B. The minimum structural member thickness for vaults shall be 5 -inches. Cement shall be Type V Portland cement as specified in ASTM C 150. The minimum 28 -day concrete compressive strength shall be 4,000 psi. All reinforcing steel shall be embedded in the concrete with a minimum clear cover as recommended by ACI 318.
C. Design Loading: Vaults in areas subject to vehicular traffic shall be designed for H-20 traffic loading. Vaults in other areas shall be designed for a vertical live load of 300 psf. Lateral loads on vaults in all areas shall be calculated from:
L = 90 h, plus surcharge of 240 psf in areas of vehicular traffic Where L = loading in psf
h = depth of fill in feet.
D. Unless noted otherwise design loading shall also take into account the lateral and uplift pressure resulting from a groundwater elevation 2 feet below existing grade.
E. Where joints are designed in pre -cast concrete vaults, such joints shall be interlocking to secure proper alignment between members and prevent migration of soil through the joint. Structural sections at joints shall be sized sufficiently to reinforce the section against localized distress during transportation and handling and against excess contact bearing pressures through the joint. All openings through the precast structure shall be reinforced to transfer loads.
1. Joints shall be sealed watertight. All joints (including joints between adjusting rings and manhole structure, other adjusting rings and frame and cover) shall be sealed with a preformed flexible sealant conforming to ASTM C 990. In addition, all joints shall be wrapped with an external joint sealant meeting ASTM C 877.
F. Where openings for access to the vault are required, the full clear space opening indicated shall be provided, without obstructions from brackets or supports. For large openings where brackets or supports are designed to protrude into the opening for support of required covers, such brackets or supports shall be designed to be easily removed and replaced with a minimum of effort and without cutting or welding.
G. Covers for access openings shall be provided. Frames for covers shall be fabricated from aluminum, and shall be integrally cast into the vault concrete sections. All covers shall be tight fitting to prevent the entrance of dirt and debris. Where edge seams are permitted, no gaps greater than 1/16 -inch between edges will be accepted. All covers, except round, heavy -weight, cast iron manhole covers, shall have securing mechanisms to hold the covers firmly in place against the effects of repetitious live loads such as pedestrian or vehicle traffic.
H. Where penetrations of the pre -cast concrete vaults are required for piping, conduit, or ducts, such penetrations shall be accommodated through pre -cast openings or wall sleeves, as indicated. Storm drain structures may also use thin -wall knock -out sections. All openings for penetrations shall be smooth and free of surface irregularities and without exposed steel reinforcing. With the exception of vaults on pressurized water system, vaults need not be designed to resist thrust from piping passing through the vault.
I. Lifting holes shall be plugged with a precast concrete plug sealed with a non -shrink grout.
J. Vault Manufacturers, or Equal
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PRECAST CONCRETE MANHOLES AND VAULTS
338000-4
1. Jensen Precast,
2. OLDCASTLE Precast
2.4 FABRICATION
A. Maintain plant records and quality control program during fabrication of structural precast concrete sections. Make all quality control records available to Engineer upon request.
B. Use molds that are rigid, and constructed of material that will result in uniform finished surfaces.
C. If self -consolidating concrete is not used, thoroughly vibrate concrete to ensure proper consolidation, elimination of cold joints, and to minimize trapped air on at the concrete surface.
D. Fabricate and provide the required lifting devices which are compatible with embedded components.
E. Ensure reinforcing steel, anchors, inserts, plates, angle and other cast -in items are sufficiently embedded, properly secured, and correctly located. Ensure the reinforcing steel is properly supported to prevent movement or shifting during fabrication. Inadequate concrete cover over reinforcing shall be cause for rejection.
F. Cure precast concrete sections under identical conditions to develop specified concrete quality.
PART 3 - EXECUTION
3.1 GENERAL
A. Prior to accepting manholes on site, ensure that manhole meet the requirements of these specifications, are constructed of the correct materials, and are not cracked or damaged in any other way.
B. Pre -cast concrete sections shall be transported and handled with care in accordance with the manufacturer's written recommendations. Where lifting devices are provided in pre -cast sections, such lifting devices shall be used as intended. Where no lifting devices are provided, the Contractor shall follow the manufacturer's recommendations for lifting procedures to provide proper support during lifting.
C. Buried pre -cast concrete vaults and manholes shall be assembled and placed in excavations on properly compacted soil foundations as indicated. Pre -cast concrete vaults and manholes shall be set to grade, plumb and level, and oriented to provide the required dimensions and clearances from pipes and other structures.
D. Prior to backfilling vaults, pipe and conduit penetrations and other, openings shall be sealed with polyurethane sealant or as indicated in the drawings. With the authorization of the Engineer, grout or a closed -cell flexible insulation may be used as filler material prior to placing a final bed of polyurethane sealant.
3.2 MANHOLES
CITY OF BEAUMONT PRECAST CONCRETE MANHOLES AND VAULTS
MESA LIFT STATION UPGRADE 338000-5
A. Connect pipe to manhole with flexible connection (unless noted otherwise), as recommended by connection manufacturer. Provide a pipe joint or additional flexible connection 18 inches from the outside of the manhole. Grout around pipe after installation is complete, unless otherwise indicated. All connections shall be watertight.
B. Place top section, cone section or flat slab on top riser section, with the opening positioned over the steps. Top of cone section or flat slab shall be from 10 to 18 inches below finished grade.
C. Install grade rings as required to adjust top of lid and frame to match finish grade elevation.
Maximum height of grade rings shall be 12 inches. Maximum number of grade rings shall be two.
D. In paved areas and as indicated in the plans, concrete collars shall be constructed around manhole covers as indicated. Collars shall be of 4000 psi concrete. Collars shall be constructed after pavement has been placed.
E. Steps shall be cast -in -place or vibrated into green concrete.
F. Steps shall be installed 12 -inches on centers vertically, not more than 1/2 inch out of plumb.
The top step shall be no more then 12 -inches below the manhole cover.
G. After manhole base has been completed, furnish and install temporary pipe plugs to seal all interior pipe opening. Plugs shall remain in place until final review and acceptance of completed pipeline. Plugs shall then be removed and shall be property of Contractor.
H. Manhole interiors shall be coated as indicated in the protective coatings schedule.
3.3 QUALITY CONTROL
A. Manholes shall be tested and accepted per the requirements of Section 331400 — Hydraulic Structures Testing. Precast concrete testing is the responsibility of the Contractor and supplier.
B. Do not install precast concrete units until concrete has attained its design compressive strength.
END OF SECTION 338000
CITY OF BEAUMONT PRECAST CONCRETE MANHOLES AND VAULTS
MESA LIFT STATION UPGRADE 338000-6
SECTION 400500 -PIPING, GENERAL
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall furnish and install all piping systems shown and specified, in accordance with the requirements of the Contract Documents. Each system shall be complete with all necessary fittings, hangers, supports, anchors, seismic restraints, expansion joints, flexible connectors, valves, accessories, heat tracing, insulation, lining and coating, testing, disinfection, excavation, backfill and encasement, to provide a functional installation.
B. The piping shown is intended to define the general layout, configuration, routing, method of support, pipe size, and pipe type. The mechanical drawings are not pipe construction or fabrication drawings. It is the Contractor's responsibility to develop the details necessary to construct all mechanical piping systems, to accommodate the specific equipment provided, and to provide and install all spools, spacers, adapters, connectors, etc., for a complete and functional system.
1.2 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. Commercial Standards
ANSI/ASME B 1.20.1 Pipe Threads, General Purpose (inch) ANSI B16.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and other Special Alloys
ANSI/AWWA C207 Steel Pipe Flanges for Water Works Service, Sizes 4 in through 144 in.
ANSI/AWWA C606 Grooved and Shouldered Joints
ANSI/AWS D1.1 Structural Welding Code
ASTM A 307 Specification for Carbon Steel Bolts and Studs, 6,000 psi Tensile ASTM A 325 Specification for High -Strength Bolts for Structural Steel Joints ASTM D 792 Test Methods for Specific Gravity and Density of Plastics by Displacement
ASTM D 2000 Classification System for Rubber Products in Automotive Applications
1.3 CONTRACTOR SUBMITTALS
A. Submit complete shop drawings and certificates, test reports, affidavits of compliance, of all piping systems, in accordance with the requirements in Section 013300 —Contractor Submittals, and as indicated in the individual piping sections. The shop drawings shall include all necessary dimensions and details on pipe joints, fittings, fitting specials, valves, appurtenances, design
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 1
calculations, and material lists. The submittals shall include detailed layout, spool, or fabrication drawings which show all pipe spools, spacers, adapters, connectors, fittings, and pipe supports and seismic restraints necessary to accommodate the equipment and valves provided in a complete and functional system.
B. All expenses incurred in making samples for certification of tests shall be borne by the Contractor at no increased cost to the Owner.
C. Submit as part of the shop drawings a statement from the pipe fabricator certifying that all pipes will be fabricated subject to a recognized Quality Control Program. An outline of the program shall be submitted to the Engineer for review prior to the fabrication of any pipe.
1.4 QUALITY ASSURANCE
A. Inspection: All 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 the Specifications.
B. Tests: Except where otherwise indicated, all 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. Perform all tests at no additional cost to the Owner.
C. Welding Requirements: All welding procedures used to fabricate pipe shall be prequalified under the provisions of ANSI/AWS D1.1. Welding procedures shall be required for, but not necessarily limited to, 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.
D. Welder Qualifications: All welding shall be done by skilled welders, welding operators, and tackers 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. Furnish all material and bear the expense of qualifying welders at no increased cost to the Owner.
1.5 MANUFACTURER'S SERVICE REPRESENTATIVE
A. Where the assistance of a manufacturer's service representative is advisable, in order to obtain perfect pipe joints, supports, or special connections, furnish such assistance at no additional cost to the Owner.
1.6 MATERIAL DELIVERY, STORAGE, AND PROTECTION
A. All piping materials, fittings, valves, and accessories shall be delivered in a clean and undamaged condition and stored off the ground, to provide protection against oxidation caused by ground contact. All defective or damaged materials shall be replaced with new materials.
1.7 CLEANUP
A. After completion of the Work, all remaining pipe cuttings, joining and wrapping materials, and other scattered debris, shall be removed from the site. The entire piping system shall be handed
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 2
over in a clean and functional condition.
PART 2 - PRODUCTS
2.1 GENERAL
A. All pipes, fittings, and appurtenances shall be furnished in accordance with the requirements of the applicable Sections of Divisions 22, 23, 33, 40 and this Section.
B. Pipe Supports: All pipes shall be adequately supported in accordance with the requirements of Section 400507 — Hangers and Supports for Process Piping, and as indicated.
C. Lining: All requirements pertaining to thickness, applications, and curing of pipe lining, shall be in accordance with the requirements of the applicable Sections of Division 40 , unless otherwise indicated.
D. Coating: All requirements pertaining to thickness, application, and curing of pipe coating, shall be in accordance with the requirements of the applicable Sections of Division 40, unless otherwise indicated. Pipes above ground or in structures shall be field -painted in accordance with Section 098000 — Protective Coatings.
E. Pressure Rating: All piping systems shall be designed for the maximum expected pressure as defined in Section 330505 - Pipeline Testing, or as indicated on the piping schedule.
F. Grooved Piping Systems: Piping systems with grooved joints and fittings may be provided, if approved by the Engineer, in lieu of screwed, flanged, welded, or mechanical joint systems for steel and ductile iron yard piping above and below ground. All grooved couplings on buried piping must be bonded. To assure uniform and compatible piping components, all grooved fittings, couplings, and valves shall be from the same manufacturer. The Contractor shall make the coupling manufacturer responsible for the selection of the correct style of coupling and gasket for each individual location.
2.2 PIPE FLANGES
A. Flanges: Where the design pressure is 150 psi or less, flanges shall conform to either ANSI/AWWA C207 Class D or ANSI B16.5 150 -pound class. Where the design pressure is greater than 150 psi, up to a maximum of 275 psi, flanges shall conform to either ANSI/AWWA C207 Class E, Class F, or ANSI B16.5 150 -pound class. However, 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. Where the design pressure is greater than 275 psi up to a maximum of 700 psi, flanges shall conform to ANSI B16.5 300 -pound class. Flanges shall have flat faces and shall be attached with bolt holes straddling the vertical axis of the pipe unless otherwise shown. Attachment of the flanges to the pipe shall conform to the applicable requirements of ANSI/AWWA C207. Flanges for miscellaneous small pipes shall be in accordance with the standards specified for these pipes.
B. Blind Flanges: Blind flanges shall be in accordance with ANSI/AWWA C207, or with the standards for miscellaneous small pipes. All blind flanges for pipe sizes 12 inches and over shall be provided with lifting eyes in form of welded or screwed eye bolts.
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 3
C. Flange Coating: All 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.
D. Flange Bolts: Contractor shall supply all bolts and nuts in conformance with Section 055000 — Metal Fabrications. Studs and bolts shall extend through the nuts a minimum of 1/4 inch. All - thread studs shall be used on all valve flange connections, where space restrictions preclude the use of regular bolts.
E. Insulating Flanges: Insulated flanges shall have bolt holes 1/4 inch diameter greater than the bolt diameter.
F. Insulating Flange Sets: Insulating flange sets shall be provided by the Contractor where shown.
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 1-1/2 inches or smaller and shall be made of acetal resin. For bolt diameters larger than 1- 1/2 inches, insulating sleeves and washers shall be two-piece and shall be made of polyethylene or phenolic. Steel washers shall be in accordance with ASTM A 325. Insulating gaskets shall be full - face.
G. Insulating Flange Manufacturers, or Equal
1. JM Red Devil, Type E
2. Maloney Pipeline Products Co., Houston
3. PSI Products, Inc., Burbank, California.
H. Flange Gaskets: Contractor shall provide flange gaskets for all pipe flanges. Gaskets for flanged joints shall be full-faced, 1/16 -inch thick compressed sheets of asbestos -free aramid fiber base, with nitrile binder and nonstick coating, suitable for temperatures to 700 degrees F, a pH of 1 to 11, and pressures to 1,000 psig. 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.
I. Flange Gasket Manufacturers, or Equal
1. John Crane, Style 2160.
2. Garlock, Style 3000.
2.3 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 nonconductive materials, and shall have ratings and properties to suit the service and loading conditions.
2.4 MECHANICAL -TYPE COUPLINGS (GROOVED OR BANDED PIPE) A. Construction: Cast mechanical -type couplings shall be provided where shown. The couplings shall conform to the requirements of ANSI/AWWA C606. Bolts and nuts shall conform to the requirements of Section 055000 — Metal Fabrications. All 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 all grooved piping shall conform with the
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 4
coupling manufacturer's recommendations to suit the highest expected pressure. To avoid stress on equipment, all equipment connections shall have rigid -grooved couplings, or harness sets in sizes where rigid couplings are not available, unless thrust restraint is provided by other means.
The Contractor shall have the coupling Manufacturer's service representative verify the correct choice and application of all couplings and gaskets, and the workmanship, to assure a correct installation.
B. Couplings for Steel Pipe, Manufacturers, or Equal
1. Victaulic Style 44 with Type D Heavy Duty Grooved Adaptor Ends.
C. Ductile Iron Pipe Couplings, Manufacturers, or Equal
1. Victaulic Style 31 (flexible or rigid grooving as specified in drawings).
2. Note: Ductile iron pipe couplings shall be furnished with flush seal gaskets.
D. Couplings for PVC Pipe, Manufacturers, or Equal
1. Victaulic Style 775.
2. Note: Couplings for PVC pipe shall be furnished with radius cut or standard roll grooved pipe ends. Grooved end couplings shall be used on PVC pipe only for Schedule 80 vent piping at the vaults. Grooved end couplings shall not be used for PVC C905 water pipe.
2.5 SLEEVE -TYPE COUPLINGS
A. Construction: Sleeve -type couplings shall be provided where indicated, in accordance with ANSI/AWWA C219 unless otherwise indicated, and shall be of steel with steel bolts, without pipe stop, and shall be of sizes to fit the pipe and fittings. The middle ring shall be not less than 1/4 inch in thickness and 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. The followers shall be single -piece contoured mill section welded and cold - expanded as required for the middle rings. They shall be 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 055000 — Metal Fabrications. Buried sleeve -type couplings shall be epoxy -coated at the factory.
B. Pipe Preparation: The ends of the pipe, where indicated, 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: 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.
1. The rubber in the gasket shall meet the following specifications:
a. Color - Jet Black.
b. Surface - Nonblooming.
c. Durometer Hardness - 74 " 5.
d. Tensile Strength - 1,000 psi Minimum.
e. Elongation - 175 percent Minimum.
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 5
2. The gaskets shall be immune to attack by impurities normally found in water or wastewater.
All gaskets shall meet the requirements of ASTM D 2000, AA709Z, meeting Suffix B13 Grade 3, except as noted above. All gaskets 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: All sleeve -type couplings on pressure lines shall be harnessed unless thrust restraint is provided by other means. Harnesses shall be in accordance with the requirements of the appropriate reference standard, or as shown.
F. Manufacturers, or Equal
1. Dresser, Style 38.
2. Ford Meter Box Co., Inc., Style FC1 or FC3.
3. Smith -Blair, Style 411.
4. Baker, Series 200
2.6 FLANGED END CONNECTORS
A. Flanged coupling adapters, shall be in accordance with AWWA C219.
B. Dismantling joints for connecting flanged pipe shall be AWWA C219 compliant. Provide studs and nuts to seal gasket separate and independent from tie -bar restraint system.
C. All dismantling joints shall be the restrained type per AWWA M-11. Tie -bar restraint system shall conform to ASTM A193 -B7 per AWWA M-11 and be designed to withstand the test pressure shown on the Drawings.
D. All dismantling joints shall use standard flanges in accordance with AWWA C207. The thickness of the dismantling joint flanges shall be equal to or greater than the class of flange that is connected to as required by the test pressure as shown on the drawings. Buried flanges shall be wrapped with petroleum was tape per AWWA C217.
E. Manufacturers, or Equal
1. Smith -Blair, Style 972 or 975
2. Baker, Series DJ
2.7 FLEXIBLE CONNECTORS
A. Flexible connectors shall be installed in all piping connections to engines, blowers, compressors, and other vibrating equipment, and where shown. Flexible connectors for service temperatures up to 180 degrees F shall be flanged, reinforced Neoprene or Butyl spools, rated for a working pressure of 40 to 150 psi, or reinforced, flanged duck and rubber, as best suited for the application. Flexible connectors for service temperatures above 180 degrees F shall be flanged, braided stainless steel spools with inner, annular, corrugated stainless steel hose, rated for minimum 150 psi working pressure, unless otherwise shown. The connectors shall be 9 inches long, face-to-face flanges, unless otherwise shown. The final material selection shall be approved by the manufacturer.
Submit manufacturer's shop drawings and calculations.
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 6
2.8 EXPANSION JOINTS
A. All 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. Submit detailed calculations and manufacturer's shop drawings, guaranteeing satisfactory performance of all proposed expansion joints, piping layouts showing all anchors and guides, and information on materials, temperature and pressure ratings.
2.9 PIPE THREADS
A. All pipe threads shall be in accordance with ANSI/ASME B1.20.1.
2.10 AIR AND GAS TRAPS
A. Air and gas pipes shall be sloping to low points, provided with drip legs, shutoff valves, strainers and traps. The traps shall be piped to the nearest drain. Air and gas traps shall be not less than 150 -pound iron body float type with stainless steel float. Bracket, lever, and pins shall be of stainless steel. Drain traps shall have threaded connections.
B. Manufacturers, or Equal
1. Armstrong Machine Works.
2. Spirax Sarco, Inc.
PART 3 - EXECUTION
3.1 GENERAL
A. All pipes, fittings, and appurtenances shall be installed in accordance with the requirements of the applicable Sections of Divisions 22 and 40. The lining manufacturer shall take full responsibility for the complete, final product and its application. All pipe ends and joints at screwed flanges shall be epoxy -coated, to assure continuous protection.
B. 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 rebars.
C. Flanges shall be installed at least 6 -inches from a wall. Fittings shall be installed with sufficient clearance for maintenance and removal and reinstallation.
D. All buried non-metallic piping, 4" and greater, shall have both a marking tape placed 12" above the pipe, and a tracer wire placed on top of the pipe. Tracer wire shall be 12 gauge solid copper wire with a plastic coat to prevent corrosion. The tracer shall be secured to the pipe 10 feet and at all bends. Tracer wire shall not be wrapped around a pipe. Tracer wire installation requires access points at least every 300 feet. At access points the tracer wire is brought up to grade with valve boxes, cleanouts, manholes, vaults, or other covered access devices. Splices in tracer wire should be made with split bolt or compression -type connectors. Wire nuts shall not be used. Testing of tracer wire continuity after installation shall be performed.
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 7
END OF SECTION 400500
CITY OF BEAUMONT PIPING, GENERAL
MESA LIFT STATION UPGRADE 400500 - 8
SECTION 400507 — HANGERS AND SUPPORTS FOR PROCESS PIPING PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall provide pipe supports, seismic restraints, hangers, guides, and anchors, complete, in accordance with the Contract Documents.
1.2 CONTRACTOR SUBMITTALS
A. General: Submittals shall be in accordance with Section 013300 — Contractor Submittals.
B. Shop Drawings: Shop drawings shall include the following information:
1. Drawings of pipe supports, restraints, hangers, anchors, and guides
2. Calculations for special supports and anchors.
PART 2 - PRODUCTS
2.1 GENERAL REQUIREMENTS
A. Code Compliance: Piping systems and pipe connections to equipment shall be properly anchored and supported to prevent undue deflection, vibration, dislocation due to seismic events and line pressures, and stresses on piping, equipment, and structures. Supports and parts thereof shall conform to the requirements of ASME B31.1— Power Piping, except as supplemented or modified below. 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 at no additional cost to the Owner. All supplementary members shall be in accordance with the requirements of the building code and the American Institute of Steel Construction and shall be acceptable to the Engineer.
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. 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, seismic disturbances, or thrust imposed by the actuation of safety valves, shall include hydraulic shock suppressors. 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.
