings supporting the blower shaft. b. The bearing shall be of an oil-free design utilizing a bump foil and spring foil combination known as a “Bump Style Design” in which the rotation of the shaft itself creates a hydrodynamic support. Layered or leaf style air bearing shall not be acceptable. c. Bearing material shall be stainless steel with a Teflon and graphite coating. d. Bearings shall be rated for 80,000 on/off cycles.
e. Blower shall utilize an axial bearing of an oil-free, air support design. f. Radial bearings shall be at each shaft end and there shall be an axial bearing at the motor end.
6. Starting/Stopping Valve (Blow Off Valve)
a. Blow off valve shall be internal to the blower acoustic hood to reduce noise. b. Blow off valve shall be electronically controlled by a solenoid valve and controlled from start to stop of the turbo blower to protect from excessive external back pressure. c. Blow off valve shall be controlled from the blower circuitry, both electrically and pneumatically, and shall not require any wiring connection in the field.
7. Blow Off Valve Silencer
a. All welded and plate steel.
b. Exterior surfaces prime coated.
c. Blow off Valve silencer shall be integral to the machine. d. Absorption material appropriate for operating conditions.
8. Acoustic Hood / Blower Enclosure
a. Furnish each blower with a sound enclosure covering the entire blower package. b. The sound enclosure shall be designed for easy inspection and maintenance of all blower package components.
c. Quick release or hinged panels shall provide easy and quick access for routine maintenance of the blower and the package components.
d. Hinged doors shall be supplied for all panels heavier than 50 lbs. e. Transport of the blower package and acoustic hood shall be possible by fork lift. f. Segmental design with internal lining to reduce the sound pressure level of the machine noise to a maximum of 82 dB(A) free field.
9. Inlet Air Filter
a. Design each blower with dedicated and independent process and motor cooling air systems. Both air streams share an inlet air filter system composed by a pre-filter and a main filter element. This inlet can be air from the room or could be ducted. b. A secondary air inlet, using air from the room, is needed to cool the controls and VFD.
Each filter to be suitably sized for the blower capacity. c. The main filter consists of pleated polyester melt/blown media pack in a galvanized steel rectangular frame potted (sealed) with a high temperature hot melt adhesive. The frame should have an affixed label indicating airflow direction. Provide filter media with a minimum efficiency of 82.4% 3-5 micron KCI particle size. The Filter Impedance should be 12” H2O @ 500 CFM.
10. Motor Cooling
a. The drive motor is cooled exclusively by a fan mounted directly on motor drive shaft. b. Motor cooling air shall be piped out of the enclosure separately and shall not be used for process air allowing an increase system efficiency by not pre-heating process air. 765
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c. Motor cooling shall be by air cooling only. No liquid or glycol cooling shall be used. d. The blower enclosure shall have appropriate connections to route motor cooling air away from the blower package or shall provide means for heat recovery.
B. Electrical Requirements
1. Blower shall be fed with one (1) 480 Volt, 3 phase, 60 Hz electrical supply.
2. All internal power distribution and necessary transformers shall be prewired within the cabinet electrical design.
3. The complete blower package shall have a Nationally Recognized Testing Laboratory (NRTL) certification to meet the appropriate UL/ANSI standards for safety and protection.
4. Blower local control panel shall contain a main power disconnect which interlocks the enclosure door.
5. Electric motors
a. The drive motor shall be designed as a directly driven permanent magnet synchronous motor (PMSM), with the lowest thermal and mechanical losses as well as thermal overload protection. The drive motor shall reach a minimum degree of efficiency of 96 % at nominal load.
b. Motors shall have thermal protection class H.
c. Motor shall be Inverter Duty type
1) Motor shall be started by and operated via frequency inverter d. Induction motors shall not be acceptable.
e. Motor nameplate
1) A standard stainless steel plate shall be fastened to the motor and shall be inscribed with the motor Manufacturer’s name, year of manufacture, serial number and principal rating data.
f. Ambient temperature ranging from 0°F to 113°F.
g. Stator temperature monitoring
h. Thermal safety shutdown by two (2) temperature switches and a thermistor temperature sensor.
i. Efficiency shall be rated at 96% at nominal load.
6. Frequency Inverter / VFD
a. The frequency inverter shall achieve an efficiency of at least 97% at nominal load.