CITY OF BEAUMONT HANGERS AND SUPPORTS FOR PROCESS PIPING MESA LIFT STATION UPGRADE 400507-1
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. 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 four times the maximum travel due to thermal expansion.
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. Components shall be structurally suitable to withstand 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: Pipe support assemblies, including framing, shall be steel construction, galvanized after fabrication, with Type 316 stainless steel hardware, and anchors, unless otherwise indicated.
2. Submerged Supports: 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, and anchors, constructed of Type 316 stainless steel, unless otherwise indicated.
3. Corrosive: Piping in chemical and corrosive areas shall be supported with support assemblies, including framing, hardware, and anchors, constructed of Type 316 stainless steel or FRP, unless otherwise indicated.
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, 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.
CITY OF BEAUMONT HANGERS AND SUPPORTS FOR PROCESS PIPING MESA LIFT STATION UPGRADE 400507-2
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 below. 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.
1. Support Spa
Nominal Pipe Diameter
(inches)
Maximum Span
(feet)
1/2
6 3/4 and 1
8 1-1/4to2
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
Maximum Spans for Pipe Supported in Minimum 120 degree contact saddles (feet) Nominal Pipe
Diameter (inches)
3/16
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1 24
33 37
41 43
45 47
26 34
38 41
44 46
48 28
34 38
41 44
47 49
30 34
38 42
45 48
49 32
34 39
42 45
48 50
34 35
39 42
46 48
50 36
35 39
43 46
49 51
55 38
35 39
43 46
49 51
55 40
35 40
43 47
49 52
56 42
--
40 43
47 50
52 56
45 --
40 44
47 50
53 57
48 --
40 44
47 50
53 58
61 51
--
41 44
48 51
53 58
62 54
--
41 44
48 51
54 58
62 57
--
41 44
48 51
54 59
63 60
--
41 45
48 52
54 59
63 67
70 63
--
41 45
49 52
55 60
64 67
71 CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
HANGERS AND SUPPORTS FOR PROCESS PIPING
400507-3
66 --
41 45
49 52
55 60
64 68
71 72
--
41 45
49 52
55 61
65 69
72 78
--
41 45
49 53
56 61
66 69
73 84
--
41 46
50 53
56 62
66 70
74 90
--
41 46
50 53
56 62
67 71
74 96
--
42 46
50 54
57 62
67 71
75 3. For steel pipe sizes not presented in this table, 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
Where:
4. Support Spa
5. Support Sp
t=
D =
L =
Thickness (inches)
Diameter (inches)
Maximum span (feet)
Normal Pipe
Diameter (inches)
Maximum Span
(feet)
All diameters
Two supports per pipe
length or 10 feet
(one of the 2 supports
located at joint)
Normal Pipe Diameter
(inches)
Maximum Span
(feet)
1/2 to 1 - 1/2
6 2to4
10 6 and greater
12 6. Support Spacin
for Schedule 80 PVC Pi s e:
Normal Pipe
Diameter (inches)
Maximum Span at 100
degrees F (feet)
1/2
4 3/4
4.5 1
5 1 - 1/4
5.5 1-1/2
5.75 2
6.25 3
7.5 4
8.25 6
10 8
11 10
12.25 12
13.25 CITY OF BEAUMONT HANGERS AND SUPPORTS FOR PROCESS PIPING MESA LIFT STATION UPGRADE 400507-4
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 Equal
1. Grinnell Corp. (Supply Sales Company), Cranston, RI
2. Power Piping Company, Pittsburgh, PA.
2.4 COATING
A. Galvanizing: Unless otherwise indicated, 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 A 123 - 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 098000 — Protective Coatings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. General: Pipe supports, seismic restraints, hangers, brackets, anchors, guides, and inserts shall be fabricated and installed in accordance with the manufacturer's printed instructions and ASME B31.1 - Power Piping. Concrete inserts for pipe hangers and supports shall be coordinated with the form work.
B. Appearance: Pipe supports and hangers shall be positioned to produce an orderly, neat piping system. Hanger rods shall be vertical, without offsets. 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, supports, and seismic restraints 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 400507
CITY OF BEAUMONT HANGERS AND SUPPORTS FOR PROCESS PIPING MESA LIFT STATION UPGRADE 400507-5
THIS PAGE INTENTIONALLY LEFT BLANK
CITY OF BEAUMONT HANGERS AND SUPPORTS FOR PROCESS PIPING MESA LIFT STATION UPGRADE 400507-6
SECTION 400519 — DUCTILE IRON PIPE
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall furnish and install all ductile iron pipe, fittings, transitions, connections and appurtenant work, complete and in accordance with the requirements of the Contract Documents.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A.
B.
C.
Section 400500 — Piping, General
Section 330505 — Pipeline Testing
Section 331400 — Hydraulic Structures Testing
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Commercial Standards:
ANSI/AWWA C104/A21.4
ANSI/AWWA C105/A21.5
ANSI/AWWA C110/A21.10
ANSI/AWWA C111/A21.11
ANSI/AWWA C115/A21.15
ANSI/AWWA C150/A21.50
ANSI/AWWA C153/A21.53
ANSI/AWWA C151/A21.51
ANSI/AWWA C209
ANSI/AWWA C214
ANSI/AWWA C600
ANSI/ASTM D 1248
ASTM C 150
ASTM A 746
1.4 CONTRACTOR SUBMITTALS
Cement -mortar lining for Ductile Iron and Gray
Iron Pipe and Fittings for Water.
Polyethylene Encasement for Gray and Ductile
Cast Iron Piping for Water and Other Liquids.
Fittings, 3 -inch through 48 -inch for Water and
Other Liquids, Gray Iron and Ductile Iron.
Rubber Gasket Joints for Ductile Iron and Gray
Iron Pressure Pipe and Fittings.
Flanged Ductile Iron and Gray Iron Pipe with
Threaded Flanges.
Thickness Design of Ductile Iron Pipe.
Mechanical Joints (MJ), Push -on joints.
Ductile Iron Pipe, Centrifugally Cast, in Metal
Molds or Sand Lined Molds for Water and Other
Liquids.
Cold Applied Coatings for the Exterior of
Special Sections, Connections and Fittings for
Steel Water Pipelines.
Tape Coating Systems for the Exterior of Steel
Water Pipelines.
Water Mains and Appurtenances, Installation of
Ductile Iron.
Polyethylene Lining Material for Ductile Iron
Pipe and Fittings.
Specification for Portland Cement.
Installation of Ductile Iron Pipe for Gravity
Sewers.
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
DUCTILE IRON PIPE
A. The Contractor shall furnish a certified affidavit of compliance for all pipe and other products or materials furnished under this Section of the Specifications and as specified in the referenced standards. Certification shall include physical and chemical properties of pipe materials and hydrostatic test reports.
B. All expenses incurred in sampling and testing for certifications shall be borne by the Contractor.
1.5 QUALITY ASSURANCE
A. Ductile iron pipe shall be manufactured with the material, have the dimensions, be within the tolerances and meet the testing requirements set forth in ASTM A746 and ANSI A21.51. Ductile iron pipe shall be manufactured in nominal 18 -foot or 20 -foot laying lengths and shall have the lining called for in the Contract Documents.
B. All pipe shall be subject to inspection at the place of manufacture in accordance with the provisions of the referenced standards, as supplemented by the requirements herein.
C. In addition to those tests specifically required, the Engineer may request additional samples of any material including lining and coating samples for testing by the Owner.
The additional samples shall be furnished at no additional cost to the Owner.
PART 2 - PRODUCTS
2.1 GENERAL
A. Mortar lined ductile iron pipe shall conform to ANSI/AWWA C151, C104, C105, C214 and D1248, subject to the following supplemental requirements. The pipe shall be of the diameter shown, shall be furnished complete with rubber gaskets as indicated in the Contract Documents and all specials and fittings shall be provided as required under the Contract Documents.
B. The pipe shall be handled by use of wide slings, padded cradles or other devices acceptable to the Engineer, designed and constructed to prevent damage to the pipe lining and/or coating. The use of chains, hooks or other equipment which might injure the pipe lining and coating will not be permitted. Stockpiled pipe shall be safely and properly supported to prevent accidental rolling. The Contractor shall be fully liable for the cost of replacement or repair of pipe which is damaged.
C. Maximum pipe laying lengths shall be 20 -foot with shorter lengths provided as required by the Drawings.
D. The pipe shall have a smooth dense interior surface and shall be free from fractures, defects and roughness.
2.2 MATERIALS
CITY OF BEAUMONT DUCTILE IRON PIPE
MESA LIFT STATION UPGRADE
A. Ductile iron pipe materials shall confonn to the requirements of ANSI/AWWA C151/A21.51.
B. Fittings for ductile iron pipe shall conform to the requirements of ANSI/AWWA C110/A21.10 or AWWA C153 for diameters 3 -inch through 48 -inch. Ductile iron fittings larger than 48 -inch shall conform to the above referenced standard with the necessary modifications for the larger size.
C. Cement for mortar lining shall conform to the requirements of ANSI/AWWA C104/A21.4; provided, that cement for mortar lining shall be Type II or V. A fly ash or pozzolan shall not be used as a cement replacement.
E. Material for the polyethylene encasement shall conform to the requirements of ANSI/AWWA C105/A21.5.
F. All elastomer gaskets used for ductile iron pipe shall be of neoprene or SBR elastomer material with a 1/8" thickness. For high temperature service (process air) gaskets shall be Viton. For high temperature water service gaskets shall be EPDM.
G. All bolts, nuts, and washers, which are buried, submerged or below the top of the wall inside any hydraulic structure used in the assembly of ductile iron pipe and fittings shall be of Type 316 Stainless Steel.
2.3 DESIGN OF PIPE
A. Ductile iron pipe shall be designed in accordance with the requirements of ANSI/AWWA C150/A21.50, as applicable and as modified in this Section. The pipe furnished shall be either mortar -lined or glass -lined as called out in the Contract Documents.
B. The pipe shall be designed, manufactured, tested, inspected and marked according to applicable requirements previously stated and except as hereinafter modified, shall conform to ANSI/AWWA C151.
C. Unless noted otherwise, the pipe and fittings shall be of the diameter shown and shall be of pressure Class 350 for pipe sizes twelve inches and below, pressure Class 250 for pipe fourteen inches to twenty inches, pressure class 200 for twenty -four -inch pipe and pressure class 150 for thirty inch and above, except that where mechanical couplings are used and the pipe is grooved, the ductile iron pipe shall be of special thickness Class 53.
D. Ductile iron pipe and fittings shall be furnished with mechanical joints, push -on joints, flanged joints and restrained joints as required.
1. All Mechanical and push -on joints may conform to ANSI/AWWA C153/A21.53 or C110/A21.10.
2. Flanged joints shall conform to ANSUAWWA C115/A21.15.
D. For bell -and -spigot ends with rubber gaskets, the clearance between the bells and spigots shall be such that when combined with the gasket groove configuration and the gasket itself, will provide watertight joints under all operating conditions when properly installed. The Contractor shall require the pipe manufacturer to submit details complete
CITY OF BEAUMONT DUCTILE IRON PIPE
MESA LIFT STATION UPGRADE
with significant dimensions and tolerances and also to submit performance data indicating that the proposed joint has performed satisfactorily under similar conditions.
In the absence of a history of field performance, the results of a test program shall be submitted.
E. Unless noted otherwise, pipe used for hot water applications shall not have an interior lining.
2.4 CEMENT -MORTAR LINING
A. Except as otherwise provided herein, interior surfaces of ductile iron pipe, fittings and specials to be furnished with cement -mortar lining shall be cleaned and lined in the shop with cement -mortar lining applied centrifugally in conformity with ANSI/AWWA C104.
If lining is damaged or found faulty at delivery site, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications.
B. The minimum lining thickness shall be as follows:
Nominal Pipe Diameter Minimum Lining Thickness
winches) (inches)
3-12 1/8
14-24 3/16
30-54 1/4
C. For all pipe and fittings with plant -applied cement mortar linings, the Contractor shall provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special openings. All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed.
2.5 PIPE ENCASEMENT
A. All buried DIP shall be polyethylene encased.
2.6 EXTERIOR COATING OF PIPE
A. The exterior surfaces of ductile iron pipe which will be exposed to the atmosphere inside structures or above ground shall be thoroughly cleaned and then given a shop coat of rust -inhibitive primer conforming to the requirements of Section 098000 entitled, "Protective Coating." This exposed piping shall not be coated with the bituminous coating by the manufacturer prior to delivery.
B. Buried ductile iron pipe shall be pipe shall be epoxy -coated according to requirements of Section 098000 "Protective Coatings".
C. Submerged ductile iron pipe shall be epoxy -coated according to requirements of Section 098000 "Protective Coatings".
2.7 RESTRAINED JOINTS
CITY OF BEAUMONT DUCTILE IRON PIPE
MESA LIFT STATION UPGRADE
A. Restrained joints shall conform to either ANSI/AWWA C111/A21.11 or ANSI/AWWA C153/A21.53.
B. Restraint devices for pipe sizes 3" — 48" shall consist of multiple gripping wedges incorporated into a follower gland meeting the applicable requirements of ANSI/AWWA C110/A21.10. The devices shall have a working pressure rating of 350 psi for 3"-16" and 250 psi for 18"-48". Ratings are for water pressure and must include a minimum safety factor of 2 to 1 in all sizes.
C. Gland body, wedges and wedge actuating components shall be cast from grade 65-45-12 ductile iron material in accordance with ASTM A536. For applications requiring restraint 30" and greater, an alternate grade of iron meeting the material requirements of ASTM A536 is acceptable, providing the device meets all end product performance requirements. Ductile iron gripping wedges shall be heat treated within a range of 370 to 470 BHN.
D. Three (3) test bars shall be incrementally poured per production shift as per UL specifications and ASTM A536. Testing for tensile, yield and elongation shall be done in accordance with ASTM E8. Chemical and nodularity tests shall be performed as recommended by the Ductile Iron Society, on a per ladle basis.
E. Mechanical joint restraint for ductile iron pipe shall be produced by EBAA Iron, Inc and shall be:
a. Megalug Series 1100 for Fittings
b. Megalug Series 1700 for Joints
c. Megalug Series 3800 for Couplings
F. Finish shall be Megabond, or equal.
PART 3 - EXECUTION
3.1 INSTALLATION OF PIPE
A. All pipe, fittings, etc. shall be carefully handled and protected against damage, impact shocks and free fall. All pipe handling equipment shall be acceptable to the Engineer.
Pipe shall not be placed directly on rough ground, but shall be supported in a manner which will protect the pipe against injury whenever stored at the trench site in accordance with Paragraph 2.1B, herein. All pipe damaged prior to Substantial Completion shall be repaired or replaced by the Contractor.
B. The Contractor shall inspect each pipe and fitting prior to installation to ensure that there are no damaged portions of the pipe. No pipe shall be installed where the lining or coating show defects that may be harmful as determined by the Engineer. Such damaged lining or coating shall be repaired, or a new undamaged pipe shall be furnished and installed.
C. The pipe shall be installed in accordance with ANSI/AWWA C600. Before placement of the pipe in the trench, each pipe or fitting shall be thoroughly cleaned of any foreign substance which may have collected thereon and shall be kept clean at all times thereafter. For this purpose, the openings of all pipes and fittings in the trench shall be closed during any interruption to the Work. As pipe laying progresses, the Contractor
CITY OF BEAUMONT DUCTILE IRON PIPE
MESA LIFT STATION UPGRADE
shall keep the pipe interior free of all debris. The Contractor shall completely clean the interior of the pipe of all sand, dirt, rocks and any other debris following completion of pipe laying prior to testing and disinfecting the completed pipeline.
D. Pipe shall be laid directly on the imported bedding material. No blocking will be permitted and the bedding shall be such that it forms a continuous, solid bearing for the full length of the pipe. Excavations shall be made as needed to facilitate removal of handling devices after the pipe is laid. Bell holes shall be formed at the ends of the pipe to prevent joint loading at the bells or couplings. Excavation shall be made as needed outside the normal trench section at field joints to permit adequate access to the joints for field connection operations and for application of coating on field joints.
E. Where necessary to raise or lower the pipe due to unforeseen obstructions or other causes, the Engineer may change the alignment and/or the grades. Such change shall be made by the deflection of joints, by the use of bevel adapters or by the use of additional fittings. However, in no case shall the deflection in the joint exceed the maximum deflection recommended by the pipe manufacturer.
F. No pipe shall be installed upon a foundation into which frost has penetrated or at any time that there is a danger of the formation of ice or penetration of frost at the bottom of the excavation. No pipe shall be laid unless it can be established that the trench will be backfilled before the formation of ice and frost occurs.
G. The openings of all pipe and specials where the pipe and specials have been cement - mortar lined in the shop shall be protected with suitable bulkheads to prevent unauthorized access by persons, animals, water or any undesirable substance. At all times, means shall be provided to prevent the pipe from floating.
H. Immediately before jointing pipe, the bell end of the pipe shall be thoroughly cleaned and a clean rubber gasket lubricated with an approved vegetable -based lubricant shall be placed in the bell groove. The spigot end of the pipe shall be carefully cleaned and lubricated with a vegetable -based lubricant. The spigot end of the pipe section shall then be inserted into the bell of the previously laid joint and telescoped into its proper position.
Tilting of the pipe to insert the spigot into the bell will not be permitted.
All valves shall be handled in a manner to prevent any injury to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation. The Contractor shall adjust all stem packing and operate each valve prior to installation to ensure proper operation. All valves shall be installed so that the valve stems are plumb and in the location shown.
K. All buried bolts shall be coated with FM grease prior to applying the polyethylene wrap.
END OF SECTION 400519
CITY OF BEAUMONT DUCTILE IRON PIPE
MESA LIFT STATION UPGRADE
SECTION 400523 - STAINLESS STEEL PIPING AND TUBING
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall provide stainless steel pipe and appurtenances, complete and in place, in accordance with the Contract Documents.
B. The requirements of Section 400500 — Piping, General apply to the Work of this Section.
1.2 DESIGN REQUIREMENTS
A. Piping Layout: Layout and fabricate piping systems with piping sections as long as possible, while still allowing shipment, so that joints made up in the field are minimized. Piping layout shall not rely on field welding, which is prohibited except as authorized by Engineer for special circumstances.
1. Piping design indicated on the Drawings illustrates piping layout and configuration and does not indicate the location of every field joint and flexible coupling that may be needed to connect piping sections fabricated in the shop.
2. Add joints and flexible couplings in a manner that achieves intent of maximizing size of individual piping sections.
3. Obtain acceptance of Engineer for joints and connectors prior to fabrication.
B. Shop Fabrication: Fabricate piping sections in the shop and pickle and passivate at point of manufacture.
C. Field Assembly: Assemble shop -fabricated piping in the field using the joints designed into the piping layout or by using flexible couplings. Field welding is prohibited, unless written authorization is provided by the Engineer.
1.3 SUBMITTALS
A. Layout Drawings: Provide detailed layout drawings showing dimensions and alignment of pipes; location of valves, fittings, and appurtenances; location of field joints and couplings; location of pipe hangars and supports; connections to equipment or structures; location and details of shop welds; and thickness and dimensions of fittings and gaskets.
1. Prepare layout drawings using latest version of AutoCAD.
2. Submit AutoCAD files after layout drawings have been reviewed and accepted by Engineer.
B. Product Data: Provide the following:
1. Photographs, drawings, and descriptions of pipe, fittings, welding procedures, and pickling and passivating procedures.
2. Material specifications for pipe, gaskets, fittings, and couplings.
3. Data on joint types and components used in the system including stub ends, backing flanges, flanged joints, grooved joint couplings and screwed joints.
C. Manufacturing certifications.
CITY OF BEAUMONT STAINLESS STEEL PIPING AND TUBING
MESA LIFT STATION UPGRADE 400523 - 1
D. Welder and weld operator qualification certificates and welding procedures. A schedule of weld operators and identification symbols, as required in Article 2.01 F. Field welding references.
PART 2- PRODUCTS
2.1 PIPE MATERIAL
A. General:
1. Pipe sizes specified in the Specifications and indicated on the Drawings are nominal.
B. Wall Thickness:
1. As specified in the piping schedule.
C. Piping Material and Manufacturing: Comply with the requirements outlined in the following table (unless otherwise specifically noted in the Drawings):
Service
Stainless Steel Grade
Pipe Manufacturing Process
Piping 3 inches in nominal
diameter and larger
Type 316L stainless steel
conforming to ASTM A 240
In accordance with ASTM A 778
Piping less than 3 inches in
nominal diameter
Type 316L stainless steel
conforming to ASTM A 240
In accordance with ASTM A 312
D. Fittings for Piping 3 inches in Nominal Diameter and Greater:
1. Material: ASTM A 240 stainless steel, grade to match the pipe.
2. Manufacturing Standard: ASTM A 774.
3. Wall Thickness of Fitting: In accordance with ANSI B 36.19 for the schedule of pipe specified.
4. End Configuration: As needed to comply with specified type of joint.
5. Dimensional Standards:
a. Fittings with Weld Ends: In accordance with ANSI B 16.9. b. Fittings with Flanged Ends: In accordance with ANSI B16.5, Class 150.
E. Fittings for Piping Less than 3 inches in Diameter:
1. Material: ASTM A 240 stainless steel, grade to match the pipe.
2. Manufacturing Standard: ASTM A 403, Class WP.
3. Wall Thickness and Dimensions of Fitting: In accordance with ANSI B16.3 or ANSI B16.9 as appropriate and as required for the schedule of pipe specified.
4. End Configuration: As needed to comply with specified type of joint.
5. Forgings conforming to ASTM A182, Grade F304 or Grade F316; or barstock conforming to ASTM A276, Type 316. Forging or barstock material shall match the piping materials.
F. Piping Joints:
1. Joint Types, Piping Greater than 2 Inches in Diameter, General:
a. Where type of joint is specifically indicated on the Drawings or specified, design and shop -fabricate piping sections utilizing type of joint illustrated or scheduled. b. Where type of joint is not specifically indicated on the Drawings or specified in the Piping Schedule, design and shop -fabricate piping sections utilizing any of the following joint types:
1) Piping stub ends with backing flanges.
2) Welded joints.
CITY OF BEAUMONT STAINLESS STEEL PIPING AND TUBING
MESA LIFT STATION UPGRADE 400523 - 2
3) Flanged joints.
c. Joints at Valves and Pipe Appurtenances: Provide flanged valves and flanged pipe appurtenances in stainless steel piping systems with flanged ends. Design and fabricate piping sections to make connections with flanged valves and pipe appurtenances using piping stub ends with backing flanges, flanged coupling adapters or flanged joints.
1) Flexible Couplings and Flanged Coupling Adapters: Provide stainless steel construction with materials matching the piping system, Dresser Industries, Style 38 or equal.
2. Joints in Piping 2 Inches in Diameter and Smaller: Flanged or screwed with Teflon tape thread lubricant.
3. Welded Joints:
a. Pipe 12 Inches and Larger in Diameter: Automatically weld joints using gas tungsten -arc procedures.
b. Piping 4 Inches Through 12 Inches in Diameter: Double butt welded joints c. Piping less than 4 Inches in Diameter: Single butt -welded joints.
4. Flanged Joints: Conforming to the requirements of ANSI B16.5, Class 150.
5. Piping Stub Ends and Backing Flanges for Pipe 3 inches and Larger:
a. Piping Stub Ends: Cast Type 316L stainless steel to match the pipe material with machined gasket and wetted surfaces of stub ends free of crevices, pits, cracks and protrusions. Manufacturers: Alaskan Copper Works, Figure SK -38 or equal. b. Backing Flanges: Cast or forged Type 316 stainless steel with drilled bolt patterns conforming to ANSI B16.1, Class 125 or ANSI B16.5, Class 150. Manufacturers:
Alaskan Copper Works, Figure SK -39 or equal.
6. Flanges for Schedule 10s, 40s and 80S Pipe:
a. Provide forged Type 316L stainless steel welding neck flanges or slip-on flanges conforming to ANSI B16.5 Class 150.
b. Material shall conform to ASTM A182.
7. Grooved Joints: Rigid type with rolled grooves.
a. Pipe and fittings roll grooved to conform with AWWA C 220. b. Grooving may be accomplished in factory or in field. c. Couplings: Rigid type, cast from ductile iron, Victaulic Style 07 or equal. Coat per Section 098000 — Protective Coatings
G. Gaskets:
1. Aeration Air Service: Unless noted otherwise - EPDM, suitable for temperatures up to 250 °F, 1/8 -inch thick (minimum), 60 shore hardness, smooth surface. Garlock Style 8314 or equal.
2. All Other Service Applications: EPDM, nitrile, or other materials compatible with the process fluid.
H. Bolts for Flanges and Stub End/Backing Flanges: In compliance with ASTM A193 heavy hex head.
Length such that after installation, end of bolt projects 1/8 -inch to 3/8 -inch beyond outer face of nut. Nuts shall comply with ASTM A194 heavy hex pattern. Bolts, nuts, and washers shall be Type 316 stainless steel.
Fabrication of Pipe Sections:
1. Welding: Weld in accordance with Section 05 50 00 and using electrodes and techniques in accordance with AWS D10.4.
2. Weld Seams:
CITY OF BEAUMONT STAINLESS STEEL PIPING AND TUBING
MESA LIFT STATION UPGRADE 400523 - 3
a. Full penetration welds, free of oxidation, crevices, pits and cracks and without undercuts.
b. Provide weld crowns of 1/16 inch with tolerance of plus 1/16 inch and minus 1/32 inch.
c. Where internal weld seams are not accessible, use gas tungsten -arc procedures with internal gas purge.
d. Where internal weld seams are accessible, weld seams inside and outside using manual shielded metal -arc procedures.
J. Pickling and Passivation:
1. Following shop fabrication of pipe sections, straight spools, fittings and other piping components, pickle and passivate fabricated pieces.
2. Immerse fabricated pieces in sulfuric acid solution followed by immersion in a nitric - hydrofluoric bath and subsequent wash at the proper temperature and length of time.
3. Finish Requirements: Remove free iron, heat tint oxides, weld scale, and other impurities, and obtain a passive finished surface.
2.2 STAINLESS STEEL TUBING
A. Stainless Steel Tubing: Seamless tubing made of Type 316L stainless steel and conforming to ASTM A 269, wall thickness not less than 0.065 inches.
B. Fittings: Swage ferrule design with components made of Type 316 stainless steel.
1. Double acting ferrule design, providing both a primary seal and a secondary bearing force.
2. Flare, bite, or compression type fittings are not acceptable.
3. Manufacturers: One of the following or equal:
a. Crawford Fitting Company, Swagelok.
b. Hoke, Gyrolok.
c. Parker, CPI.
C. Valves for Use with Stainless Steel Tubing:
1. Ball type valves with swage ends to match tubing diameter.
2. Type 316 / 316L stainless steel with TFE seats.
3. Manufacturers: Apollo, Nupro or equal.
2.3 SOURCE QUALITY CONTROL
A. Visually inspect pipe for welding defects such as crevices, pits, cracks, protrusions, and oxidation deposits.
B. Provide written certification that the pipe as supplied conforms to the requirements of ASTM A778.
Supplemental testing is not required.
C. Provide written certification that the fittings as supplied conform to the requirements of ASTM A774. Supplementary testing is not required.
CITY OF BEAUMONT STAINLESS STEEL PIPING AND TUBING
MESA LIFT STATION UPGRADE 400523 - 4
PART 3 - EXECUTION
3.1 PIPE PREPARATION
A. Prior to installation, each pipe length shall be carefully inspected, be flushed clean of any debris or dust, and be straightened if not true. Ends of threaded pipes shall be reamed and filed smooth. Pipe fittings shall be equally cleaned before assembly.
3.2 INSTALLATION
A. General: Stainless steel pipe shall be installed in a neat and workmanlike manner, properly aligned and cut from measurements taken at the Site to avoid interferences with structural members, architectural features, openings, and equipment. Exposed pipe shall afford maximum headroom and access to equipment, and where necessary all piping shall be installed with sufficient slopes for venting or drainage of liquids and condensate to low points. Installation shall be acceptable to the Engineer.
B. Supports and Anchors: Piping shall be firmly supported with fabricated or commercial hangers or supports in accordance with Section 40 00 01 — Pipe Supports. Where necessary to avoid stress on equipment or structural members, the pipe shall be anchored or harnessed. Expansion joints and guides shall compensate for pipe expansion due to temperature differences.
C. Valves and Unions: Unless otherwise indicated, connections to fixtures, groups of fixtures, and equipment shall be provided with a shutoff valve and union, unless the valve has flanged ends.
Unions shall be provided at threaded valves, equipment, and other devices requiring occasional removal or disconnection.
D. Protection: Preserve appearance and finish of stainless steel piping by providing suitable protection during handling and installation and until final acceptance of the Work.
1. Handling methods and equipment used shall prevent damage to the coating and shall include the use of wide canvas slings and wide padded skids.
2. Bare cables, chains, hooks, metal bars, or narrow skids shall not be used.
3.3 PIPE JOINTS
A. Threaded Joints: Pipe threads shall conform to ANSI/ASME B 1.20.1 — Pipe Threads, General Purpose (inch), and shall be full and cleanly cut with sharp dies. Not more than three threads shall remain exposed after installation.
B. Welded Joints: Welded joints shall conform to the specifications and recommendations of ANSI/ASME B 31.1 — Power Piping. Welding shall be done by skilled and qualified welders per Section 40 05 00 — Piping, General.
1. Field welding is prohibited unless written authorization is provided. Pipe butt welds may be performed at the Site, if authorized by the Engineer, providing the butt welds are performed only with an inert gas shielded process and that other indicated welding requirements are followed rigidly.
2. Residue, oxide, and heat stain shall be removed from any type of field weld and the affected areas adjacent by the use of stainless steel wire brushes, followed by cleaning, inside and outside of pipe, with an agent such as Eutectic Company's "Euclean" or equal, followed by complete removal of the agent.
CITY OF BEAUMONT STAINLESS STEEL PIPING AND TUBING
MESA LIFT STATION UPGRADE 400523 - 5
C. Grooved Joints: Grooves for grooved couplings and fittings shall be made with specially designed grooving tools to the manufacturer's recommendations and conforming to ANSI/AWWA C606.
Grooves shall be clean and sharp without flaws, and the pipe ends shall be accurately cut at 90 degrees to the pipe axis.
3.4 INSPECTION AND FIELD TESTING
A. Inspection: The finished installation shall be carefully inspected for proper supports, anchoring, interferences, and damage to pipe, fittings, and coating. Damage shall be repaired to the satisfaction of the Engineer.
B. Field Testing: Prior to enclosure or burying, piping systems shall be pressure tested as required in the Piping Schedule, for a period of not less than one hour, without exceeding the tolerances listed in the Piping Schedule. Where no pressures are indicated, the pipes shall be subject to 1-1/2 times the maximum working pressure. The Contractor shall furnish all test equipment, labor, materials, and devices at no extra cost to the Owner.
1. Leakage may be determined by loss of pressure, soap solution, chemical indicator, or other positive and accurate method. All fixtures, devices, or other accessories which are to be connected to the lines and which would be damaged if subjected to the test pressure shall be disconnected and ends of the branch lines plugged or capped as required during the testing procedures.
2. Leaks shall be repaired to the satisfaction of the Engineer and the system shall be re -tested until no leaks are found.
END OF SECTION 400523
CITY OF BEAUMONT STAINLESS STEEL PIPING AND TUBING
MESA LIFT STATION UPGRADE 400523 - 6
SECTION 400533 - HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS PART 1 - GENERAL
1.1 SECTION INCLUDES
A. The Contractor shall provide high density polyethylene pipe and appurtenances, complete in place, in accordance with the Contract Documents.
1.2 RELATED SECTION
A. Section 312000 — Earth Moving
1.3 REFERENCES
A. The Materials and Work furnished shall be, as a minimum, in accordance with the latest editions of the following standards except as such Standard are modified and supplemented in this section.
AWWA C906 Standard for Polyethylene (PE) Pressure Pipe & Fittings, 4 inch (100 mm) through 63 inch (1,575 mm) for Water Distribution and Transmission
ASTM D1238 Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer
ASTM D1248 Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable
ASTM D1505 Standard Test Method for Density of Plastics by the Density - Gradient Technique
ASTM D2837 Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Products
ASTM F714 Standard Specification for Polyethylene (PE) Plastic Pipe (SDR- PR) Based on Outside Diameter
ASTM D3035 Standard Specification for Polyethylene (PE) Plastic Pipe (DR - PR) Based on Controlled Outside Diameter
ASTM D3261 Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing ASTM D3350 Standard Specification for Polyethylene Plastics Pipe and Fittings Materials
ASTM D256 Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics
ASTM D2683 Standard Specification for Socket -Type Polyethylene Fittings for Outside Diameter -Controlled Polyethylene Pipe and Tubing ASTM F1055 Standard Specification for Electrofusion Type Polyethylene Fittings for Outside Diameter Controlled Polyethylene Pipe and Tubing
ASTM D2657 Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings
ASTM F2164 Standard Practice for Field Leak Testing of Polyethylene (PE) Pressure Piping Systems Using Hydrostatic Pressure
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-1
ASTM F1417
PPI TR-33
1.4 SUBMITTALS
Standard Test Method for Installation Acceptance of Plastic Gravity Sewer Lines Using Low -Pressure Air
Generic Butt Fusion Joining Procedure for Field Joining of PE Pipe
A. The Contractor shall submit the following information and data. See Section 013300 — Contractor Submittals.
1. Product Data: Provide data indicating pipe, pipe accessories and fittings.
2. Manufacturer's Installation Instructions: Indicate special procedures required to install products specified.
3. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.
4. Certified Resin Test Reports covering the physical, stress, regression, thermal and impact tests of resin material to be used for the pipe. Submit this information prior to manufacturing or fabricating any pipe.
5. Proposed butt fusion procedures including training and qualification requirements and joint repair procedures shall be submitted to the Engineer for review and approval.
6. Qualifications of Butt Fusion Welders and Welding Operators a. All butt fusion welders and welding operators shall be qualified and certified for all portions of the work specified in this section. Welder qualification requires that during the past 12 months all welders and welding operators have successfully completed certified butt -fusion joints using the pipe and welding machine proposed for this project.
b. Current welder and welding operator performance qualification test records shall be submitted to the Engineer for review and approval prior to commencing field operations.
c. Personnel that will be operating the butt fusion welder shall be certified by either 1 and 3, or 2 and 3 of the following criteria:
1) Previous demonstrated experience during the past 12 months, in the use of the procedure on similar projects using the same welding machines and type of pipe proposed.
2) Appropriate training and apprenticeship
3) All operators shall make a specimen joint from the pipe to be used on the project. This joint shall then be subjected to the test requirements specified herein.
7. Fusion parameters including the recommended limits of all criteria recorded by the data logger.
8. Fusion report for each joint, which shall include the following information. a. Pipe size and dimensions
b. Machine size
c. Operator identification
d. Job identification number
e. Weld number
f. Fusion, heating and drag resistance settings
g. Heater plate temperature
h. Time Stamp
i. Heating and curing time of weld
j. Curing temperature readings and time stamps of readings k. Ambient air temperature and humidity
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-2
1. Error message and warnings for out of range temperature or pressure settings.
1.5 REGULATORY REQUIREMENTS
A. Conform to applicable codes for materials and installation of the Work in this Section.
1.6 PROJECT CONDITIONS
A. Coordinate the Work on existing utility lines and connections to existing utility lines with the Owner.
1.7 QUALITY CONTROL
A. Any pipe manufactured prior to review and approval of all required prefabrication submittals will be at the Contractor's own risk.
B. Review of the Contractor's shop drawings shall not relieve the Contractor of any responsibility for accuracy of dimensions and details, nor shall mutual Agreement of dimensions or details relieve the Contractor of responsibility for Agreement and conformity of its Shop Drawings with the Contract.
1.8 QUALITY ASSURANCE
A. Fabrication, processing, testing and inspection operations affecting the pipe and associated accessories shall, at any time, be subject to quality assurance surveillance by Owner, or Engineer.
Such surveillance shall be at the discretion of the Owner. Such surveillance does not relieve the Contractor from responsibility for the Work.
B. All deviations from this specification section must be documented and referred to Engineer for resolution.
C. The Contractor shall submit to the Engineer an affidavit from the manufacturer that the pipe, specials, fittings, and other products of material furnished under this Contract comply with all applicable provisions of AWWA C906 standards and this specification.
D. DOCUMENTATION: The following items shall be documented and stored as part of the manufacturer's permanent records. Copies of all documentation shall be provided to the Engineer.
1. Documentation from the resin's manufacturer showing results of the following tests for resin identification:
a. Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer, ASTM D1238
b. Standard Test Method for Density of Plastics by the Density - Gradient Technique, ASTM D1505
2. The polyethylene pipe manufacturer shall provide certification that stress regression testing has been performed on the specific polyethylene resin being utilized in the manufacture of this product. This stress regression testing shall have been done in accordance with ASTM D2837 and the manufacturer shall provide a product supplying a minimum Hydrostatic Design Basis (HDB) of 1,600 psi as determined in accordance with ASTM D2837.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-3
3. Production staff shall check each length of pipe produced for the items listed below. The results of all measurements shall be recorded on production sheets, which becomes part of the manufacturer's permanent records.
a. Pipe in process shall be checked visually, inside and out for cosmetic defects (grooves, pits, hollows, etc.)
b. Pipe outside diameter shall be measured using a suitable periphery tape to ensure conformance with ASTM D3035.
c. Pipe wall thickness shall be measured at 12 equally spaced locations around the circumference at both ends of the pipe to ensure conformance with ASTM D3035. d. Pipe length shall be measured.
e. Pipe marking shall be examined and checked for accuracy. f. Pipe ends shall be checked to ensure they are cut square and clean. g. Subject inside surface to a "reverse bend test" to ensure the pipe is free of oxidation (brittleness).
h. Copies of all manufacturer documentation shall be submitted to the Engineer for review and approval upon completion of manufacturing.
E. In addition to those tests specifically required, the Engineer may request additional samples of any material for testing by the Owner. The additional samples shall be furnished as a part of the Work.
PART 2 - PRODUCTS
2.1 GENERAL REQUIREMENTS
A. Contractor shall comply with the following minimum requirements:
1. Referenced standards for all materials, processes, methods, tests, etc to be used in completion of the Work.
2. Delivery of all pipe and materials, all aspects of which shall be conducted in such a manner as to minimize handling, provide proper weather protection and storage, and to meet schedule requirements.
3. Furnish and use load rated nylon -type slings for securing, lifting, and unloading pipe sections; or, the use of acceptable protective wraps to minimize damage from the alternate rigging equipment.
4. Internal timber bracing shall be provided to maintain pipe shape and integrity throughout plant storage, transportation, and site storage operations through installation and backfill placement. Internal bracing shall not be removed until a minimum of 2 feet of compacted trench zone material is placed above the top of the pipe.
2.2 MANUFACTURER
A. All HDPE pipe and HDPE fittings shall be from a single manufacturer, who is fully experienced, reputable and qualified in the manufacture of the HDPE pipe to be furnished. The pipe shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these Specifications. Qualified manufacturers shall be: PLEXCO Division of Chevron Phillips Chemical Company, DRISCOPIPE as manufactured by Chevron Phillips Co., Inc., WL Plastics or equal.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-4
2.3 PIPE IDENTIFICATION
A. The following shall be continuously indent printed on the pipe or spaced at intervals not exceeding 5 -feet:
1. Name and/or trademark of the pipe manufacturer.
2. Nominal pipe size.
3. Dimension ratio.
4. The letters PE followed by the polyethylene grade in accordance with ASTM
5. D1248 followed by the hydrostatic design basis of 1600 psi, e.g., PE 4710.
6. Manufacturing standard reference, e.g., ASTM D-3035, as required.
7. A production code from which the date and place of manufacture can be determined.
8. Color Identification, either striped by co -extruding longitudinal identifiable color markings or shall be solid in color and as follows:
a. BLUE — Potable Water
b. GREEN — Sanitary Sewer
c. PURPLE — Non -Potable (Recycled) Water
B. Marking Tape: Marking tape shall be provided and installed as shown in Drawings and per Engineer approval.
2.4 COMPATIBILITY
A. Contractor is responsible for compatibility between pipe materials, fittings and appurtenances.
2.5 WARRANTY
A. The pipe Manufacturer shall provide a warranty against manufacturing defects of material and workmanship for a period of ten years after the final acceptance of the project by the Owner. The Manufacturer shall replace at no expense to the Owner any defective pipe/fitting material including labor within the warranty period.
2.6 MATERIALS
A. Materials used for the manufacture of polyethylene pipe and fittings shall be made from a PE 4710 high density polyethylene resin compound meeting a minimum cell classification 445574C per ASTM D3350 and ASTM F714.
B. High Density Polyethylene (HDPE) pipe shall be manufactured in accordance with AWWA C901- 96 for sizes 1/2 -inch through 3 -inch diameters and to the requirements of ASTM D 3035. Pipe 4 - inches and above shall be manufactured to the requirements of ASTM F714 and AWWA C906-99.
C. Unless otherwise noted, diameters shown in the Contract Documents shall refer to Iron Pipe Size (IPS) system conforming to the requirements of AWWA C906.
D. If rework compounds are required, only those generated in the Manufacturer's own plant from resin compounds of the same class and type from the same raw material supplier shall be used. Clean rework material of the same type grade, and cell classification generated from the manufacturers own pipe and fitting production may be used by the same manufacturer as long as the pipe, tubing and fittings produced meet all requirements of AWWA C906.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-5
E. Dimensions and workmanship shall be as specified by ASTM F714. HDPE fittings and transitions shall meet ASTM D3261. HDPE pipe shall have a range of density 0.956-0.964 grams per cubic centimeter. All HDPE pipe and fittings shall have a Hydrostatic Design Basis (HDB) of 1,600 psi at 73.0°F in accordance with ASTM D2837.
F. The extruded pipe shall have impact strengths greater than 42 in-lb/in in accordance with ASTM D256 Method A, with a material thickness representative of the cross-section in which the material is to be used.
G. Pipe and things used for potable water applications shall be NSF 61 certified.
H. The pipe Manufacturer shall certify compliance with the above requirements.
2.7 FABRICATION
A. Pipe shall be homogenous throughout and uniform in color, opacity, density and other properties as prescribed in the Resin Manufacturers Specifications. The inside and outside surfaces shall be semi -matte to glossy in appearance and free from sticky or tacky material. The pipe walls shall be free from cuts, cracks, holes, blisters, voids, foreign inclusions, or other defects that are visible to the naked eye that may affect wall integrity.
B. Pipe dimensions and wall thickness variations shall be in conformance with requirements of AWWA C906.
C. Pipe shall be finished smooth throughout all inside surfaces and true to all specified tolerances circumference and diameter such that: The difference between maximum and minimum diameters, at any cross-section along the length of the pipe does not exceed 1% of the nominal diameter.
D. Special pipe sections, fittings, and special pieces shall be completely fabricated in the shop. All pipe fittings shall be fabricated or molded to correct dimensions throughout the entire length. Ends cuts shall be clean, squarely -made, and suitable for field welding, without drawn, ragged, gouged, or split ends.
E. All HDPE fittings, unless noted otherwise on the drawings shall be fabricated in conformance with the requirements of AWWA C906. Molded fittings shall meet the requirements of ASTM D3261 for butt -type fittings and this specification.
2.8 FITTINGS
A. All molded fittings and fabricated fittings shall be fully pressure rated to match the pipe SDR pressure rating to which they are made. All fittings shall be molded or fabricated by the manufacturer. No Contractor fabricated fittings shall be used unless approved by the Engineer.
B. Polyethylene fittings furnished under this specification shall be manufactured using compounds complying with the requirements of HDPE pipe above and all appropriate requirements of AWWA C906. Socket fittings shall comply with ASTM D2683, Butt Fusion fittings shall comply with ASTM D3261. Electrofusion fittings shall comply with ASTM F1055. Mechanical fittings (e.g. back-up rings, etc.) shall be of stainless steel, including stainless steel hardware, as indicated in the drawings and shall be approved only after submission of appropriate test data and service histories indicating their acceptability for intended service. In all cases, the specification and requirements
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-6
for the fittings supplied shall comply with the appropriate sections of AWWA C906 and must be approved by the Engineer. NO size on size wet taps shall be permitted.