Protection type of the control panel is IP 51.
b. Frequency inverter with overcurrent and thermal safety switch off, surge voltage protection at the input by varistors and single phase loss. Monitoring of the output for excessive output rating (short-circuit proof). Check of the DC-Link circuit voltage for overvoltage and undervoltage.
c. Sensorless vector control of the drive for quick and efficient coil commutation at varying operation conditions. Continuous control of current, torque and frequency. Loaddepending control of output voltage and phase angle (vector control), to achieve optimal operating speed and efficiency depending on the ambient conditions. Power inverter shall be designed for an efficient operation of high frequency applications with control and variation of the multilevel inverter output stage at turbo blowers above 40 kW. Standard inverter topologies for low frequency applications, where just the software is adapted according to high frequency applications are not allowed. d. Multi-level inverter topology (more than two dc-voltage levels) that is able to significantly reduce (by 4 times) the current ripple and eddy currents that are induced by the high switching semiconductors, due to reduction of the voltage level per semiconductor switching period (must be equipped at turbo blowers above 40 kW) e. Drive motor and frequency inverter are specifically tuned to each other, as well as parametrized by hard and software design.
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f. Radial fans, conveying filtered air through the heat sink of the frequency inverter, exclusively provide the inverter cooling.
g. The accessibility to repair and check / inspect the frequency inverter on site shall be ensured.
h. The control panel shall be designed with a circuit breaker for protection against overload and short circuit. Furthermore, an emergency pushbutton is required according to according to NFPA 79.
i. The Aerzen High-Rise-to-Surge / active surge prevention through motor current control.
C. Blower Local Control Panel (LCP) Requirements
1. The blower local control panel shall be an integrated microprocessor, CPU based control system.
2. Blower LCP shall be prewired and pre-programmed by the Manufacturer.
3. Manufacturer shall provide each blower LCP with a touch screen, Human Machine Interface (HMI) located on the blower enclosure. The HMI shall be LS Industrial System eXP or equal and shall provide the following as a minimum:
a. 7 inch diagonal display
b. 24-bit color graphics, TFT LCD display of 800 x 480 pixels c. Resistive film touch screen interface
d. 64 MB Flash EPROM application memory
e. Ethernet network interface module and driver complete with interface cable f. Windows-based configuration software complete with download cable g. Operating voltage: 24 VDC
h. Environment: 0-50°C, 10-85% relative humidity, non-condensing
4. The HMI (touch panel) shall include intuitive menu navigation as well as a clear and comprehensible representation of the display values.
5. The Blower Control shall also have the ability to communicate via Fieldbus communication using Ethernet /IP (or via hardwire) to a plant control system.
6. The Blower Control Panel shall monitor and display the following as analog outputs at each blower LCP.
a. Inlet / filter differential pressure (psig)
b. Inlet air temperature (°F)
c. Discharge pressure (psig)
d. Discharge air temperature (°F)
e. Motor rotational speed (rpm)
f. Power (kW)
g. Flow (cfm)
h. Run time (hrs)
7. The Blower Control Panel shall monitor and display the following as discrete outputs at each blower LCP
a. Run indication
b. Stopped indication
c. Status
d. Mode selection
e. All fault indications
f. All impeding fault indications
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8. The Blower Control Panel shall monitor and display the following as analog outputs at each blower LCP
a. Operational Mode command
b. Set Value
c. Start/Load/Unload/Stop Command
2.4 OPERATION
A. The integrated turbo control shall operate such that all input/output signals are processed and evaluated in real time.
B. All sensors necessary for the optimal and safe operation shall be integrated into the packaged units and in the control system.
C. In case of failure, the control of the operating data, regulating and shutdown processes shall run completely automated.
D. Control operation shall have the ability to take place via a HMI (touch panel), via hardwire control or via LAN control from remote SCADA/Master Control Panel/DCS system.
E. The control shall have all start-up and shutdown processes and internal locking carried out automatically by the packaged control unit.
F. The control shall have all operating conditions evaluated in real time and the operating point shall be adjustable automatically according to the corresponding conditions.
G. The blower operation shall provide the option of various regulation modes (motor current, volume flow, pressure, and direct dissolved oxygen control).
H. The turbo blower package shall utilize an integrated volume flow measurement.
1. The measurement shall be carried out by means of an inlet nozzle measurement according to the procedures of DIN 1952.
2. Calculated flows based on impeller speed are not acceptable.
I. The turbo blower shall have the ability to operate in an unloaded (idle) mode to allow for frequent switching procedures as well as intermittent operation.
1. Unloaded mode shall allow for an air wedge developed in the bearing which will continue to properly support the motor rotor.
2. The necessary power consumption for maintaining the air cushion of the bearing shall be no more than 2% of the maximum rated power of the blower.
3. Units that do not have the ability to operate unloaded or that use more than 2% of the maximum power consumption for maintaining the air cushion of the bearing shall not be acceptable.
J. Surge Protection
1. Blower shall have automatic surge protection based on actual flow/pressure and dynamic operation detected from the integral flow measurement system.