C. The manufacturer of the HDPE pipe shall supply all HDPE fittings and accessories as well as any adapters and/or specials required to perform the work as shown on the Drawings and specified herein.
2.9 SHIPPING, STORAGE & HANDLING
A. All materials shall be properly loaded so that they will not bear on each other, and shall be braced to prevent damage to material during shipping. Pipe shall be stacked on level ground and per the manufacturer's recommendations to prevent pipe from becoming out of round.
B. All loose parts shall be crated or boxed for shipping, appropriately identified and shipped with the associated pipe sections.
C. Contractor shall protect pipeline sections stored at the site from damage, including weather and vandalism.
D. Pipes shall be stored on level ground, preferably turf or sand, free of sharp objects, which could damage the pipe OR on wooden sleepers, spaced suitably and of such width as not to allow deformation of the pipe at the point of contact with the sleeper or between supports. Stacking of the polyethylene pipe shall be limited to a height that will not cause excessive deformation of the bottom layers of pipes under anticipated temperature conditions. The Contractor shall abide by the required handling techniques specified by the Supplier.
E. The handling of the pipe shall be in such a manner that the pipe is not damaged by dragging it over sharp and cutting objects
F. All piping products shall be kept free from dirt, grease, all petroleum based products, and other foreign matter.
G. The Contractor shall provide suitable lifting equipment, slings, spreader bars, rigging etc needed to handle the pipe. In no case shall any equipment be used that is not rated to handle the intended loading or conditions of use to which it is subjected. The use of cables and chains is prohibited.
H. The Contractor shall be responsible for the pipe until such time as it is installed and accepted by the Engineer.
I. The Contractor shall remove any temporary attachments to special components for installation by the Supplier for transportation purposes.
2.10 BEDDING AND COVER MATERIALS
A. Pipe bedding Material: As specified in Section 312000 — Earth Moving.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-7
PART 3 - EXECUTION
3.1 INSTALLATION — HDPE PIPING
A. High Density Polyethylene (HDPE) Pipe shall be installed in accordance with the instructions of the manufacturer, as shown on the Drawings and as specified herein. A factory qualified joining technician as designated by the pipe manufacturer shall perform all heat fusion joints.
B. Under no circumstances shall the pipe or accessories be dropped into the trench or forced through a directional bore upon "pull -back".
C. The maximum allowable depth of cuts, scratches or gouges on the exterior of the pipe is 5 percent of wall thickness. The interior pipe surface shall be free of cuts, gouges or scratches. Sections of pipe with cuts, scratches or gouges exceeding 5 percent of the pipe wall thickness shall be removed completely and the ends of the pipeline rejoined. Repair of damaged pipe during or after installation shall conform to the fabricator's repair procedures or by an Engineer approved repair method.
D. When laying pipe is not in progress, the open ends of the pipe shall be closed by fabricated plugs, or by other approved means.
E. The interior of the pipe shall be cleaned of any foreign matter before being lowered in the trench and kept clean during placement, joint welding, bedding and backfilling operations by plugging or other approved method. Groundwater shall not be permitted to enter the pipe. The full length of each pipe section and each bend shall rest solidly on the compacted bedding material.
F. All HDPE pipe must be at the temperature of the surrounding soil at the time of backfilling and compaction.
G. If a defective pipe is discovered after it has been installed, it shall be removed and replaced with a sound pipe in a satisfactory manner at no additional cost to the Owner. All pipe and fittings shall be thoroughly cleaned before installation, shall be kept clean until they are used in the work and when laid, shall conform to the lines and grades required.
H. Contractor shall install HDPE pipe when the ambient air temperature conforms to manufacturer's specifications. The Contractor will be responsible for verifying the temperature by maintaining a log listing dates, times, length of pipe installed and ambient temperature during installation.
I. Trench bottoms shall be graded such that each section of pipe shall be placed to the specified depth or elevation with uniform support. When the bottom of the trench has been excavated below the specified depth or elevation it shall be brought to the specified depth or elevation by backfilling with approved pipe zone material. When material at the bottom of the trench is determined to be unsuitable by the Engineer, it shall be removed and the trench backfilled with approved subgrade material or bedding material to the specified depth of excavation.
J. During pipe installation, the trench bottom shall be kept free of frost, frozen earth, or standing water. The Contractor shall maintain the trench in good, stable condition at all times to prevent caving.
K. Precautions shall be taken to prevent flotation of the pipe in the trench.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-8
L. The pipeline may be buried as it is installed, provided all inspection, testing and backfill requirements are met.
M. All areas disturbed by installation of the pipeline shall be restored in accordance with the specification and drawings.
3.2 JOINING METHOD
A. HDPE pipe shall be joined with butt, heat fusion joints as outlined in ASTM D3261 and conform to the Generic Butt Fusion Joining Procedure for Field Joining of Polyethylene Pipe, Technical Report TR-33, published by the Plastic Pipe Institute (PPI). All joints shall be made in strict compliance with the manufacturer's recommendations. A factory qualified joining technician as designated by pipe manufacturer or experienced, trained technician shall perform all heat fusion joints in the presence of the Inspector. The Contractor shall install the HDPE pipeline complete, including bends, couplings, valves, and other associated fittings and appurtenances as shown on the drawings or specified herein and make all necessary connections to the lines and grades shown on the Drawings and in accordance with these specifications.
B. The Contractor shall furnish all welding equipment and all construction materials and equipment required for lugs, railings, templates, spiders or other supports and internal bracing as may be required to hold the components firmly within the specified tolerances during welding, concrete placement or backfill placement. The contractor shall also furnish and install all necessary positioning devices, ties, pedestals and supports required for installation. Details of such equipment shall be included in the proposed installation procedure to be submitted to the engineer prior to the start of work.
C. Lengths of pipe shall be assembled into suitable installation lengths by the butt -fusion process. All pipes so joined shall be made from the same class and type of raw material made by the same raw material supplier. Pipe shall be furnished in standard laying lengths not to exceed 50 feet and no shorter than 20 feet. Installation shall be in accordance with the requirements of AWWA C906 unless otherwise noted, and the Manufacturer's instructions. Contractor shall be responsible for correct fitting of all pipeline members and components.
D. The polyethylene flange adapters shall be used at pipe material transitions and other locations as indicated in the drawings. The adapters shall be connected together or to other flanges by using a stainless steel "back-up" ring conforming to ANSI B16.1 and shaped as necessary to suit the outside dimensions of the pipe. Ensure that back up rings are in place prior to joining flange adapter to piping or other components. The flange adapter assemblies shall be connected with corrosion resistant bolts and nuts of Type 316 Stainless Steel as specified in ASTM A726 and ASTM A307.
All bolts shall be tightened to the manufacturer's specified torques. Bolts shall be tightened alternatively and evenly. After installation apply a non -oxide grease coating to bolts and nuts.
E. Where indicated, sleeve couplings shall be used to make HDPE joints. When sleeve couplings are used, stainless steel (Type 316), pipe stiffeners shall be inserted inside of each HDPE pipe end as recommended by the manufacture to prevent the pipe from going out of round and to ensure a leak free joint. Sleeve couplings shall be specifically rated for service with HDPE pipe and shall be as specified in the Contract Documents. Sleeve coupling shall only be used where indicated in the plans and in conjunction with an HDPE Pipe Anchor Block.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-9
3.3 PREPARATION
A. Butt -fusion welded joints: Refer to Manufacturers recommended procedures. All joints formed by butt fusion processes shall be completed in strict accordance with the Manufacturers specified procedures, except where specifically called out in the specifications or drawings. Minimum requirements for butt -fusion welded joints are as follows:
1. Pipe ends shall be made clean and square prior to fitting and alignment
2. Care shall be taken to assure a clean work area, free from airborne dust, moisture, or other foreign matter which may contaminate the finished weld.
3. All internal surfaces of the pipe shall be maintained clean following completion of a weld and prior to starting the next joint.
4. All butt -fusion joints shall be water tight under the maximum internal pressure.
3.4 BACKFILL PLACEMENT
A. Pipe zone material shall be placed in accordance with Section 312000 — Earth Moving. Care shall be taken to ensure that the material is carefully worked and compacted into the area beneath and around the pipe to provide continuous support to the pipe. Material shall be properly haunched to provide support. Care shall be taken to avoid movement of the pipe during placement and compaction of the bedding material. Pipe bedding shall be placed to the limits shown on the drawings.
B. Trench backfill shall be placed in accordance with section 312000 — Earth Moving.
C. No construction vehicles or ride -on mechanical compaction equipment shall be permitted to travel over the pipe until a minimum of 2 feet of trench backfill is placed above the top of the pipe.
3.5 CONNECTION TO EXISTING
A. Mechanical connections of the polyethylene pipe to auxiliary equipment such as valves, pumps and tanks shall be through flanged connections which shall consists of the following:
1. A polyethylene flange adapter shall be thermally butt -fused to the stub end of the pipe.
2. A Type 316 stainless steel back up ring shall mate with the polyethylene flange adapter.
3. Type 316 stainless steel bolts and nuts shall be used to complete the connection.
4. Flange connections shall be provided with a full -face neoprene gasket.
B. All transitions from HDPE pipe to ductile iron or PVC shall be made per the approval of Engineer and per the HDPE pipe manufacturer's recommendations and specifications. A molded flange connector adapter with a back-up ring assembly shall be used for pipe type transitions. Ductile iron back-up rings shall mate with cast iron flanges per ANSI B16.1. A type 316 stainless steel back- up ring shall mate with a type 316 stainless steel flange per ANSI B16.1 and shall be used in all buried applications.
1. Transition from HDPE to ductile iron fittings and valves shall be approved by Engineer before installation.
2. No solid sleeves couplings shall be allowed between such material transitions.
3. The pipe supplier must certify compliance with the above requirements C. Prior to making connections to any existing structure or pipe, ensure that new pipe has had the time required to acclimate to the buried conditions. Make the appropriate adjustments required by the
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-10
thermal expansion and contraction properties of HDPE materials before connecting to any dissimilar material or structure.
3.6 FIELD QUALITY CONTROL
A. On days butt fusions are to be made, the first fusion shall be a trial fusion in the presence of the Inspector. The following shall apply:
1. Heating plates shall be inspected for cuts and scrapes. The plate temperature shall be measured at various locations to ensure proper heating/melting per manufacturer's recommendations and as approved by the Inspector.
2. The fusion or test section shall be cut out after cooling completely for inspection.
3. The test section shall be 12" or 30 times (minimum) the wall thickness in length and 1" or
1.5 times the wall thickness in width (minimum).
4. The joint shall be visually inspected as to continuity of "beads" from the melted material, and for assurance of "cold joint" prevention (i.e. — joint shall have visible molded material between walls of (pipe). Joint spacing between the walls of the two ends shall be a minimum of 1/16" to a maximum 3/16".
3.7 TOLERANCES
A. The centerline of the pipe shall not deviate from a straight line drawn between the centers of the openings at the ends of the pipe by more than 1/16 -in per foot of length. If a piece of pipe fails to meet this requirement check for straightness, it shall be rejected and removed from the site. Laying instructions of the manufacturer shall be explicitly followed. Good alignment shall be preserved during installation. Deflection of the pipe shall occur only at those places on design drawings and as approved by the Engineer. Fittings, in addition to those shown on the Drawings, shall be used only if necessary or required by the Engineer.
3.8 CLEANING
A. Do not allow dirt, grease, mud, groundwater, tools, equipment and all other foreign matter to enter the pipe at any point during construction.
B. All pipes shall be completely flushed at a rate with water velocities no less than 4.0 feet per second for pipes up to 12 inches in diameter and 3.0 feet per second for all other pipes. For large diameter pipes, alternate methods, including pigging, of cleaning the pipe may be proposed by the Contractor, subject to the approval of the Engineer, provided proposed method will provide a clean pipe equivalent to flushing as determined by the Engineer.
C. No debris, rubbish, dirt, rocks, or other foreign material shall be permitted to enter downstream sections of the pipeline or system.
D. Furnish, install and permanently remove all cross -connections, piping, valving, ports, etc required to complete the cleaning process. Obtain approval of the Engineer prior to adding any components to the pipeline.
3.9 HYDROSTATIC PRESSURE TESTING
A. Hydrostatic pressure testing shall be conducted per the requirements of ASTM F 2164 and these specifications.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-11
B. All HDPE mains shall be field-tested. Contractor shall supply all labor, equipment, material, gages, pumps, plugs, meters and incidentals required for testing. Each main shall be pressure tested upon completion of the pipe laying and backfilling operations, including placement of any required temporary roadway surfacing.
C. Submit a plan for testing, including schedule, method for water conveyance, control, and disposal, to the Engineer for review at least 10 days before starting the test and notify the Engineer a minimum of 48 hours prior to test
D. The maximum test pressure shall be as indicated in the Drawings but shall not exceed 150 percent of the maximum working pressure of the pipe or the design pressure of any component on the pipe, whichever is less.
E. The test temperature of the piping and the test liquid (water) shall not exceed 73 degrees F. or the temperature related to the pressure rating of the pipe as reported by the manufacturer.
F. Test equipment, preparations and procedures shall implicitly follow the requirements of ASTM F 2164 and the Manufacturer's recommendations.
G. In preparing for test, fill line slowly with water. Maintain flow velocity less than 2 feet per second or less than the capacity of any air release devices use to expel trapped air, whichever is less.
H. Expel air completely from the line during filling and again before applying test pressure. Air shall be expelled by means of taps at points of highest elevation. Any taps installed solely for the purpose of releasing trapped air shall be permanently capped at the conclusion of the test.
I. Once all air is expelled and all testing equipment and pipeline components are adequately braced, gradually increase the pressure in the pipeline to the required maximum test pressure. Hold test pressure for four hours adding make-up water as required to maintain the noted maximum test pressure.
J. After the four hour equalization period, reduce pressure in the pipeline by 10 psi to the test pressure and monitor the pressure for 1 hour. Do not increase the pressure or add make-up water during this time.
K. During and after the one -hour test period, observe all components, joints, fittings, and appurtenances of the pipeline for visible signs of leakage. Any visible signs of leakage indicate a failed test, all such leaks shall be repaired and pipeline retested before pipeline will be accepted. If any visible signs of leakage in any butt -fusion joints in the pipe are noted, immediately stop the test and carefully release the test pressure. Repair the noted leaks and restart test procedure from beginning.
L. A successful hydrostatic pressure test will be indicated by no visible signs of leakage and a steady pipeline pressure within 5 psi of the test pressure throughout the one hour test period without increasing the pressure or the addition of make-up water.
M. Upon completion of the test, the pressure shall be bled off from a location other than the point where the pressure is monitored. The pressure drop shall be witnessed by the Engineer at the point where the pressure is being monitored and shall show on the recorded pressure read-out submitted to the Engineer.
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-12
N. Repair and/or replace any failed pipeline sections, components, fittings, valves or other appurtenances to the satisfaction of the Engineer and at no additional expense to the Owner.
3.10 LOW PRESSURE AIR TESTING
A. HDPE pipelines intended for use as air ducts shall be tested for leakage prior to placing the pipe in service. Air test shall not be used for acceptance of any HDPE pipeline except those indicated herein or in the Drawings. Furnish, install and completely remove all fittings, branches, plugs, valves and other appurtenances required to complete the testing process.
B. Prior to beginning air test, HDPE pipeline shall be isolated from pipeline components not rated for the air pressures called for in the test.
C. Low pressure air testing shall be completed per the requirements of ASTM F1417 as given in Section 221066 — Pipeline Testing.
D. Pipeline shall be inspected for all visible infiltration leaks as evidenced by infiltrating groundwater.
Leaks shall be located and repaired at no additional cost to the Owner and to the satisfaction of the Engineer.
3.11 MANDREL TESTING
A. After successful completion of hydrostatic test, mandrel test all buried HDPE piping.
B. Mandrel configuration: Rigid with circular cross-section with a diameter of not less than 95% of the average inside diameter of the pipeline with a length of circular proportion equal to the nominal diameter of the pipeline.
C. Mandrel pulling method shall be by hand, rope or as directed by the Engineer.
END OF SECTION 400533
CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-13
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CITY OF BEAUMONT HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS MESA LIFT STATION UPGRADE 400553-14
SECTION 400557 — ACTUATORS FOR PROCESS VALVES AND GATES PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall provide valve and gate actuators and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to valves and gates except where otherwise indicated in the Contract Documents.
C. Unit Responsibility: The valve or gate manufacturer shall be made responsible for coordination of design, assembly, testing, and installation of actuators on the valves and gates; however, the Contractor shall be responsible to the Owner for compliance of the valves, gates, and actuators with the Contract Documents.
D. Single Manufacturer: Where 2 or more valve or gate actuators of the same type or size are required, the actuators shall be produced by the same manufacturer.
E. The requirements of Section 260000 - Electrical General Provisions apply to the Work of this Section.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 013300 — Contractor Submittals.
B. Shop Drawings: Shop Drawing information for actuators shall be submitted together with the valve and gate submittals as a complete package.
C. Calculations: Selection calculations showing dynamic seating and unseating torques versus output torque of actuator.
D. Technical Manuals: The Contractor shall furnish technical manuals for the butterfly valves, butterfly valve manual actuators, and butterfly valve electric motor actuators under one cover and in accordance with the requirements of Section 013300 — Contractor Submittals.
PART 2 - PRODUCTS
2.1 GENERAL
A. Unless otherwise indicated, shut-off and throttling valves and externally actuated valves and gates shall be provided with manual or power actuators. The Contractor shall furnish actuators complete and operable with mounting hardware, motors, gears, controls, wiring, solenoids, handwheels, levers, chains, and extensions, as applicable. Actuators shall have the torque ratings equal to or greater than required for valve seating and dynamic torques, whichever is greater, and shall be capable of holding the valve in any intermediate position between fully -open and fully -closed without creeping or fluttering. Actuator torque ratings for butterfly valves shall be determined in
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 1
accordance with AWWA C504 - Rubber -Seated Butterfly Valves. Wires of motor -driven actuators shall be identified by unique numbers.
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, the Contractor shall coordinate selection to have the fewest number of manufacturers possible.
C. Materials: Actuators shall be current models of the best commercial quality materials and be liberally -sized for the required torque. Materials shall be suitable for the environment in which the valve or gate is to be installed.
D. Actuator Mounting and Position Indicators: Actuators shall be securely mounted by means of brackets or hardware specially designed and sized for this purpose and be 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. 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, actuators shall be in accordance with AWWA C 540 - Power -Actuating Devices for Valves and Slide Gates.
F. Functionality: Electric, pneumatic, and hydraulic actuators shall be coordinated with the power requirements of Division 26.
G. Fasteners: Fasteners shall be in accordance with Section 055000 — Metal Fabrications.
H. Protective Coatings: Protective coatings shall be in accordance with Section 098000 — Protective Coatings.
2.2 MANUAL ACTUATORS
A. General: Unless otherwise indicated, valves and gates shall be furnished with manual actuators.
Valves in sizes up to and including 4 -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. Buried and submerged gear -assisted valves, gates, gear -assisted valves for pressures higher than 250 psi, valves 30 -inches in diameter and larger, and where so indicated, shall have worm gear actuators, hermetically -sealed water -tight and grease -packed. Other valves 6 -inches to 24 -inches in diameter may have traveling nut actuators, worm gear actuators, spur or bevel gear actuators, as appropriate for each valve.
B. Buried Valves: Unless otherwise indicated, buried valves shall have extension stems to grade, with square nuts or floor stands, position indicators, and cast-iron 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 required by the local Utility Company or the Engineer. Wrench nuts shall comply with AWWA C 500 - Metal - Seated Gate Valves for Water Supply Service.
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 2
C. Chain Actuator: Manually -activated valves with the stem located more than 7 -feet above the floor or operating level shall be provided with chain drives consisting of sprocket -rim chain wheels, chain guides, and operating chains provided by the valve manufacturer. The wheel and guide shall be of ductile iron, cast iron, or steel, and the chain shall be hot -dip galvanized steel or stainless steel, extending to 5 -feet 6 -inches above the operating floor level. The valve stem of chain -actuated valves shall be extra strong to allow for the extra weight and chain pull. Hooks shall be provided for chain storage where chains interfere with pedestrian traffic.
D. Floor Stands: Valve actuator floor stands shall be cast iron or fabricated steel pedestals. The centerline of the actuator shall be approximately 42 to 48 inches above the base of the pedestal.
E. Floor Boxes: Hot dip galvanized cast iron or steel floor boxes and covers to fit the slab thickness shall be provided for operating nuts in or below concrete slabs. For operating nuts in the concrete slab, the cover shall be bronze -bushed.
F. Tee Wrenches: Buried valves with floor boxes shall be furnished with 2 operating keys or 1 key per 10 valves, whichever is greater. Tee wrenches sized so that the tee handle will be 2 to 4 feet above ground, shall fit the operating nuts.
G. Manual Worm Gear Actuator: The actuator shall consist of a single or double reduction gear unit contained in a weather-proof cast iron or steel body with cover and minimum 12 -inch diameter handwheel. The actuator shall be capable of 90 degree rotation and shall be equipped with travel stops capable of limiting the valve opening and closing. The actuator shall consist of spur or helical gears or worm gearing. The gear ratio shall be self-locking to prevent "back -driving." The spur or helical gears shall be of hardened alloy steel and the worm gear shall be alloy bronze. The worm gear shaft and the handwheel shaft shall be of 17-4 PH or similar stainless steel. Gearing shall be accurately cut with hobbing machines. Ball or roller bearings shall be used throughout. Output shaft end shall be provided with spline to allow adjustable alignment. Actuator output gear changes shall be mechanically possible by simply changing the exposed or helical gearset ratio without further disassembly of the actuator. Gearing shall be designed for a 100 percent overload. The entire gear assembly shall be sealed weatherproof. Manual worm gear actuators shall be Auma GS Series, Limitorque HBC Series, no "Or -Equals".