2.5 SYSTEM ACCESSORIES
A. Check Valve
1. Each blower shall be supplied with one check valve that shall be installed by the Contractor on the discharge line.
2. Check valve shall be split disc, wafer style, cast iron body.
3. Furnish valve with 304 stainless steel spring and EPDM seat.
4. The performance conditions in Section 1.02 of this specification shall be met while including the friction loss of the check valve and all ancillary piping supplied as part of the Manufacturer’s packaged equipment.
B. Expansion Joint
1. Each blower shall be supplied with a stainless steel bellows style expansion joint. 768
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C. Discharge Isolation Valve
1. Each blower shall be supplied with an isolation valve suitable for air service and meeting the temperature requirements.
2. Valve shall be wafer style, resilient seated, lever operated, tight closing butterfly valve for positively isolating the blower from discharge manifold piping.
3. Furnish valve with cast iron body, ductile iron disc and EPDM seat.
D. Harmonic Filter
1. Each VFD shall be supplied with a passive harmonic filter that reduces the total harmonic distortion (THD) to performance of 5% or lower THD with loads as low as 50%.
2. Harmonic filter shall reduce background voltage distortion as high as 5%.
3. Harmonic filter shall have a rating of 100 kA SCCR.
4. Harmonic filter shall meet the most stringent requirements of IEEE 519.
5. Harmonic filter shall be within a NEMA 1 enclosure.
6. Acceptable Manufacturers:
a. Transcoil, Inc. No Equal
2.6 SPARE PARTS
A. The following spare parts shall be provided:
1. One (1) inlet pre-filter and fine filter set for each blower supplied.
2. One (1) spare LS OIT unit, pre-programmed and configured for drop-in replacement by plant operations personnel.
PART 3 - EXECUTION
3.1 DELIVERY, STORAGE AND HANDLING
A. Blower package shall be completely factory assembled and properly crated to protect against damage during shipment.
B. Factory assembled parts and components shall not be dismantled for shipment. Contractor shall not be required to do any on site assembly of the blower package and shall not disassemble any factory assembled component without the Blower Manufacturer’s written approval.
C. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion.
D. No shipment shall be made until approved in writing by the Contractor.
E. All equipment delivered to the site shall be stored in accordance with Manufacturer’s instructions.
F. Blowers shall not, under any conditions, be allowed to sit outdoors unprotected.
G. During installation of each unit and at all times that construction does not require exposure of the equipment, blower package shall be covered with a waterproof material to protect from precipitation. Covering shall be securely anchored in place.
3.2 INSTALLATION
A. Furnish, install, and place in service, the blower and all appurtenances in accordance with the Manufacturer’s recommendations.
B. The Blower Manufacturer shall supply blower packages shipped fully pre-assembled. Only the electrical, external control connections, and pipe connections shall be performed on-site by the Contractor.
C. Contractor shall install anchor bolts per the blower Manufacturer’s instructions and calculations.
3.3 STARTUP AND FIELD TESTING
A. The Manufacturer’s Representative shall inspect the installation of the equipment, make any necessary adjustments, test, and place the equipment into satisfactory operating condition. 769
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B. If required, Contractor shall make any changes, at his own expense, to the installation that may be necessary to assure satisfactory operation. Contractor shall be held liable for changes needed in the installation.
C. Any defects in the equipment or failure of the equipment to meet the requirements of the Specifications shall be promptly corrected by the Manufacturer.
D. After installation of all equipment has been completed and as soon as conditions permit, the manufacturer shall provide one (1) trip for a total of TWO (2) 8-hour days to verify the installation and conduct an acceptance test under actual operating conditions, to determine the operation is satisfactory and free from excessive vibration as defined by the blower Manufacturer. The test shall consist of 3 hours operation of each blower package with readings taken and recorded as directed by the Manufacturer.
E. After installation of the units and all appurtenances, each unit shall be subjected to a field running test under actual operating conditions. Field tests shall be conducted by the Contractor in the presence of and as directed by the Manufacturer’s Representative. The field tests shall demonstrate the following under all conditions of operation:
1. Each unit has not been damaged by transportation or installation.
2. Each unit has been properly installed.
3. Each unit has no mechanical defects.
4. Each unit is in proper alignment.
5. Each unit has been properly connected.
6. Each unit is free of overheating of any parts.
7. Each unit is free of all transferable vibration.
8. Each unit is free of excessive noise.
9. Each unit is free of overloading of any parts.
10. Each unit will operate as specified with the control system.
F. Manufacturer shall provide a written field test / start up report after completion of testing.
END OF SECTION 46 5100
770
CITY COUNCIL AGENDA REPORT
A D E L A N T O G O V E R N M E N T A L C E N T E R | 1 1 6 0 0 A I R E X P R E S S W A Y | A D E L A N T O , C A L I F O R N I A 9 2 3 0 1
DATE: March 26, 2025
TO: Honorable Mayor and City Council Members
FROM: Jessie Flores, City Manager
BY: Todd Litfin, City Attorney
SUBJECT: ORDINANCE AMENDING SECTIONS 2.04.010 AND 2.04.020 OF THE ADELANTO
MUNICIPAL CODE REGARDING REGULARLY SCHEDULED CITY COUNCIL MEETINGS STAFF RECOMMENDATION:
It is recommended that the City Council adopt an ordinance amending Sections 2.04.010 and 2.04.020 of the Adelanto Municipal Code to reflect the changes in the schedule of regularly scheduled City Council meetings as outlined in the City Council resolutions dated September 14, 2022 and August 28, 2024.
BACKGROUND:
On September 14, 2022 and August 28, 2024, the City Council adopted resolutions updating the times for closed sessions and regularly scheduled City Council meetings. The proposed amendments to the Municipal Code reflect these changes and ensure that the code is in alignment with the newly adopted resolutions.
The proposed amendments involve changes to the dates and times of regular meetings and study sessions, as well as the place of meetings. The changes are as follows:
1. Section 2.04.010 - Date of Regular Meetings and Study Sessions:
o Regular meetings will now be held on the second and fourth Wednesday of each month, starting at 11:00 a.m. and concluding by 2:00 p.m., with the option to extend the meeting by a majority vote if needed.
o If the regular meeting falls on a holiday, it will be rescheduled to the next business day unless otherwise determined by the City Council.
o Study sessions will be scheduled as needed, following the legal requirements for notice.
2. Section 2.04.020 - Place of Meetings and Study Sessions:
o Regular meetings will continue to be held at the City of Adelanto City Hall, located at 11600 Air Expressway, Adelanto, California, unless otherwise specified by the City Council.
o In the event of an emergency, the City Council may relocate the meeting as deemed necessary.
771
The proposed amendments to Sections 2.04.010 and 2.04.020 will ensure that the City’s Municipal Code is updated to reflect the changes made by the City Council regarding the regular meeting schedule and locations. Adoption of the ordinance will provide clarity and consistency in the scheduling and conduct of City Council meetings.
FISCAL IMPACT:
There is no significant fiscal impact associated with this proposed amendment to the Municipal Code.
The changes are administrative and procedural in nature.
ATTACHMENTS:
• Ordinance No. 655
• Resolution No’s 22-62 and 24-80 from September 14, 2022 and August 28, 2024 772
ORDINANCE NO. 655
AN ORDINANCE OF THE CITY COUNCIL OF THE CITY OF ADELANTO,
COUNTY OF SAN BERNARDINO, AMENDING ADELANTO MUNICIPAL
CODE SECTIONS 2.04.010 AND 2.04.020 REGARDING REGULARLY
SCHEDULED CITY COUNCIL MEETINGS
WHEREAS, the City Council adopted resolutions on August 28, 2024, and September 22, 2024 updating the times of closed session and regularly scheduled City Council meetings; WHEREAS, the City Council hereby amends the Municipal Code to reflect the changes to the regular meeting time for the City Council.
THE CITY COUNCIL FOR THE CITY OF ADELANTO DOES HEREBY ORDAIN AS FOLLOWS:
SECTION 1. The findings and determinations reflected in the Recitals above are true and correct and are incorporated herein by this reference.
SECTION 2. Sections 2.04.010 and 2.04.020 of the Adelanto Municipal Code are hereby amended to read in their entirety as follows:
Section 2.04.010 Date of Regular Meetings and Study Sessions.
The regular meetings of the City Council shall be held on the second and fourth Wednesday of each month, beginning at 11:00 a.m. and concluding by 2:00 p.m. on the same day. The City Council may, by motion and a simple majority vote, extend the meeting by thirty (30) minutes, allowing the meeting to end at 2:30 p.m. The Council may by another motion and simple majority vote extend the meeting an additional thirty (30) minutes to 3:00 p.m. Additionally, the City Council may, by a four-fifths (4/5) vote, extend the meeting beyond 3:00 p.m. When regular meetings are preceded by a closed session, the closed session shall begin at 10:00 a.m. and be adjourned by 11:00 a.m., to ensure the prompt commencement of the open session of the regular meeting. If additional time is required for the closed session, Council may go back into closed session after the open session of the City Council meeting. If the day for holding any regular meeting falls on a holiday, the meeting shall be held on the next business day, unless otherwise ordered by the City Council in a prior meeting. Study sessions shall be held as determined and noticed by the City Council in accordance with legal requirements.