H. Traveling -Nut Actuator: The actuator shall consist of a traveling -nut with screw (Scotch yoke) contained in a weatherproof cast iron or steel housing with spur gear and minimum 12 -inch diameter handwheel. The screw shall run in 2 end bearings, and the actuator shall be self-locking to maintain the valve position under any flow condition. The screw and gear shall be of hardened alloy steel or stainless steel, and the nut and bushings shall be of alloy bronze. The bearings and gear shall be grease -lubricated by means of nipples. Gearing shall be designed for a 100 percent overload.
I. Schedule for Manual Actuator Types: For a complete schedule of manual actuators required on project valves (4" diameter and larger), see Valve Schedule Drawings.
2.3 ELECTRIC MOTOR ACTUATORS
A. General
1. Equipment Requirements: Where electric motor actuators are indicated, an electric motor - actuated valve control unit shall be attached to the actuating mechanism housing by means of a flanged motor adapter piece.
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 3
2. Gearing: The motor actuator shall include the motor, reduction gearing, reversing starter, torque switches, and limit switches in a weather-proof NEMA 4X assembly. The actuator shall be a single or double reduction unit consisting of spur or helical gears and worm gearing. The spur or helical gears shall be of hardened alloy steel, and the worm gear shall be alloy bronze. Gearing shall be accurately cut with hobbing machines. Power gearing shall be grease- or oil -lubricated in a sealed housing. Ball or roller bearings shall be used throughout. Actuator output speed changes shall be mechanically possible by simply removing the motor and changing the exposed or helical gearset ratio without further disassembly of the actuator.
3. Starting Device: Except for modulating valves, the unit shall be so designed that a hammer blow is imparted to the stem nut when opening a closed valve or closing an open valve.
The device should allow free movement at the stem nut before imparting the hammer blow.
The actuator motor must attain full speed before stem load is encountered.
4. Switches
a. Electronic Type Switches: Limit switches or valve position shall be sensed by a 15 bit, optical, absolute position encoder. The open and closed positions shall be stored in a permanent, non-volatile memory. The encoder shall measure valve position continuously, including both motor and hand wheel operation, with or without use of battery. An electronic torque sensor shall be furnished. The torque limit may be adjusted from 40 to 100 percent of rating in 1 percent increments.
The motor shall be de -energized if the torque limit is exceeded. A boost function shall be included to prevent torque trip during initial valve unseating, and a "jammed valve" protection feature with automatic retry sequence shall be incorporated to de -energize the motor if no movement occurs. Valve actuators with electronic type switches shall be as manufactured by Limitorque or Auma Actuators, Inc.
b. The actuator shall be wired in accordance with the schematic diagram. Wiring for external connections shall be connected to marked terminals. One of 1 -inch and one of 1.25 -inch conduit connection shall be provided in the enclosing case. A calibration tag shall be mounted near each switch correlating the dial setting to the unit output torque. Switches shall not be subject to breakage or slippages due to over -travel. Traveling -nuts, cams, or micro switch tripping mechanisms shall not be used. Limit switches shall be of the heavy-duty open contact type with rotary wiping action.
5. Handwheel Operation: A permanently attached handwheel shall be provided for emergency manual operation. The handwheel shall not rotate during electrical operation.
The maximum torque required on the handwheel under the most adverse conditions shall not exceed 60 lb.ft, and the maximum force required on the rim of the handwheel shall not exceed 601b. An arrow and either the word "open" or "close" shall be cast or permanently affixed on the handwheel to indicate the appropriate direction to turn the handwheel. A clutch lever shall be provided to put actuator into handwheel operation. Valves with electric motor actuators having stems more than 7 -feet above the floor shall be provided with chain activator handwheels. The clutch lever shall be provided with a cable secured to the chain to allow disengagement for manual operation.
6. Motor: The motor shall be of the totally enclosed, non -ventilated, high -starting torque, low -starting current type for full voltage starting. It shall be suitable for operation on 480 volt, 3 -phase 60 Hz current or 120 volt, 1 -phase 60 Hz current as indicated on drawings, and have Class H insulation and a motor frame with dimensions in accordance with the latest revised NEMA MG Standards. The observed temperature rise by thermometer shall not exceed 55 degrees C above an ambient temperature of 55 degrees C when operating continuously for 15 minutes under full rated load. With a line voltage ranging between 10
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 4
percent above to 10 percent below the rated voltage, the motor shall develop full rated torque continuously for 15 minutes without causing the thermal contact protective devices imbedded in the motor windings to trip or the starter overloads to drop -out. Bearings shall be of the ball type, and thrust bearings shall be provided where necessary. Bearings shall be provided with suitable seals to confine the lubricant and prevent the entrance of dirt and dust. Motor conduit connections shall be watertight. Motor construction shall incorporate the use of stator and rotor as independent components from the valve operation such that the failure of either item shall not require actuator disassembly or gearing replacement.
Two Class B thermal contacts or solid state thermistors imbedded within the motor windings shall be provided to protect against over -temperature damage. The motor shall be provided with a space heater unless the entire actuator is a hermetically sealed, non - breathing design with a separately sealed terminal compartment which prevents moisture intrusion. Each electric motor actuator shall be provided with a local disconnect switch or circuit breaker to isolate power from the motor and controller during maintenance activities.
7. Open/Close Operating Speed: Unless otherwise indicated, electric actuators shall provide a full close to full open or full open to full close operating time range from [30 to 60 seconds].
8. Schedule for Electric AC Actuator Type: For a complete schedule of electric actuators required on project valves (4" diameter and larger), see Mechanical Schedule Drawings. a. All electric actuators identified as "OPEN/CLOSE ELECTRIC" in Schedules, shall have AC Reversing type actuators with an open to close and close to open speed times of 60 seconds and 60 seconds, respectively. b. All electric actuators identified as "MODULATING ELECTRIC" in Schedules, shall have AC Modulating type actuators with an open to close and close to open speed times of 60 seconds and 60 seconds, respectively.
9. Remote Actuator Control Station. Valves with electric motor actuators where the valve centerline is located at a height greater than 6.5 -feet above the floor shall provide a remote actuator control station at a location no higher than 4 -feet above the floor. The Contractor shall provide conduit and wiring between the actuator controls and the valve actuator for these applications. The actuator controls shall be wall -mounted beneath the valve at a location approved by the Design Engineer.
B. Electric Motor Actuators (AC Reversing (Open / Close) Control Type)
1. General: Where indicated, electric motor actuators shall be the AC reversing type complete with local control station with open / stop / close and local/off/remote selector switches on the actuator local control station.
2. Actuator Appurtenances: The actuator for each valve shall be provided with a padlockable disconnect switch, open and closed status lights, open, close and lockout stop pushbuttons, a local/off/remote selector switch, and other devices indicated. The disconnect switches in certain applications are required to be located remotely from the actuator body itself, as shown on the Contract Drawings. The local control station may also be provided as an integral part of the actuator or remotely as otherwise indicated or required to permit operation by a person at floor elevation and within sight of the valve actuator. The Contractor shall provide conduit and wiring between the actuator controls and the valve actuator for these applications.
3. Starter: The starter shall be a suitably sized amperage rated reversing starter with its coils rated for operation on 480 volt, 3 -phase, 60 Hz current or 120 volt, 1 -phase, 60 Hz current as indicated on the drawings. A control power transformer shall be included to provide a 120 volt source, unless otherwise indicated. The starter shall be equipped with 3 overload relays of the automatic reset type. Its control circuit shall be wired as indicated. The
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 5
integral weatherproof compa'tinent shall contain a suitably sized 120 volt ac, single phase, 60 Hz space heater to prevent moisture condensation on electrical components. A local power disconnect switch shall be provided with each actuator. A close -coupled, padlockable switch shall be provided with each actuator.
4. Local Control Station: Each actuator shall be provided with a local control station with the valve actuator assembly. The station shall include open, close, and stop push buttons, and a local/remote selector switch.
5. Manufacturers:
a. Auma, SA Series (for valves 12 inches and smaller) or SA with GS worm gear (for valves 14 inches and larger).
b. Limitorque, MX/QX Series
c. Rotork, IQ3 Series
d. No "Or -Equals" allowed.
C. Electric Motor Actuators (AC Modulating Control Type)
1. General: Where indicated, modulating electric motor actuators shall be the AC modulating type complete with a local control station with power disconnect switch or circuit breaker, provided with open/stop/close and local/off/remote selector switches on the actuator local control station, and open/close status lights.
2. Actuator Appurtenances: The actuator for each valve shall be provided with a padlockable disconnect switch, open and closed status lights, open, close and lockout stop pushbuttons, a local/off/remote selector switch, and other devices indicated. The disconnect switches in certain applications are required to be located remotely from the actuator body itself, as shown on the Contract Drawings. The local control station may also be provided as an integral part of the actuator or remotely as otherwise indicated or required to permit operation by a person at floor elevation and within sight of the valve actuator. The Contractor shall provide conduit and wiring between the actuator controls and the valve actuator for these applications.
3. Control Module: The control module shall be of the electronic solid-state ac type with control outputs for positioning the valve via 4 - 20 ma input signals.
4. Starter: The actuator shall control a solid-state reversing starter designed for minimum susceptibility to power line surges and spikes. The solid-state starter and control module shall be rated for continuous modulating applications. Power supply shall be 480 volt, 3 phase, 60 Hz or 120 volt 1 -phase, 60 Hz as indicated on the drawings. A disconnect switch shall be included with each actuator. The assembly shall be rated for 100% duty continuous operation.
5. Construction: The control unit shall be microprocessor -based and shall contain an analog/digital converter, separate input-output switches, non-volatile random access memory for storage of calibration parameters and pushbutton calibration elements for field setup. Potentiometer adjustments shall contain a PID control function internally. In addition, the controller shall contain as standard feature a loss of command signal protection selectable to lock in last or lock in pre-set valve position and a valve position output signal in 4 - 20 ma. As an alternative to the construction requirement, the motor shall be capable of modulating at a rate of 600 starts per hour at the 50 percent to 85 percent travel range of the valve. The system shall allow control of the open, close, or percent open function when the local/off/remote switch is in the remote position. Each actuator shall have a frequency shut down system which when pre-programmed, shall function as directed upon receipt of an ESD signal.
6. Manufacturers:
a. Auma, SA Series (for valves 12 inches and smaller) or SA with GS worm gear (for valves 14 inches and larger).
b. Limitorque, MX/QX Series
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 6
c. Rotork IQ3 Series
d. No "Or -Equals" allowed.
D. 120 VAC Quarter -Turn and Multiturn Electric Valve Operators on Isolation Valves 3 -Inch Dia. and Smaller. Where indicated on Contract Drawings, and primarily on vendor supplied equipment skids and control packages, 120 VAC electric actuators may be supplied on smaller valves of 3 - inch diameter and smaller, as follows:
1. Provide 120 VAC, 1 -phase motor -operated valve operator suitable for use with quarter - turn ball valves, multiturn diaphragm valves, and multiturn globe valves. Operator shall have the following characteristics and features:
a. Reversing capacitor -start motor rated for operation on 120 V ac, 60 Hz, single phase. Output torque as required for valve application and pressure differential. b. Integral motor overload protection, with auto reset
c. Permanently -lubricated gear train
d. For open/close control, provide four single pole, double throw cam actuated limit switches (2 OPEN, 2 CLOSED). One set of limit switches shall be used for both motor control and local indication. The other set shall be available for connection to remote monitoring. Limit switch contacts shall be adjustable and shall be rated for not less than 5 amps at 120 V ac.
e. Local Control Station: Open/Close: Corrosion -resistant, NEMA 4X, for mounting near valve actuator. Provide 2 position selector switch for LOCAL -REMOTE selection and 2 pushbuttons, OPEN and CLOSE. In addition, provide OPEN and CLOSE indicating lights operating at 120 V ac for connection to valve control limit switches.
f. For modulating control, provide an electronic positioner and feedback potentiometer. The positioner shall utilize a 4 - 20 ma signal to adjust the valve opening. Feedback potentiometer shall be 0 - 1000 ohms. g. Local Control Station Modulating: Corrosion resistant, NEMA 4X, for mounting near valve actuator. Provide 2 position selector switch for LOCAL -REMOTE selection, one OPEN and one CLOSE push buttons, a resistance to current converter with 4 - 20 ma output, and a 0 to 100 percent electronic valve position indicator.
h. Local power disconnect switch (NEMA 4X) for disconnecting 120 V ac power to valve. Disconnect shall be installed in the field within sight of the valve actuator, in accordance with the requirements of NPFA 70.
2. See Drawings for control diagram wiring interface.
3. Two wire control systems are not required for this actuator.
4. Operators shall be RCS, Asahi/America Quarter Master or equal.
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.
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 7
3.2 INSTALLATION
A. Valve and gate actuators and accessories shall be installed in accordance with Section 400551 - Valves, General. 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 two (2) Work Days
2. Inspection, checking, and adjusting the equipment for not less two (2) Work Days.
3. Startup and field-testing for proper operation for not less than two (2) Work Days.
C. Instruction of Owner's Personnel: The authorized service representative shall visit the Site for not less than 2 Days to instruct the Owner's personnel in the operation and maintenance of the equipment including step-by-step troubleshooting procedures with necessary test equipment.
END OF SECTION 400557
CITY OF BEAUMONT ACTUATORS FOR PROCESS VALVES AND GATES MESA LIFT STATION UPGRADE 400557 - 8
SECTION 400561 —GATE VALVES
PART 1 - GENERAL
1.1 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation instructions for each type of valve. Include pressure drop curve or chart for each type and size of valve.
B. Shop Drawings: Submit manufacturer's assembly -type (exploded view) shop drawings for each type of valve, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of valve. Include this data, product data, shop drawings in maintenance manual; in accordance with requirements of Division 1.
1.2 QUALITY ASSURANCE
A. Supplier shall have at least ten (10) years' experience in the manufacture of gate valves utilizing elastomer cartridge seats, and shall provide references and a list of installations upon request.
B. Valve Identification: Provide valves with manufacturer's name (or trademark) and pressure rating clearly marked on valve body.
C. Codes and Standards:
1. MSS Compliance: Mark valves in accordance with MSS -25 "Standard Marking System for Valves, Fittings, Flanges and Unions".
2. ANSI Compliance: For face-to-face and end -to -end dimensions of flanged- or welded -end valve bodies, comply with ANSI B16.10 "Face -to -Face and End -to -End Dimensions of Ferrous Valves".
PART 2 - PRODUCTS
2.1 RESILIENT WEDGE GATE VALVES
A. Resilient wedge gate valves shall meet or exceed all applicable requirements of current revision of ANSI/AWWA C515. They shall be UL listed, FM approved and certified to ANSI/NSF 61 & 372.
B. Valves shall have an AWWA/UL/FM 350 psig working pressure. Each valve shall be factory seat tested to 525 psig and shell tested to 700 psig. The following end types are available: MJ x MJ, FL x FL, FL x MJ, SO x SO, FL x SO.
C. Valve type shall be NRS (non -rising stem).
D. Valves shall have an arrow cast on the operating nut or hand wheel showing opening direction. The direction of opening shall be as specified by owner.
E. Valves shall be provided with a 2" square operating nut. The bolt that attaches the operating nut to the stem shall be recessed into the operating nut so as not to interfere with valve wrench operation.
Bolt shall be stainless steel.
CITY OF BEAUMONT GATE VALVES
MESA LIFT STATION UPGRADE 400561-1
F. Valves shall have Type 316 stainless steel bolts and nuts for the stuffing box and bonnet.
G. Valve stems shall have "anti -friction" thrust washers, one above and one below the stem thrust collar to reduce operating torque. Valve stem design shall be such that if excessive input torque is applied, stem failure shall occur above the stuffing box at such a point as to enable the operation of the valve with a pipe wrench or other readily available tool.
H. Valve stems shall be made of bronze ASTM B138 alloy C67600 H04 hard bar stock material. The bronze stem collar is to be hot forge upset; collars not integral with the stem are not acceptable.
The stem material shall provide a minimum 73,000 psi tensile strength, yield strength of 48,000 psi and 8% minimum elongation. Optional bronze stems materials may be ASTM B98 alloy C66100 H02 (half hard).
I. Valves shall have a stuffing box with bolts in line with flow and be 0 -ring sealed. Stuffing box shall have two integrally cast lifting lugs. Two 0 -rings shall be placed above and one 0 -ring below the stem thrust collar. The thrust collar shall be factory lubricated. The thrust collar and its lubrication shall be isolated by the 0 -rings from the waterway and from outside contamination providing permanent lubrication for long term ease of operation. Valves without a stuffing box are unacceptable. Valves without at least three stem 0 -rings are also unacceptable.
J. The valve body, bonnet, stuffing box and operating nut shall be composed of ASTM A536 ductile iron. The body and bonnet shall adhere to the minimum wall thickness as set forth in AWWA C515- 09 Table 2, section 4.4.1.2. Wall thicknesses that do not meet AWWA minimums are not acceptable.
K. The valve disc and guide lugs shall be composed of ASTM A126 Class B or ASTM A536 ductile iron and fully encapsulated in SBR ASTM D2000 rubber. Guide caps of an acetal bearing material shall be placed over solid guide lugs to prevent abrasion and to reduce the operating torque. Guide lugs placed over bare metal are not acceptable. EPDM ASTM D2000 shall be available as an option.
L. Valves shall have all internal and external ferrous surfaces coated with a fusion bonded thermosetting powder epoxy coating of 10 mils nominal thickness. The coating shall conform to AWWA C550.
M. Tapping valves shall have an inlet flange conforming to ANSI B16.1 Class 125 for attachment to a tapping sleeve or cross. In addition, the valve inlet flange shall have a machined projection or raised alignment lip complying with MSS SP -60 for accurate alignment to the mating recess in the tapping sleeve flange. The seat opening of the tapping valves shall be at least .30" or larger than the nominal pipe size to permit full size shell cutters.
N. Valves shall be warranted by the manufacturer against defects in materials or workmanship for a period of ten (10) years from the date of manufacture. The manufacturing facility for the valves must have current ISO certification.
O. NRS valves shall be MUELLER A2361 series or approved equal.
P. NRS tapping valves shall be Mueller T2361 series or approved equal.
PART 3 - EXECUTION
CITY OF BEAUMONT GATE VALVES
MESA LIFT STATION UPGRADE 400561-2
3.1 INSTALLATION
A. Valve shall be installed in accordance with manufacturer's written Installation and Operation Manual and approved submittals.
B. Except as otherwise indicated, comply with the following requirements:
1. Install valves where required for proper operation of piping and equipment, including valves in branch lines where necessary to isolate sections of piping. Locate valves so as to be accessible and so that separate support can be provided when necessary.
2. Install valves with stems pointed up, in vertical position where possible, but in no case with stems pointed downward from horizontal plane.
C. Insulation: Where insulation is indicated, install extended -stem valves, arranged in proper manner to receive insulation.
D. Valve System: Select and install valves with outside screw and yoke stems, except provide inside screw non -rising stem valves where headroom prevents full opening of OS&Y valves.
E. Renewable Seats: Select and install valves with renewable seats, except where otherwise indicated.
3.2 ADJUSTING AND CLEANING:
A. Valve Adjustment: After piping systems have been tested and put into service, but before final testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace packing to stop leaks, replace valve if leak persists.
B. Valve Identification: Tag each valve in accordance with Division -22 section "Identification for Piping and Equipment".
3.3 VALVE INSTALLATION:
A. Locate all valves in locations which will allow easy operation and facilitates maintenance.
B. Provide chain operators for any valves located more than 8 feet above finished floor. This means double acting lever handles for quarter turn valves, or chain wheels for multi -turn valves. Arrange valves and set up chain length for proper operation.
3.4 MANUFACTURER'S CUSTOMER SERVICE
A. Manufacturer's authorized representative shall be available for customer service during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
B. Manufacturer shall also make customer service available directly from the factory in addition to authorized representatives for assistance during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
END OF SECTION 400561
CITY OF BEAUMONT GATE VALVES
MESA LIFT STATION UPGRADE 400561-3
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CITY OF BEAUMONT GATE VALVES
MESA LIFT STATION UPGRADE 400561-4
SECTION 400562 - PLUG VALVES
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall provide plug valves and appurtenances, complete and operable, in accordance with the Contract Documents.
B. The requirements of Section 400557 - Valve and Gate Actuators apply to this Section.
C. Plug valves shall have undergone a proof -of -design test to demonstrate that the valve components operate at the service flow, pressure, temperature, and fluid conditions, free from binding, excessive noise, and premature failures. Proof -of -design test results shall be available to the Engineer on request. The proof -of -design test shall be conducted in accordance with the applicable provisions of AWWA C517.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 013300.
PART 2 - PRODUCTS
2.1 GENERAL
A. Plug Valves shall be quarter -turn, non -lubricated with resilient encapsulated plug. Valves shall have port areas of not less than 100% of pipe area.
B. Standards, Approvals and Verification:
1. Valves shall be designed, manufactured and tested in accordance with American Water Works Association Standard ANSI/AWWA C517.
2. All Plug Valves shall be certified Lead -Free in accordance with NSF/ANSI 372.
3. Manufacturer shall have a quality management system that is certified to ISO 9001 by an accredited, certifying body.
C. Connections:
1. Threaded valves shall have threaded NPT full size inlets. The connection shall be hexagonal for a wrench connection.
2. Flanged valves shall have flanges with drilling to ANSIB16.1, Class 125.
3. Mechanical Joint valves shall fully comply with ANSI/AWWA C111/A21.11.
D. Manufacture:
1. Manufacturer shall demonstrate a minimum of ten (10) years' experience in the manufacture of plug valves. When requested, the manufacturer shall provide test certificates, dimensional drawings, parts list drawings and operation and maintenance manuals.
2. The interior and exterior of the valve shall be coated with an NSF/ANSI 61 approved fusion bonded epoxy. Where specifically indicated in the contract documents interior shall be rubber for abrasive or corrosive fluids and glass for a smooth, non-stick surface.
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PLUG VALVES
400562 - 1
3. Valve shall be marked with the Serial Number, Manufacturer, Size, Cold Working Pressure (CWP) and the Direct and Reverse Actuator Pressure Ratings on a corrosion resistant nameplate.
4. Acceptable Manufacturers:
a. Valmatic (Basis of Design)
b. DeZurik
c. Or equal
2.2 ECCENTRIC PLUG VALVES (1/2 -INCH TO 3 -INCHES)
A. Design:
1. Threaded valve seat shall be a machined seating surface.
2. 2 %2 in. valves and larger shall have a valve seat that is a welded overlay of 95% pure nickel applied directly to the body on a pre -machined, cast seating surface and machined to a smooth finish.
3. Threaded valves shall have shaft seals which consist of V -type lip seal in a fixed gland with a resilient 0 -ring spring.
4. 2 '/2 in. valves and larger shall have shaft seals which consist of V -type packing in a fixed gland with an adjustable follower designed to prevent over compression of the packing and to meet design parameter of the packing manufacturer. Removable POPTM shims shall be provided under the follower flanges to provide for adjustment and prevent over tightening.
5. Permanently lubricated, radial shaft bearings shall be supplied in the upper and lower bearing journals. Thrust bearings shall be provided in the upper and lower journal areas, except for threaded type which only have upper thrust bearings.
6. Both the packing and bearings in the upper and lower journals shall be protected by a Grit- GuardTM "drip tight" Buna-N shaft seal located on the valve shaft to minimize the entrance of grit into the bearing journal and shaft seal areas.
7. The threaded valve body shall have 1/8" NPT upstream and downsteam pressure ports.
B. Materials:
1. Valve bodies and covers shall be constructed of ASTM A126 Class B cast iron for working pressures up to 175 psig and ASTM A536 Grade 65-45-12 for working pressures up to 250 psig. The words "SEAT END" shall be cast on the exterior of the body seat end.
2. Threaded valve plugs shall be of one-piece construction and made of ASTM A126 Class B cast iron fully encapsulated with a resilient facing per ASTM D2000-BG and ANSI/AWWA C517 requirements.
3. 2 1/2 in. plugs and larger shall be of one-piece construction and made of ASTM A126 Class B cast iron or ASTM A536 Grade 65-45-12 ductile iron and fully encapsulated with resilient facing per ASTM D2000-BG and ANSI/AWWA C517 requirements.
4. Threaded valves shall have radial shaft bearings constructed of self-lubricating Type 316 stainless steel. The top thrust bearing shall be Teflon.
5. 2 %2 in. plug valves and larger shall have radial shaft bearings constructed of self-lubricating Type 316 stainless steel. The top thrust bearing shall be Teflon. The bottom thrust bearing shall be self-lubricating Type 316 stainless steel. Cover bolts shall be corrosion resistant with zinc plating.
C. Actuators:
1. Threaded valves shall be equipped with a hand lever with a dial indicator and open memory stop.
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PLUG VALVES
400562 - 2
2. Valves 2 '/z in. and larger shall be equipped with a 2 -inch square nut for direct quarter turn operation. The packing gland shall include a friction collar and an open position memory stop. The friction collar shall include a nylon sleeve to provide friction without exerting pressure on the valve packing.
3. All gear actuators shall be designed to withstand, without damage, a rim pull of 2001b. on the hand wheel and an input torque or 300 ft-lbs. for nuts.
4. Buried service actuators shall be packed with grease and sealed for temporary submergence to 20 feet of water. Exposed worm shafts shall be stainless steel.
2.3 ECCENTRIC PLUG VALVES (3 -INCHES TO 54 -INCHES)
A. Design:
1. Valves shall have port areas of not less than 100% of pipe area.
2. Valves shall have a valve seat that is a welded overlay of 95% pure nickel applied directly to the body on a pre -machined, cast seating surface and machined to a smooth finish.
3. Valves shall have shaft seals which consist of V -type packing in a fixed gland with an adjustable follower and removable shims under the follower flange to provide for adjustment and prevent over compression.
4. Permanently lubricated, radial shaft bearings shall be supplied in the upper and lower bearing journals to eliminate the need for grease fittings. Thrust bearings shall be provided in the upper and lower journal areas, except for threaded type which only have upper thrust bearings.
5. Both the packing and bearings in the upper and lower journals shall be protected by Buna- N shaft seals located on the valve shaft to minimize the entrance of grit into the bearing journal and shaft seal areas.
B. Materials:
1. Valve bodies and covers shall be constructed of ASTM A126 Class B for working pressures up to 175 psig. The words "SEAT END" shall be cast on the exterior of the body seat end.
2. Plugs shall be of one-piece construction and made of ASTM A536 Grade 65-45-12 ductile iron and fully encapsulated with resilient facing per ASTM D2000-BG and ANSI/AWWA C517 requirements.
3. Plug valves shall have radial shaft bearings constructed of self-lubricating Type 316 stainless steel. The thrust bearings shall be PTFE. Cover bolts shall be corrosion resistant with zinc plating.
C. Actuation:
1. Valves shall be equipped with a 2 inch square nut for direct quarter turn operation with a hand lever. The packing gland shall include a friction collar and an open position memory stop. The friction collar shall include a nylon sleeve to provide friction without exerting pressure on the valve packing.
2. Valves shall include a totally enclosed and sealed worm gear actuator with position indicator (above ground service only) and externally adjustable open and closed stops. The worm segment gear shall be ASTM A536 Grade 65-45-12 ductile iron with a precision bore and keyway for connection to the valve shaft. Bronze radial bearings shall be provided for the segment gear and worm shaft. Alloy steel roller thrust bearings shall be provided for the hardened worm.
3. All gear actuators shall be designed to withstand, without damage, a rim pull of 200 lb. on the hand wheel and an input torque or 300 ft-lbs. for nuts.
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PLUG VALVES
400562 - 3
4. Buried service actuators shall be packed with grease and sealed for temporary submergence to 20 feet of water. Exposed worm gear shafts shall be stainless steel.
D. Coatings:
1. The interior and exterior of the valve shall be coated with a fusion bonded epoxy.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Plug valves shall be installed in strict accordance with the manufacturer's published recommendations.
B. Eccentric Plug Valves: Unless otherwise directed, the following rules shall be observed for the installation of eccentric plug valves on sewage, sludge, or other liquid systems containing solids, silt, or fine sand:
1. The valves shall be positioned with the stem in the horizontal direction.
2. In horizontal pipelines, the plug shall swing upwards when opening, to permit flushing out of solids.
3. The orientation of the valve shall prevent the valve body from filling up with solids when closed; however, where the pressure differential through the valve exceeds 25 psi, the higher pressure for valves without worm gear, electric, or air operators shall be through the valve to force the plug against the seat.
4. Valves which may be closed for extended periods (stand-by, bypass, or drain lines) and valves with reversed flow (higher pressure on downstream side, forcing the plug away from its seat), shall be equipped with worm gear operators for the full range of sizes.
5. For special applications or when in doubt, consult with the manufacturer prior to installation.
C. Except as otherwise indicated, comply with the following requirements:
1. Install valves where required for proper operation of piping and equipment, including valves in branch lines where necessary to isolate sections of piping. Locate valves so as to be accessible and so that separate support can be provided when necessary.
2. Install valves with stems pointed up, in vertical position where possible, but in no case with stems pointed downward from horizontal plane.
D. Insulation: Where insulation is indicated, install extended -stem valves, arranged in proper manner to receive insulation.
E. Valve System: Select and install valves with outside screw and yoke stems, except provide inside screw non -rising stem valves where headroom prevents full opening of OS&Y valves.
F. Renewable Seats: Select and install valves with renewable seats, except where otherwise indicated.
G. Locate all valves in locations which will allow easy operation and facilitates maintenance.
H. Provide chain operators for any valves located more than 8 feet above finished floor. This means double acting lever handles for quarter turn valves, or chain wheels for multi -turn valves. Arrange valves and set up chain length for proper operation.
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PLUG VALVES
400562 - 4
3.2 ADJUSTING AND CLEANING:
A. Valve Adjustment: After piping systems have been tested and put into service, but before final testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace packing to stop leaks, replace valve if leak persists.
B. Valve Identification: Tag each valve in accordance with Division -22 section "Identification for Piping and Equipment".
3.3 MANUFACTURER'S CUSTOMER SERVICE
A. Manufacturer's authorized representative shall be available for customer service during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
B. Manufacturer shall also make customer service available directly from the factory in addition to authorized representatives for assistance during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
END OF SECTION 400562
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PLUG VALVES
400562 - 5
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CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
PLUG VALVES
400562 - 6
SECTION 400565 - VALVES FOR PUMP CONTROL AND CHECK SERVICE PART 1 - GENERAL
1.1 SUBMITTALS
A. Product Data: Submit manufacturer's technical product data, including installation instructions for each type of valve. Include pressure drop curve or chart for each type and size of valve.
B. Shop Drawings: Submit manufacturer's assembly -type (exploded view) shop drawings for each type of valve, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of valve. Include this data, product data, shop drawings in maintenance manual; in accordance with requirements of Division 1.
1.2 QUALITY ASSURANCE
A. Supplier shall have at least ten (10) years' experience in the manufacture of knife gate valves utilizing elastomer cartridge seats, and shall provide references and a list of installations upon request.
B. Valve Identification: Provide valves with manufacturer's name (or trademark) and pressure rating clearly marked on valve body.
C. Codes and Standards:
1. MSS Compliance: Mark valves in accordance with MSS -25 "Standard Marking System for Valves, Fittings, Flanges and Unions".
2. ANSI Compliance: For face-to-face and end -to -end dimensions of flanged- or welded -end valve bodies, comply with ANSI B16.10 "Face -to -Face and End -to -End Dimensions of Ferrous Valves".
PART 2 - PRODUCTS
2.1 SWING CHECK VALVES (2-1/2 INCHES AND SMALLER)
A. General: Swing check valves for steam, water, oil, or gas in sizes 2-1/2 inches and smaller shall be suitable for a steam pressure of 150 psi and a cold water pressure of 300 psi. Units shall have screwed ends unless otherwise indicated, and screwed caps.
B. Body: The valve body and cap shall be of bronze conforming to ASTM B 763 - Copper Alloy Sand Castings for Valve Application, or ASTM B 584 with threaded ends conforming to ASME B1.20.1 - Pipe Threads, General Purpose (inch).
C. Disc: Valves for steam service shall have bronze or brass discs conforming to ASTM B 16 - Free - Cutting 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.
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 1
E. Manufacturers, or Equal
1. Crane Company
2. Milwaukee Valve Company
3. Stockham Valves and Fittings
4. Wm. Powell Company
2.2 PLASTIC BALL CHECK VALVES
A. General: Plastic ball check valves for corrosive fluids, in sizes up to 4 -inches, shall be used for vertical up -flow conditions only, unless the valves are provided with spring actions.
B. Construction: The valve bodies and balls shall be of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyvinylidene fluoride (PVDF), or polypropylene (PP) construction, as best suited for each individual service condition. They shall have unions with socket connections or flanged ends conforming to ASME B16.5 - Pipe Flanges and Flanged Fittings, class 150. Seals shall have Viton O -rings, and valve design shall minimize possibility of the balls sticking or chattering. The valves shall be suitable for a maximum working non -shock pressure of 150 psi at 73 degrees F.
C. Manufacturers, or Equal
1. ASAHI-AMERICA
2. George Fischer, Inc.
3. NIBCO Inc. (Chemtrol Division)
4. Spears Mfg. Co. (PVC, CPVC, AND PP only)
2.3 PLASTIC SWING OR WYE -CHECK VALVES
A. General: Plastic swing or wye-check valves for corrosive fluids, in sizes up to 8 -inches or as available, may be used for horizontal or vertical up -flow conditions.
B. Construction: The valve bodies and discs or piston shall be of PVC, PP, or PVDF construction as best suited for each individual service condition. They shall have flanged ends conforming to ASME B16.5 Class 150, and flanged top access covers and shall shut positively at no -flow conditions. The seats and seals shall be of EPDM, Teflon, or Viton. The PVC valves shall be rated for a maximum non -shock working pressure of 150 psi at 73 degrees F for sizes 3 -inches and smaller. For larger sizes and other materials and temperatures the pressure rating may be lower.
C. Manufacturers, or Equal
1. Valmatic (Swing Flex)
2. ASAHI-AMERICA
3. George Fischer, Inc.
4. Spears Mfg. Co. (Plastic Swing Check only)
2.4 SWING — FLEX CHECK VALVES
A. Scope
1. This section covers the design, manufacture, and testing of 2 in. through 48 in. Swing -Flex Check Valves suitable for cold working pressures up to 250 psig, in water, wastewater, abrasive, and slurry service.
2. The check valve shall be of the full flow body type, with a domed access cover and only one moving part, the flexible disc.
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 2
B. Standards and Approvals
1. The valves shall be designed, manufactured, tested and certified to American Water Works Association Standard ANSI/AWWA C508.
2. The valves used in potable water service shall be certified to NSF/ANSI 61 Drinking Water System Components — Health Effects, and certified to be Lead -Free in accordance with NSF/ANSI 372.
3. Manufacturer shall have a quality management system that is certified to ISO 9001 by an accredited, certifying body.
C. Connections
1. The valves shall have flanges with drilling to ANSI B16.1, Class 125.
D. Design
1. The valve body shall be full flow equal to nominal pipe diameter at all points through the valve. The 4 in. valve shall be capable of passing a 3 in. solid. The seating surface shall be on a 45 degree angle to minimize disc travel. A threaded port with pipe plug shall be provided on the bottom of the valve to allow for field installation of a backflow actuator or oil cushion device without special tools or removing the valve from the line.
2. The top access port shall be full size, allowing removal of the disc without removing the valve from the line. The access cover shall be domed in shape to provide flushing action over the disc for operating in lines containing high solids content. A threaded port with pipe plug shall be provided in the access cover to allow for field installation of a mechanical, disc position indicator.
3. The disc shall be of one-piece construction, precision molded with an integral 0 -ring type sealing surface and reinforced with alloy steel. The flex portion of the disc contains nylon reinforcement and shall be warranted for twenty-five years. Non -Slam closing characteristics shall be provided through a short 35 degree disc stroke and a memory disc return action to provide a cracking pressure of 0.25 psig.
4. The valve disc shall be cycle tested 1,000,000 times in accordance with ANSUAWWA C508 and show no signs of wear, cracking, or distortion to the valve disc or seat and shall remain drop tight at both high and low pressures.
E. Materials
1. The valve body and cover shall be constructed of ASTM A536 Grade 65-45-12 ductile iron or ASTM A126 class B gray iron for 30 in. (800mm) and larger. Optional body materials include ASTM A-351 Grade CF8M, stainless steel for sizes 3" (80 mm) through 12" (300 mm).
2. The disc shall be precision molded Buna-N (NBR), ASTM D2000-BG. Optional disc material includes Viton, EPDM, Hypalon.
F. Manufacture
1. Manufacturer shall demonstrate a minimum of five (5) years' experience in the manufacture of resilient, flexible disc check valves with hydraulic cushions.
2. All valves shall be hydrostatically tested and seat tested to demonstrate zero leakage. When requested, the manufacturer shall provide test certificates, dimensional drawings, parts list drawings, and operation and maintenance manuals.
3. The exterior and interior of the valve shall be coated with an NSF/ANSI 61 approved fusion bonded epoxy coating.
4. Swing -Flex® Check Valves shall be Series #500 as manufactured by Val-Matic® Valve & Mfg. Corporation, Elmhurst, IL. USA or equal.
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 3
2.5 DUAL DISK CHECK VALVES
A. Scope
1. This specification covers the design, manufacture, and testing of 2 in. through 12 in. dual disc check valves suitable for pressures up to 250 psig water service.
2. The check valve shall be of the dual disc, wafer style with torsion spring induced closure.
B. Standards, approvals and verification
1. The valves shall be designed, manufactured and tested in accordance with American Water Works Association standard ANSI/AWWA C518.
2. The valves for use in fire protection systems shall be Underwriters Laboratories listed and Factory Mutual approved in sizes 2 1/2"-12".
3. The valves shall be certified to be lead-free in accordance with NSF/ANSI 61, Annex G.
4. Manufacturer shall have a quality management system that is certified to ISO 9001 by an accredited, certifying body.
C. Connections
1. Wafer style valves shall be provided in sizes 2 in through 12 in for installation between ANSI B16.1 Class 125 iron flanges, or between ISO 7005-2 PN10 or PN16 flanges.
Grooved end valves shall be provided in 2" through 12" for installation on pipe with cut grooves per ANSI/AWWA C606 for steel IPS pipe.
D. Design
1. The body shall be of one-piece construction incorporating a vulcanized synthetic seal.
2. Seal design shall include a raised sealing bead for positive seating at both high and low pressures. The disc shall fully overlap the synthetic seal, preventing pressure indentations.
3. Opening and closing of the valve shall utilize a lift and pivot action to prevent seal wear and ensure long seal life.
4. Disc stabilization in the full open position shall be provided by the use of a stop pin.
5. The stop and pivot pins shall be stabilized by the use of synthetic spheres to prevent wear due to vibration during operating conditions. The design shall incorporate a raised seat and 1/2" body wall to disc clearance to ensure proper operation after long periods of inactivity and potential corrosion buildup.
6. Cv flow coefficients shall be equal to or greater than specified below and verified by an independent testing laboratory.
Valve
Size
Cv
Wafer
Grooved
2 in
76 77
2.5 in
161
129
3 in
224
209
4 in
400
358
5 in
648
573
6 in
1060
898
8 in
1890
1740
10 in
3340
3180
12 in
5270
4950
8. Closure shall be assisted with a torsion spring to provide a cracking pressure of 0.25 psig.
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 4
E. Materials
1. The valve body shall be constructed of astm a536 grade 65-45-12 ductile iron.
2. The disc shall be constructed of astm b584, alloy c87600 (2"-12") cast bronze. The pivot pins and stop pins shall be type 316 stainless steel.
3. The torsion spring shall be astm a313 type 316 stainless steel.
4. The seal shall be buna-n per astm d2000-bg.
F. Manufacture
1. The valves shall be hydrostatically tested at 2 times their rated cold working pressure. A seat closure test at 2 times the valve rating shall be conducted to demonstrate zero leakage.
Additional tests shall be conducted per awwa, ansi, mss or api standards when specified.
When requested, the manufacturer shall provide test certificates, dimensional drawings, parts list drawings, and operation and maintenance manuals.
2. The exterior of the valve shall be coated with a universal alkyd primer.
3. Check valves shall be series #8800w (wafer style) and series #8800g (grooved end) as manufactured by val-matic® valve & mfg. Corporation, elmhurst, il. Usa or approved equal.
2.6 SUCTION LINE FOOT VALVES
A. Scope
1. This section covers the design, manufacture, and testing of 2 in. through 42 in. Sure Seal Foot Valves suitable for pressures up to 200 psig water service.
2. The Foot Valve shall be of the full flow globe style designed to provide silent operation, positive seating, and full flow area.
B. Standards, Approvals and Verification
1. The valves shall be certified to be Lead -Free in accordance with NSF/ANSI 61, Annex G.
2. Manufacturer shall have a quality management system that is certified to ISO 9001 by an accredited, certifying body.
C. Connections
1. The Foot Valves shall be provided with flanges in accordance with ANSI B16.1 for Class 125 iron flanges.
D. Design
1. The valve design shall incorporate a center guided disc, guided at opposite ends and having a short linear stroke that generates a flow area equal to the pipe size.
2. All component parts shall be field replaceable without the need of special tools. A replaceable guide bushing shall be provided and held in position by threaded bushing retainer.
3. The valve disc shall be concave to the flow direction providing for disc stabilization, maximum strength, and a minimum flow velocity to open the valve.
4. The valve disc and seat shall have a seating surface finish of 32 micro -inch or better to ensure positive seating at all pressures. A Buna-N seal shall be provided on the seat to provide for zero leakage at both high and low pressures without overloading or damaging the seal. The seal design shall provide both a metal to metal and a metal to Buna-N seal.
5. A heavy-duty basket type screen shall be bolted to the inlet flange outside diameter and provide 3-4 times the pipe area.
E. Materials
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 5
1. The valve body shall be constructed of ASTM A126 Class B cast iron.
2. The seat and plug shall be ASTM A351 Grade CF8M stainless steel.
3. The basket screen shall be stainless steel, Type 304.
F. Manufacture
1. The valves shall be hydrostatically tested at 1.5 times their rated cold working pressure.
Additional tests shall be conducted per AWWA, ANSI, MSS or API standards when specified. When requested, the manufacturer shall provide test certificates, dimensional drawings, parts list drawings, and operation and maintenance manuals.
2. The exterior of the valve shall be coated with a universal alkyd primer.
3. Foot Valves shall be Series #1900 as manufactured by Val-Matic® Valve & Mfg.
Corporation, Elmhurst, IL. USA or equal.
2.7 SURGE RELIEF ANGLE VALVES
A. Scope
1. This section covers the design, manufacture and testing of Surge Relief Angle Valves.
2. Surge Relief Angle Valves shall be normally closed against the system pressure by external spring(s) in compression and shall open quickly to relieve pressure when the system pressure exceeds the pressure relief setting. The pressure relief setting shall be factory set and field adjustable by adjusting the spring compression. The valve will begin to close when the system pressure subsides below the pressure relief setting. The closing speed shall be adjustable to suit the application by means of infinitely adjustable, lockable flow control valve.
B. Design
1. Body shall be a 90 degree elbow design conforming to the center -to -face dimension for long -radius elbows per ASME B16.1 and ASME B16.42. Valve shall be a compact design to fit in tight installation spaces.
2. Body and cover shall be constructed of ASTM A536 Grade 65-45-12 ductile iron. Body Seat shall be 316 stainless steel. Flanges shall be flat faced and conform to ASME B16.42 Class 150. Valve shall be proof -of -design tested to 5,000 cycles.
3. A self-contained, sealed hydraulic system shall provide closing speed control. The valve cover shall provide an air gap between the line fluid and the hydraulic oil that will indicate seal wear and prevent contamination of line fluid or hydraulic oil. The valve shall be capable of being mounted in any position without modification or customization of the hydraulic system components. A mechanical stroke counter with manual reset shall provide local indication of total valve cycles.