Section 2.04.020 Place of Meetings and Study Sessions.
Meetings shall be held at the City of Adelanto City Hall in the Council Chambers, unless otherwise ordered by the City Council. The address of City Hall is 11600 Air Expressway, Adelanto, California, 92301. Meetings may be held at an alternative location within the City limits 773
as determined and noticed by the City Council in accordance with legal requirements. If by reason of fire, flood or other emergency it shall be unsafe to meet in the City Council Chambers, the meeting may be held for the duration of the emergency at such other place as is designated by the Mayor or, if he/she should fail to act, by four (4) members of the City Council. Special Meetings of the City Council shall be held at the place designated herein for regular meetings or at such other place as provided for in the notice and call of the meeting.
SECTION 3. Severability. If any section, subsection, sentence, clause, phase, or portion of this Ordinance is for any reason held to be invalid or unconstitutional by the decision of any court of competent jurisdiction, such decision shall not affect the validity of the remaining portions of this Ordinance. The City Council hereby declares that it would have adopted this Ordinance, and each section, subsection, subdivision, sentence, clause, phrase or portion thereof, irrespective of the fact that any one or more sections, subsections, subdivisions, sentences, clauses, phrases or portions might subsequently be declared invalid or unconstitutional.
SECTION 4. This Ordinance shall take effect in accordance with legal requirements. The City Clerk shall certify to the adoption of this Ordinance and shall cause this ordinance or a summary thereof to be published in the manner required by law.
PASSED, APPROVED AND ADOPTED THIS _____th DAY ________, 2025. ____________________________________
Gabriel Reyes, Mayor of the City of Adelanto
____________________________________
Brenda Lopez, City Clerk
APPROVED AS TO FORM:
__________________________________________
Todd Litfin, City Attorney
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I, Brenda Lopez, City Clerk of the City of Adelanto, California, do hereby certify that the foregoing Ordinance No. ____ was duly introduced for the first reading on the ___th day of ______, 2025 and regularly adopted at a regular meeting of the City Council of the City of Adelanto on this __________th day of _________, 2025, by the following vote, to-wit:
AYES:
NOES:
ABSENT:
ABSTAIN:
IN WITNESS WHEREOF, I hereunto set my hand and affix the official seal of the City of Adelanto on this ___th day of ___________, 2025.
___________________________________
Brenda Lopez, City Clerk
SEAL
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RESOLUTION NO. 24-80
A RESOLUTION OF THE CITY COUNCIL OF THE CITY
OF ADELANTO, COUNTY OF SAN BERNARDINO,
CALIFORNIA, AMENDING THE RULES OF PROCEDURE
AND DECORUM TO SPECIFY THE START AND END
TIMES OF REGULAR MEETINGS OF THE CITY
COUNCIL
WHEREAS, California’s open meeting law pursuant to Government Code section 54950, et seq., (“Brown Act”) mandates that city councils adopt rules for “the conduct of business” and requires that agendas for regular meetings provide “an opportunity for members of the public to directly address the legislative body on any item of interest to the public,” including agenda items before or during the legislative body’s consideration of the item that is within the subject matter jurisdiction of the legislative body; and
WHEREAS, Government Code section 54954.3, subdivision (b), provides that city councils “may adopt reasonable regulations to ensure the intent” of the Brown Act is carried out.
The primary intent of the Brown Act is that the people’s business be conducted open and transparently, after providing an opportunity to the largest number of members of the public to directly address the council before the council takes action on any item; and WHEREAS, the Rules of Procedure and Decorum, as amended by the City Council of the City of Adelanto (“City Council”), provide an opportunity for members of the public to directly address the City Council on any item on the agenda before consideration of the item, in full compliance with the Brown Act, at a reasonable time; and WHEREAS, periodically, the City Council reviews and amends its Rules of Procedure and Decorum to facilitate the efficient and transparent conduct of the City of Adelanto’s (“City”) business at a reasonable hour; and
WHEREAS, the City Council desires to amend the rules of procedure and decorum to facilitate effective and efficient meeting management, greater transparency and meaningful public participation.
NOW, THEREFORE, THE CITY COUNCIL OF THE CITY OF ADELANTO DOES HEREBY RESOLVE AS FOLLOWS:
Section 1. The recitals above are true and correct and incorporated herein by reference.
Section 2. Section 1 of the City of Adelanto’s Rules of Procedure and Decorum is amended to add Subsection K to read as follows:
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Resolution No. 24-80