4. External spring(s) located on the valve cover in a protective steel enclosure shall provide closing force. Springs shall be sized to optimally match customer -specified relief pressure setting to minimize pressure rise above the set -point in order to fully open valve. A single adjustment screw shall be provided for field adjustment of relief pressure setting.
5. Valve Disc shall have a replaceable seat ring of Acrylonitrile-Butadiene (NBR); Terpolymer of Ethylene, Propylene and A Diene (EPDM) or Fluoro Rubber (FKM) for tight shutoff.
C. Manufacturer
1. APCO Model SRA-3000A as manufactured by DeZurik or approved equal.
D. Warranty
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 6
1. Valves and actuators shall be warranted by the manufacturer for defects in materials and workmanship for a period of two years (24 months) from date of shipment.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Valve shall be installed in accordance with manufacturer's written Installation and Operation Manual and approved submittals.
B. Except as otherwise indicated, comply with the following requirements:
1. Install valves where required for proper operation of piping and equipment, including valves in branch lines where necessary to isolate sections of piping. Locate valves so as to be accessible and so that separate support can be provided when necessary.
2. Install valves with stems pointed up, in vertical position where possible, but in no case with stems pointed downward from horizontal plane.
C. Insulation: Where insulation is indicated, install extended -stem valves, arranged in proper manner to receive insulation.
D. Renewable Seats: Select and install valves with renewable seats, except where otherwise indicated.
3.2 ADJUSTING AND CLEANING:
A. Valve Adjustment: After piping systems have been tested and put into service, but before final testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace packing to stop leaks, replace valve if leak persists.
B. Valve Identification: Tag each valve in accordance with Division -22 section "Identification for Piping and Equipment".
3.3 VALVE INSTALLATION:
A. Locate all valves in locations which will allow easy operation and facilitates maintenance.
3.4 MANUFACTURER'S CUSTOMER SERVICE
A. Manufacturer's authorized representative shall be available for customer service during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
B. Manufacturer shall also make customer service available directly from the factory in addition to authorized representatives for assistance during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
END OF SECTION 400565
CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 7
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CITY OF BEAUMONT VALVES FOR PUMP CONTROL AND CHECK SERVICE MESA LIFT STATION UPGRADE 400565 - 8
SECTION 400567 — BALL VALVES
PART 1 - GENERAL
1.1 SCOPE:
A. Furnish and install all valves complete and in accordance to the requirements of the Contract Documents.
1.2 SUBMITTALS:
A. Product Data: Submit manufacturer's technical product data, including installation instructions for each type of valve. Include pressure drop curve or chart for each type and size of valve.
B. Shop Drawings: Submit manufacturer's assembly -type (exploded view) shop drawings for each type of valve, indicating dimensions, weights, materials, and methods of assembly of components.
C. Maintenance Data: Submit maintenance data and spare parts list for each type of valve.
Include this data, product data, shop drawings in maintenance manual; in accordance with requirements of Division 1.
1.3 QUALITY ASSURANCE:
A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of valves, of types and sizes required, whose products have been in satisfactory use in similar service.
B. Valve Types: Provide valves of same type by same manufacturer.
C. Valve Identification: Provide valves with manufacturer's name (or trademark) and pressure rating clearly marked on valve body.
D. Codes and Standards:
1. MSS Compliance: Mark valves in accordance with MSS -25 "Standard Marking System for Valves, Fittings, Flanges and Unions".
2. ANSI Compliance: For face-to-face and end -to -end dimensions of flanged- or welded -end valve bodies, comply with ANSI B16.10 "Face -to -Face and End -to -End Dimensions of Ferrous Valves".
3. U -PVC: Conforming to ASTM D1784 Cell Classification 12454 A
4. CPVC — Conforming to ASTM D1784 Cell Classification 23567 A
5. Polypropylene — Conforming to ASTM D4101 Cell Classification PP0210B67272
6. PVDF — Conforming to ASTM D3222 -91A Cell Classification Type II PART 2 - PRODUCT
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BALL VALVES
400567-1
2.1 PLASTIC BALL VALVES (1/2" — 6")
A. All valves shall be true -union design with 2 -way blocking capability. PTFE seats shall have elastomeric backing cushions to provide smooth even stem torque and to compensate for wear.
Valves shall feature molded ISO mounting top flange for actuation installation and Panel Mount feature on bottom of valve for securing in -line. The handle shall double as the spanner wrench for maintenance and carrier adjustment.
B. Valve shall have a pressure rating of 150 psi at 70°F.
C. Where noted on contract drawings, a 1/8" Vent Hole factory drilled and de -burred by the manufacturer shall be added to eliminate the hazard of pressurization.
D. Acceptable Manufacturers: Subject to compliance with requirements, manufacturers offering ball valves which may be incorporated in the work are:
1. Asahi America, Inc.
2. George Fischer
3. Dura Plastic Products, Inc.
4. Hayward
5. Or equal.
2.2 STAINLESS STEEL BALL VALVES
A. Features:
1. 316 SS Ball Construction
2. SS Body construction
3. RPTFE seat
4. Threaded
5. Full Port
6. Two piece body design
7. Solid Ball Construction
8. SS Lever and Nut
9. Blow out proof stern design
10. Nylon lever grip
11. 150 psi rated
B. Acceptable Manufacturers: Subject to compliance with requirements, manufacturers offering ball valves which may be incorporated in the work are:
1. Apollo Valves
2. Or equal
PART 3 - EXECUTION
3.1 INSTALLATION:
A. General: Except as otherwise indicated, comply with the following requirements:
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MESA LIFT STATION UPGRADE 400567-2
Install valves where required for proper operation of piping and equipment, including valves in branch lines where necessary to isolate sections of piping. Locate valves so as to be accessible and so that separate support can be provided when necessary.
Install valves with stems pointed up, in vertical position where possible, but in no case with stems pointed downward from horizontal plane.
B. Insulation: Where insulation is indicated, install extended -stem valves, arranged in proper manner to receive insulation.
C. Selection of Valve Ends (Pipe Connections): Except as otherwise indicated, select and install valves with the following ends or types of pipe/tube connections.
1. Pipe Size 2" and Smaller: One of the following, at Installer's option:
a. Threaded valves.
b. Flanged valves.
2. Pipe Size 2-1/2" and Larger:
a. Flanged valves.
b. Grooved joint valves.
D. Valve System: Select and install valves with outside screw and yoke stems, except provide inside screw non -rising stem valves where headroom prevents full opening of OS&Y valves.
E. Renewable Seats: Select and install valves with renewable seats, except where otherwise indicated.
3.2 ADJUSTING AND CLEANING:
A. Valve Adjustment: After piping systems have been tested and put into service, but before final testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace packing to stop leaks, replace valve if leak persists.
B. Valve Identification: Tag each valve in accordance with Division -22 section "Identification for Piping and Equipment".
3.3 VALVE INSTALLATION:
A. Locate all valves in locations which will allow easy operation and facilitates maintenance.
B. Provide chain operators for any valves located more than 8 feet above finished floor. This means double acting lever handles for quarter turn valves, or chain wheels for multi -turn valves. Arrange valves and set up chain length for proper operation.
END OF SECTION 400567
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BALL VALVES
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SECTION 400578 — COMBINATION AND SURGE RELIEF VALVES
PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall provide combination and surge relief valves and appurtenances, complete and operable, in accordance with the Contract Documents.
1.2 CONTRACTOR SUBMITTALS
A. Furnish submittals in accordance with Section 013300.
PART 2 - PRODUCTS
2.1 GENERAL
A. This specification is intended to cover the design, manufacture, and testing of 1 in. through 8 in. combination air and surge relief valves suitable for pressures up to 175 psig.
B. Combination air valves shall be automatic float operated valves designed to exhaust large quantities of air during the filling of a piping system and close upon liquid entry. The valve shall open during draining or if a negative pressure occurs. The valve shall also release accumulated air from a piping system while the system is in operation and under pressure. The valve shall perform the functions of both air release and air/vacuum valves and furnished as a single body or dual body type as indicated on the plans.
2.2 STANDARDS, APPROVALS AND VERIFICATION
A. Valves shall be manufactured and tested in accordance with American Water Works Association (AWWA) Standard C512.
B. Valves used in potable water service shall be certified to NSF/ANSI 61 Drinking Water System Components.
C. Manufacturer shall have a quality management system that is certified to ISO 9001 by an accredited, certifying body.
2.3 WASTEWATER COMBINATION VALVES
A. Connections
1. Single body valves sizes 4 in. and smaller shall have full size NPT inlets and outlets equal to the nominal valve size with a 2 in. inlet on 1 in. valves. The body inlet connections shall be hexagonal for a wrench connection. The body shall have 2" NPT cleanout and 1" NPT drain connection on the side of the casting.
2. Dual body valves sizes 3 in. and smaller shall have full size NPT inlets and outlets equal to the nominal valve size with a 2 in. inlet on 1 in. valves. The body inlet connection shall be hexagonal for a wrench connection. Valve sizes 4 in. through 6 in. shall have bolted
CITY OF BEAUMONT COMBINATION AND SURGE RELIEF VALVES
MESA LIFT STATION UPGRADE 400578 - 1
flanged inlets and NPT outlets. 8 in. valves shall have flanged inlets and outlets. Flanges shall be in accordance with ANSI B16.1 for Class 125 iron flanges.
3. The valve shall have three additional NPT connections for the addition of backwash accessories.
B. Design:
1. Both single and dual body valves shall provide an extended body with a through flow area equal to the nominal size. Floats shall be unconditionally guaranteed against failure including pressure surges. A resilient bumper shall be provided on 4 in. and larger sizes to cushion the float during sudden opening conditions. The seat shall provide drop tight shut off to the full valve pressure rating.
2. Dual body valves shall consist of a wastewater air release valve piped to a wastewater air/vacuum valve with a full -ported brass ball valve.
a. The wastewater air release valve shall have an extended leverage mechanism with sufficient mechanical advantage so that the valve will open under full operating pressure. An adjustable threaded resilient orifice button shall be used to seal the precision discharge orifice in the cover.
b. The wastewater air/vacuum valve sizes 4 in. and larger shall have a cover fitted to the valve body by means of a machined register to maintain concentricity between the top and bottom guide bushings at all times. The tandem float assembly shall have a hexagonal guide shaft supported in the body by circular bushings to prevent binding from debris. The upper float shall be protected against direct water impact by an internal baffle. The seat shall be a minimum of 0.5 in. thick on 2 in. and larger valves and secured in such a manner as to prevent distortion.
3. Single body valves shall have a full port orifice, a double guided plug, and an adjustable threaded orifice button. The 1 in. body shall be globe style to increase float clearance and reduce clogging. The plug shall be protected against direct water impact by an internal baffle and an extended float stem. The plug shall have a precision orifice drilled through the center stem. The float shall include a sensitivity skirt to minimize spillage.
C. Materials:
1. The valve body and cover shall be constructed of ASTM A126 Class B cast iron.
2. The float, plug, guide shafts, and bushings shall be constructed of type 316 stainless steel.
Non-metallic guides and bushings are not acceptable. Resilient seats shall be Buna-N.
2.4 SURGE RELIEF AIR VALVES
A. Scope
1. This specification is intended to cover the design, manufacture, and testing of 1/2 in. (15 mm) through 20 in. (500 mm) Surge Suppression Air Valves suitable for pressures up to 740 psig (5100 kPa) clean water or raw water service.
2. Surge Suppression Air Valves shall be automatic float operated valves designed to control the exhaust of air during the filling of a piping system and close upon liquid entry. The valve shall fully open during draining or if a negative pressure occurs. The valve shall also release accumulated air from a piping system while the system is in operation and under pressure. The valve is equipped with a regulated exhaust device and performs the functions of both Air Release and Air/Vacuum Valves and furnished as a single body or dual body type as indicated on the plans.
3. Provide valves
B. Standards, Approvals and Verification
CITY OF BEAUMONT COMBINATION AND SURGE RELIEF VALVES
MESA LIFT STATION UPGRADE 400578 - 2
1. Valves shall be manufactured and tested in accordance with American Water Works Association (AWWA) Standard C512.
2. Valves used in potable water service shall be certified to NSF/ANSI 61 Drinking Water System Components - Health Effects.
3. Manufacturer shall have a quality management system that is certified to ISO 9001 by an accredited, certifying body.
C. Connections
1. Dual body valve sizes 3 in. (75 mm) and smaller and single body valve sizes 4 in. (100 mm) and smaller shall have full size NPT inlets and outlets equal to the nominal valve size.
The body inlet connection shall be hexagonal for a wrench connection.
2. Larger sizes shall have bolted flanged inlets and threaded or flanged outlets. Inlet flanges shall be in accordance with ANSI B16.1 for Class 125 or Class 250 iron flanges and ANSI B16.5 for Class 300 steel flanges.
3. The valve shall have two additional NPT connections for the connection to gauges, testing, and draining.
D. Design
1. Both single and dual body valves shall provide a through flow area equal to the nominal size. Floats shall be unconditionally guaranteed against failure including pressure surges.
The cover shall be bolted to the body and sealed with a flat gasket. A resilient bumper shall be provided on 4 in. (100 mm) and larger sizes to cushion the float during sudden opening conditions. The resilient seat shall be replaceable and provide drop tight shut off to the full valve pressure ratings.
2. Dual body combination valves shall consist of an Air Release Valve piped to an Air/Vacuum Valve with a quarter -turn, full -ported bronze ball valve on 4 in. and larger sizes.
3. The Air Release Valve shall have a leverage mechanism with sufficient mechanical advantage so that the valve will open under full operating pressure. Simple lever designs shall consist of a single pivot arm and a resilient orifice button. Compound lever designs shall consist of two levers and an adjustable threaded resilient orifice button.
4. The Air/Vacuum Valve sizes 4 in. (100 mm) and larger shall have a cover fitted to the valve body by means of a machined register to maintain concentricity between the top and bottom guide bushings at all times. The float shall be double guided with a guide shaft extending through the float to prevent any contact with the body. The float shall be protected against direct water impact by an internal baffle bolted to the cover or integrally cast in the body. The seat shall be a minimum of .5 in. (12 mm) thick on 2 in. (50 mm) and larger valves and secured in such a manner as to prevent distortion. Valves with working pressures above 500 psig (3450 kPa) shall have metal seats with synthetic seals.
5. Single body combination valves shall have an expanded outlet to provide full flow area around the guide mechanism. The valve shall have a double guided plug on 2 in. (50 mm) and larger sizes, and an adjustable threaded orifice button. The plug shall be protected against direct water impact by an internal baffle. On valve sizes 4 in. (100mm) and smaller, the plug shall have a precision orifice drilled through the center stem. On valve sizes 6 in. (150 mm) and larger, air release and air/vacuum mechanisms shall be provided as separate units contained within the same body and meet the same design specifications for the Dual Body Combination Valve in section C.2 above.
6. A Regulated Exhaust Device shall be provided to reduce pressure surges due to column separation or rapid changes in velocity and pressure in the pipeline.
CITY OF BEAUMONT COMBINATION AND SURGE RELIEF VALVES
MESA LIFT STATION UPGRADE 400578 - 3
7. The Regulated Exhaust Device shall be mounted on the inlet of the Combination Air Valve, allow free air flow in and out of the valve, close upon rapid air exhaust, and control the air exhaust rate to reduce pressure surges.
8. The device shall have a flanged globe -style body with a center guided disc and seat assembly. The disc shall have threaded holes to provide adjustment of the air exhaust rate through the valve. The holes shall provide for a flow area of 5% of the nominal valve size.
E. Materials
1. The valve body and cover shall be constructed of ASTM A126 Class B cast iron for Class 125 and Class 250 valves. Class 300 ductile iron valves shall be constructed of ASTM A536 Grade 65-45-12 ductile iron. Dual Body Class 300 steel valves shall be constructed of ASTM A216 Grade WCB cast steel.
2. The float, guide shafts, and bushings shall be constructed of Type 316 stainless steel. Non- metallic floats, linkage, or bushings are not acceptable. Resilient seats shall be Buna-N.
Class 300 steel dual body valves shall have a 316 stainless steel seat with Buna-N seal to provide an initial contact to Buna-N with a final metal -to -metal contact to prevent over compression of the resilient seal.
3. The Regulated Exhaust Device body shall be ASTM A536 Grade 65-45-12 ductile iron up to 12" and ASTM A126 Class B for 14" and larger. The seat and disc shall be bronze.
F. Coating
1. Valve interiors and exteriors shall be coated with an NSF/ANSI 61 certified fusion bonded epoxy in accordance with AWWA C550 when specified.
G. Manufacturer
1. The manufacturer shall demonstrate a minimum of five (5) years experience in the manufacture of air valves. When requested, the manufacturer shall provide test certificates, dimensional drawings, parts list drawings, and operation and maintenance manuals.
2. Surge Suppression Air Valves shall be Series 201CSSA (single body) or Series 100SSA/38 (Dual Body) as manufactured by Val-Matic Valve and Manufacturing Corporation, Elmhurst, Il, USA or approved equal.
2.5 SURGE RELIEF ANGLE VALVES
A. Scope
1. This specification is intended to cover the design, manufacture, and testing of Surge Relief Angle Valves suitable with pressures relief ratings up to 200 psig (1380 kPa) clean water or raw water service. The valves shall be designed and manufacture for an installation with a maximum 175 psig system ppressure.
B. Manufacturer
1. All valves shall be APCO model SRA-3000A Surge Relief Angle Valves as manufactured by DeZURIK or approved equal.
C. Design
1. Surge Relief Angle Valves shall be normally closed against the system pressure by external spring(s) in compression and shall open quickly to relieve pressure when the system pressure exceeds the pressure relief setting. The pressure relief setting shall be factory set and field adjustable by adjusting the spring compression. The valve will begin to close when the system pressure subsides below the pressure relief setting.
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MESA LIFT STATION UPGRADE 400578 - 4
2. The closing speed shall be adjustable to suit the application by means of infinitely adjustable, lockable flow control valve.
3. Body shall be a 90 degree elbow design conforming to the center -to -face dimension for long -radius elbows per ASME B16.1 and ASME B16.42. Valve shall be a compact design to fit in tight installation spaces.
4. Body and cover shall be constructed of ASTM A536 Grade 65-45-12 ductile iron. Body Seat shall be 316 stainless steel. Flanges shall be flat faced and conform to ASME B16.42 Class 150. Valve shall be proof -of -design tested to 5,000 cycles.
5. A self-contained, sealed hydraulic system shall provide closing speed control. The valve cover shall provide an air gap between the line fluid and the hydraulic oil that will indicate seal wear and prevent contamination of line fluid or hydraulic oil. The valve shall be capable of being mounted in any position without modification or customization of the hydraulic system components. A mechanical stroke counter with manual reset shall provide local indication of total valve cycles.
6. External spring(s) located on the valve cover in a protective steel enclosure shall provide closing force. Springs shall be sized to optimally match customer -specified relief pressure setting to minimize pressure rise above the set -point in order to fully open valve. A single adjustment screw shall be provided for field adjustment of relief pressure setting.
7. Valve Disc shall have a replaceable seat ring of Acrylonitrile-Butadiene (NBR) for tight shutoff.
D. Warranty
1. Warranty Valves and actuators shall be warranted by the manufacturer for defects in materials and workmanship for a period of two years (24 months) from date of shipment.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Except as otherwise indicated, comply with the following requirements:
1. Install valves where required for proper operation of piping and equipment, including valves in branch lines where necessary to isolate sections of piping. Locate valves so as to be accessible and so that separate support can be provided when necessary.
2. Install valves with stems pointed up, in vertical position where possible, but in no case with stems pointed downward from horizontal plane.
B. Insulation: Where insulation is indicated, install extended -stem valves, arranged in proper manner to receive insulation.
C. Valve System: Select and install valves with outside screw and yoke stems, except provide inside screw non -rising stem valves where headroom prevents full opening of OS&Y valves.
D. Renewable Seats: Select and install valves with renewable seats, except where otherwise indicated.
E. Locate all valves in locations which will allow easy operation and facilitates maintenance.
F. Provide chain operators for any valves located more than 8 feet above finished floor. This means double acting lever handles for quarter turn valves, or chain wheels for multi -turn valves. Arrange valves and set up chain length for proper operation.
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MESA LIFT STATION UPGRADE 400578 - 5
3.2 ADJUSTING AND CLEANING:
A. Valve Adjustment: After piping systems have been tested and put into service, but before final testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace packing to stop leaks, replace valve if leak persists.
B. Valve Identification: Tag each valve in accordance with Division -22 section "Identification for Piping and Equipment".
3.3 MANUFACTURER'S CUSTOMER SERVICE
A. Manufacturer's authorized representative shall be available for customer service during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
B. Manufacturer shall also make customer service available directly from the factory in addition to authorized representatives for assistance during installation and start-up, and to train personnel in the operation, maintenance and troubleshooting of the valve.
3.4 WARRANTY
A. Unless noted otherwise, a minimum 12 -month warranty from date of installation or 18 months from shipment shall be provided for parts and workmanship.
END OF SECTION 400578
CITY OF BEAUMONT COMBINATION AND SURGE RELIEF VALVES
MESA LIFT STATION UPGRADE 400578 - 6
SECTION 40 61 13 — PROCESS CONTROL SYSTEM GENERAL PROVISIONS PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes the following:
1. General requirements which apply to all Instrumentation and Control for Process Systems (hereafter referred to as I&C).
B. Related Sections
1. The Contract Documents are a single integrated document. As such, all Divisions and Sections are applicable. The Contractor and its Subcontractors are responsible to review all parts of the Contract Documents to provide a complete and coordinated project.
C. Complete I&C System
1. The requirements for the I&C System shall be the responsibility of a single company hereafter referred to as the Instrumentation Supplier (IS). The IS shall be responsible for all parts of this Section and Sub -Sections as well as all other related sections that may pertain to the I&C System.
2. The Contractor, through the IS and qualified electrical and mechanical installers, shall be responsible to the Owner for the implementation of a complete I&C System. The IS shall provide all necessary coordination, material, and labor such that the entire system be complete and functional. This includes but is not limited to the proper operation and monitoring of electrical power systems, process systems, mechanical equipment, instrumentation, control panels, programmable controllers, communications/networking, and SCADA system.
3. The overall I&C system design is based upon non -certified information that has been furnished by various equipment manufacturers and vendors. It is the Contractor's responsibility to include in the bid and installation all labor and material to provide a complete system based upon actual information from equipment being supplied for the project. Any changes or additions due to non -certified manufacturer or vendor information shall be provided at no additional cost to the Owner.
1.2 REFERENCES
A. The installation and commissioning of the I&C System shall conform to all applicable codes, regulations, standards, and specifications, including, but not limited to those listed below. These publications are referenced to by designation but not by edition. The latest edition accepted by the Authority Having Jurisdiction in effect at the time of bid shall govern.
1. State and Local Codes and Authority Having Jurisdiction (AHJ)
2. American National Standards Institute (ANSI)
3. American Petroleum Institute (API)
CITY OF BEAUMONT PROCESS CONTROL SYSTEM GENERAL PROVISIONS MESA LIFT STATION UPGRADE 406113-1
4. Federal Communications Commission (FCC)
5. Federal Occupational Safety and Health Act (OSHA)
6. International Society of Automation (ISA)
7. Institute of Electrical and Electronic Engineers (IEEE)
8. National Electric Code (NEC).
9. National Electrical Manufacturers Association (NEMA)
10. National Fire Protection Association (NFPA)
11. Underwriters Laboratories, Inc. (UL)
1.3 DEFINITIONS
A. The following definitions may be used throughout this section and subsections (refer to the contract drawings sheet GI -1 for instrumentation abbreviations):
1. CTC: Communications termination cabinet.
2. FAT: Factory acceptance test.
3. HMI: Human machine interface.
4. I&C: Instrumentation and control for process systems
5. IS: Instrumentation supplier.
6. LAN: Local area network.
7. LCP: Local control panel.
8. NC: Normally closed.
9. NO: Normally open.
10. OIT: Operator interface terminal.
11. OSI: Owner's System Integrator.
12. PC: Personal computer.
13. PID: Control action, proportional plus integral plus derivative.
14. PLC: Programmable logic controller.
15. P&ID: Process and instrumentation diagram
16. RIO: Remote input/output
17. SCADA: Supervisory control and data acquisition.
18. SI: System Integrator.
19. UPS: Uninterruptible power supply.
20. VCP: Vendor control panel.
21. WAN: Wide area network
1.4 I&C SYSTEM REQUIREMENTS
A. Work provided outside of Contractor's scope:
1. The following equipment is being furnished by the Owner:
a. SCADA Equipment
B. The Work is to provide a complete and operational I&C System as described by the Contract Documents. This includes but is not limited to the following:
1. Before providing a bid as the IS, coordinate with all bidders such that all costs associated with a complete I&C System are accounted for. The Owner shall not be responsible for any additional costs for scope items that have been excluded from the bid because of not coordinating with all bidders.
CITY OF BEAUMONT PROCESS CONTROL SYSTEM GENERAL PROVISIONS MESA LIFT STATION UPGRADE 406113-2
2. The IS shall submit a statement of qualifications verifying that it meets the requirements of 406113.1.8. The IS must be approved by the Engineer before proceeding with the Work.
3. In order to provide a complete system, oversee and coordinate with all equipment and services being provided outside of Contractor's scope.
a. The Engineer is responsible to ensure that equipment being supplied by others related to the I&C System complies with the requirements of the Contract Documents
b. The Contractor and IS are responsible to coordinate the installation, commissioning and scheduling of equipment related to the I&C System that are provided by others.
4. Oversee and coordinate with all equipment and services being provided by the Contractor but outside of the IS's scope.
a. Inform all vendors and suppliers providing equipment related to the I&C System the requirements of Division 40.
b. The Owner is not responsible for any additional costs incurred by requiring vendors and/or subcontractors to meet the requirements of Division 40. c. If a vendor or supplier is unable to meet the requirements of Division 40, the Contractor may submit in writing to the Engineer the reasons for non-compliance.
The Engineer will then evaluate the reasons and determine whether a solution may be determined or if a different vendor or supplier is required. d. The Contractor and IS are responsible for coordinating with vendors and suppliers the FAT, installation, commissioning, calibration, and scheduling for the associated I&C equipment.
e. The IS is responsible to ensure that panel and loop drawings be supplied for vendor and subcontractor equipment. If the vendors and/or subcontractors are preparing the panel and/or loop drawings, they shall comply with the requirements of Division 40 and shall match those provided by the IS.
5. The IS shall conduct a Pre -Submittal Conference before producing any submittals. The conference should include all parties involved with the I&C System including the Engineer and Owner. The purpose of the conference shall be to review the project, make sure all parties understand their roles and responsibilities and to go over submittal requirements.
6. Prepare I&C System Submittals which includes the following:
a. Instrumentation hardware submittal (including TR20 forms). b. Recommended spare parts submittal.
7. Following submittal approvals, do the following:
a. Procure all instrumentation hardware and accessories. b. Procure hardware for and fabricate all control panels being provided. c. Perform FAT's for all control panels being provided.
8. Programming and integration shall be supplied by the OSI. Oversee and coordinate the programming and integration with the OSI for a complete I&C System.
9. Oversee the installation of the I&C System.
10. Perform bench and field calibrations of instruments as required.
CITY OF BEAUMONT PROCESS CONTROL SYSTEM GENERAL PROVISIONS MESA LIFT STATION UPGRADE 406113-3
11. Oversee and document loop testing.
12. Oversee and document commissioning.
13. Maintain record drawings.
a. Maintain on the construction site a set of the Instrumentation Drawings that shall be continuously marked up during construction.
b. The drawings should be updated at least weekly and will be checked monthly by the Owner's representative.
c. Upon completion of startup, submit the marked -up drawings to the Engineer for review and for drafting.
14. Prepare O&M manuals.
a. Provide O&M manuals in accordance with Section 017823. b. Prepare an O&M manual for each major process area or building. Each of these manuals shall be divided into the following categories:
1) Table of Contents/Index.
2) Process & Instrumentation Diagrams
3) Control Panel Record Drawings, Bill of Materials and Design Data. 4) Record Loop Drawings
c. Prepare O&M manuals that cover comprehensive information for the I&C System.
These manuals shall include the following:
1) Table of Contents/Index.
2) Finalized Instrument Summary
3) Finalized TR20 Instrument Forms
4) Instrumentation Installation Details
5) Instrument Operational Manuals
6) Recommended Spare Parts List
15. Provide training.
1.5 ACTION SUBMITTALS
A. General
1. Submittals for Division 40 shall meet the requirements of Section 013300 Contractor Submittals. In addition, the following requirements shall be met:
a. Submittals shall include bills of materials with quantities, makes, models, exact part numbers and descriptions.
b. Edit all submittals such that only pertinent information is submitted. Neatly cross out information that does not apply, options that are not being supplied, etc. c. Show product dimensions, construction, and installation details, wiring diagrams, and specifications.
d. If there are exceptions to the Contract Drawings and Specifications, provide a list of exceptions with detailed explanations for the exceptions. The Engineer will review the list of exceptions and determine whether a solution may be determined or if the exception(s) will not be allowed.
2. Furnish submittal required by each Section within Division 40.
3. When submitting on equipment, use the equipment and instrumentation tags depicted in the Contract Drawings.
CITY OF BEAUMONT PROCESS CONTROL SYSTEM GENERAL PROVISIONS MESA LIFT STATION UPGRADE 406113-4
B. Instrumentation hardware submittal
1. Provide a comprehensive submittal that includes all instrumentation being supplied by the IS. Divide the submittal into the following:
a. Table of Contents/Index.
b. Instrument summary.
c. Instrument TR20 Forms.
d. Instrument Cut Sheets.
e. Instrument Installation Drawings.
2. Provide an instrument summary (sorted by tag number) that has the following information:
a. Tag number.
b. Make, model and description.
c. Associated process.
d. Location.
e. Calibrated range.
f. Referenced loop drawing number and P&ID.
g. Associated PLC.
3. Furnish TR20 instrumentation forms for each instrument using the forms outlined in ISA- TR20.00.01-2007. This requirement includes all instruments that are being installed as part of the project, whether they are Contractor, Owner and/or Vendor supplied. Show on each sheet who is the responsible party for supplying the instrument. The TR20 sheets should be provided electronically in Microsoft Word or Excel as well.
4. Provide instrument cut sheets for each instrument make and model being supplied for the project. Each cut sheet should have a list of instrument tag numbers that pertain to that cut sheet. The cut sheets should have enough information to verify that the instrument conforms to the Contract Drawings and Specifications.
5. Instrument installation drawings
a. Provide instrument installation drawings for each make and model of instrument being supplied.
b. Delineate what is being supplied by the IS and what is being supplied by other installers.
c. Show overall dimensions, mounting locations and elevations. d. Show all cabling, conduit and piping locations.
e. Show the ambient conditions of the location where the instrument is being installed which includes ambient temperature and humidity extremes, whether the atmosphere is corrosive and the area classification.
f. Show mounting requirements, brackets, stands and anchoring. g. Show means for sun protection where required.
C. Recommended Spare Parts Submittal
1. Submit a list of spare parts for all the equipment associated with the I&C System. The list of spare parts shall include list pricing for each item.
2. Provide the name, address and phone number for each manufacturer and manufacturer's local sales representative.
3. Indicate whether the spare parts are being provided under this contract or not.
1.6 INFORMATIONAL SUBMITTALS
A. Field quality -control test reports.
B. Calibration certificates.
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C. As -built TR20 forms.
1.7 CLOSEOUT SUBMITTALS
A. Operation and maintenance data.
1.8 QUALITY ASSURANCE
A. All equipment supplied for this project shall meet the requirements of the National Electric Code (NEC) and shall be listed by and bearing the label of the Underwriters' Laboratories (UL).
B. The IS shall be a company that has been actively involved in the installation and commissioning of I&C Systems for a minimum period of five years.
C. The IS shall have adequate facilities, manpower and technical expertise to perform the Work associated with the I&C System and as outlined by the Contract Documents.
D. The IS shall have similar project experience of at least four successfully completed projects for a similar wastewater system. The IS company must have performed similar work for these projects as required herein.
PART 2 - PRODUCTS
2.1 MATERIALS
A. All materials provided under this Contract shall be new and free from defects.
2.2 MANUFACTURERS
A. All equipment provided for the I&C System shall be the most recent field -proven models marketed by their manufacturers at the time of submittal of the Shop Drawings unless otherwise required to match existing equipment.
B. Instruments which utilize a common measurement principle (for example, float switches) shall be furnished by a single manufacturer. Panel mounted instruments shall have matching style and general appearance. Instruments performing similar functions shall be of the same type, model, or class, and shall be from a single manufacturer.
2.3 OPERATING CONDITIONS
A. The I&C System shall be designed and constructed for satisfactory operation and long, low maintenance service under the following conditions:
1. Environment: Wastewater Treatment Plant.
2. Temperature Extremes: -4°F to 104°F (Outdoors); 40°F to 104°F (Indoors).
3. Relative Humidity: 20% to 90%, non -condensing.
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B. Indoor and outdoor control panels and instrument enclosures shall be suitable for operation in the ambient conditions associated with the locations designated in the Contract Documents. Heating, cooling, and dehumidifying devices shall be provided to maintain instrumentation devices 20 percent within the minimums and maximums of their rated environmental operating ranges. The Contractor shall provide power wiring for these devices. Enclosures suitable for the environment shall be furnished. Instrumentation in hazardous areas shall be suitable for use in the hazardous or classified location in which it is to be installed.
PART 3 - EXECUTION
3.1 DELIVERY, STORAGE AND HANDLING
A. After completion of shop assembly, factory test, and approval, equipment, cabinets, panels, and consoles shall be packed in protective crates and enclosed in heavy duty polyethylene envelopes or secured sheeting to provide complete protection from damage, dust, and moisture.
Dehumidifiers shall be placed inside the polyethylene coverings. The equipment shall then be skid -mounted for final transport. Lifting rings shall be provided for moving without removing protective covering. Boxed weight shall be shown on shipping tags together with instructions for unloading, transporting, storing, and handling at the Site.
B. Special instructions for proper field handling, storage, and installation required by the manufacturer shall be securely attached to each piece of equipment prior to packaging and shipment.
C. Each component shall be tagged to identify its location, instrument tag number, and function in the system. A permanent stainless steel or other non -corrosive material tag firmly attached and permanently and indelibly marked with the instrument tag number, as given in the tabulation, shall be provided on each piece of equipment in the PCIS. Identification shall be prominently displayed on the outside of the package.
D. Equipment shall not be stored outdoors. Equipment shall be stored in dry permanent shelters, including in -line equipment, and shall be adequately protected against mechanical injury. If any apparatus has been damaged, such damage shall be repaired by the Contractor. If any apparatus has been subject to possible injury by water, it shall be thoroughly dried out and put through tests as directed by the Engineer. If such tests reveal defects, the equipment shall be replaced.
3.2 MANUFACTURER'S SERVICES
A. Manufacturer's services shall be furnished for the following equipment:
1. Vendor supplied equipment that contain programmable controllers, operator interfaces and/or instrumentation that requires site calibration.
B. The Contractor shall furnish the following manufacturer's services for the instrumentation listed below:
1. Perform bench calibration.
2. Oversee installation.
3. Verify installation of installed instruments.
4. Certify installation and reconfirm manufacturer's accuracy statement.
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5. Oversee loop testing and pre -commissioning
6. Train the Owner's personnel.
3.3 INSTALLATION
A. Instrumentation shall be installed per the Instrument Installation Drawings that have been submitted and approved and per the requirements of Division 40. This includes all instrumentation for the I&C System, regardless of who the supplier is. Instrumentation shall be mounted so that it is easily accessible and viewable and such that it does not restrict access to other equipment. Mount instrumentation to pipe stands or wall mounts if they are not directly mounted or if the Contract Drawings indicate otherwise.
B. The I&C System indicated throughout the design are diagrammatic and therefore locations of equipment are approximate. The exact locations and routing of wiring and cables shall be governed by structural conditions and physical interferences and by the location of electrical terminations on equipment. Equipment shall be located and installed so that it will be readily accessible for operation and maintenance. Where job conditions require reasonable changes in approximated locations and arrangements, or when the Owner exercises the right to require changes in location of equipment which do not impact material quantities or cause material rework, the Contractor shall make such changes without additional cost to the Owner.
C. The I&C System is integrally connected to electrical, mechanical, and structural systems.
Coordinate with these other disciplines the installation of these related components. All conduit, cables and field wiring shall be as required by Division 26.
D. Instruments, control panels and all other I&C System related equipment shall be anchored by methods that comply with seismic requirements applicable to the Site.
E. Each existing instrument to be removed and reinstalled shall be cleaned, reconditioned, and recalibrated by an authorized service facility of the instrument manufacturer. The Contractor shall provide certification of this Work prior to reinstallation of each instrument.
F. The Contract Documents show necessary conduit and instruments required to make a complete instrumentation system. The Contractor shall be responsible for providing any additional or different type connections as required by the instruments and specific installation requirements.
Such additions and such changes, including the proposed method of installation, shall be submitted to the Engineer for approval prior to commencing that Work. Such changes shall not be a basis of claims for extra Work or delay.
G. Instrumentation, control panels, wiring and all other I&C equipment shall be properly tagged and/or labeled per the requirements of Section 260553.
H. Installation of the I&C System shall be according to the finalized Loop Drawings
3.4 FACTORY ACCEPTANCE TESTING (FAT)
A. The IS shall arrange for the manufacturers of the equipment and fabricators of panels and cabinets supplied under this Section to allow the Engineer and Owner to inspect and witness the testing of the equipment at the site of fabrication. Equipment shall include the cabinets, special control
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systems, and other pertinent systems and devices. A minimum of 10 days notification shall be furnished to the Engineer prior to testing. No shipments shall be made without the Engineer's approval.
B. For each FAT, the IS shall develop and submit a FAT Plan and Procedure Document within 10 days of the FAT. The FAT Plan and Procedure shall as a minimum shall have the following:
1. Descriptions of test methods to be performed during the FAT.
2. FAT Schedule and Procedure
3. FAT Checklists that allow for sign -off and comments for each test method and procedure.
C. Control Panel Completion Test Methods: The following test methods should be performed during the FAT for each control panel:
1. Completed Shop Drawings: Demonstrate that the control panel has been built according to the shop drawings and that the shop drawings are accurate.
2. Panel Layout: Demonstrate that the control panel has been laid out as designed and as required by Division 40.
3. Power Distribution: Demonstrate all power distribution circuits, including but not limited to AC power circuits, UPS operation, signals and circuits and DC circuits.
4. Control Circuits: Demonstrate the correct installation of each control circuit. Using a signal generator or multi -meter, show the correct operation of each input, output, relay, barrier, buttons, switches, or any other control device. Demonstrate the proper functionality of any hard -wired interlocks that may be associated with each control circuit.
5. Panel Networking/Communications: If any form of communications is associated with the control panel, verify the proper operation of each communication port and link.
D. Control Loop Test Methods: To demonstrate that the control panel will provide its function as intended, provide the following control loop test methods. If programming for the control panel is provided by others, coordinate with the programmer to have all programming completed and tested prior to the FAT. If needed, coordinate to have the programmer present for the FAT.
1. Alarm Functions: Verify and/or simulate each alarm condition associated with each control loop.
2. Local Manual and Auto Functions: Verify and/or simulate each Local Manual and/or Auto function associated with each control loop.
3. SCADA Manual and Auto Functions: Verify and/or simulate each SCADA Manual and/or Auto function associated with each control loop.
4. Control Loop Interlocks: Demonstrate the functionality of any software interlocks that may be associated with each control loop.
E. If the FAT does not pass and needs to be repeated, the IS shall be responsible for additional per diem costs incurred by the Engineer and Owner.
F. All changes and/or corrections made during the FAT shall be noted on the checklists.
G. Following completion and approval of all FAT, provide the finalized checklists to the Engineer and as part of the equipment shop drawings.
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3.5 FIELD QUALITY CONTROL
A. Allow for inspections by the Engineer and/or Owner of the I&C System at any time during the construction. Inspections shall be conducted to verify that the installation is per the requirements of the Contract Documents.
3.6 CALIBRATION
A. Devices provided under Division 40 shall be calibrated according to the manufacturer's recommended procedures to verify operational readiness and ability to meet the indicated functional and tolerance requirements.
B. Each instrument shall be calibrated at 0, 25, 50, 75, and 100 percent of span using test instruments to simulate inputs. The test instruments shall have accuracies traceable to National Institute of Standards and Testing.
C. Instruments that have been bench -calibrated shall be examined in the field to determine whether any of the calibrations need adjustment. Such adjustments, if required, shall be made only after consultation with the Engineer.
D. Instruments which were not bench -calibrated shall be calibrated in the field to ensure proper operation in accordance with the instrument loop diagrams or specification data sheets.
E. Each analyzer system shall be calibrated and tested as a workable system after installation.
Testing procedures shall be directed by the manufacturers' technical representatives. Samples and sample gases shall be furnished by the manufacturers.
F. For each instrument calibration, provide a calibration sheet and update the corresponding TR20 Instrument Form with the new calibration data. The Calibration sheet shall include the following as a minimum:
1. Date of calibration
2. Project Name.
3. Tag Number.
4. Manufacturer, model and serial number.
5. Calibration data including range, input, output and measurement at each calibration point.
6. Space for comments.
7. Space for sign -off by party performing calibration.
G. A calibration and testing tag shall be attached to each piece of equipment or system at a location determined by the Engineer. The IS shall sign the tag when calibration is complete. The Engineer will sign the tag when the calibration and testing has been accepted.
3.7 LOOP TESTING
A. Each control loop shall have been installed according to the finalized loop drawing. Prior to the commencement of loop testing, the following pre -requisites should have been met:
1. All associated equipment, conduit and wire has been permanently installed, terminated, and inspected.
2. All wiring has been properly pulled, terminated, and labeled.
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3. Each wire has been tested with a point-to-point test.
4. All control panels and electrical equipment have been checked out and tested as required by Division 26.
5. All instrumentation has been appropriately installed and calibrated.
6. Loop Test Forms for each loop to be tested have been created and will be available during the loop testing.
B. Each loop test shall have a Loop Test Form prepared and ready prior to each loop test. The loop test form shall have the following:
1. Loop Number and Description
2. Check -Off List with room for sign -off and dated by the IS, Programmer, and Owner's Witness as well as room for comments. The list of items to be checked off for each loop should include but is not limited to the following:
a. Each power distribution circuit.
b. Each control circuit.
c. Each alarm circuit.
d. Each PLC input/output point.
e. Each Local Manual, Local Auto, SCADA Manual & SCADA Auto function. f. Each hard -wired and software interlock.
C. Upon completion of the above pre -requisites for loop testing, the IS shall oversee and coordinate each loop test. The IS is responsible to be present for all loop testing, whether the equipment was supplied by the IS or not. The IS is responsible to have all responsible parties associated with each loop present. This includes but is not limited to manufacturer representatives, vendor technicians, electrical installers, mechanical installers, and programmer. The IS shall coordinate with the Owner and Engineer to allow for witnessing of loop testing as deemed necessary by the Owner and Engineer.
D. Issues that arise during loop testing should be addressed and fixed immediately. If it is not feasible to immediately fix the issues, the loop testing should be re -scheduled as soon as possible to avoid delays. Any costs associated with re -testing and requiring all parties to return to the site shall in no way be incurred to the Owner.
E. Following a successful loop test, the appropriate parties should sign and date the Loop Test Forms. All Forms shall be certified and submitted to the Engineer as part of the O&M Manuals.
F. Following loop testing, in no way should any parts of the loop be modified. In no way shall any wiring be re-routed or re -terminated. If any such work occurs, all affected loops shall be re -tested at no expense to the Owner.
3.8 COMMISSIONING
A. The IS shall oversee, coordinate and be present during all commissioning activities. The IS shall be responsible for obtaining the assistance of the Contractor and Subcontractors as may be required for commissioning activities.
B. Commissioning shall commence after acceptance of wire test, calibration tests and loop tests, and inspections have demonstrated that the instrumentation and control system complies with Contract requirements. Pre -commissioning shall demonstrate proper operation of every system
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with process equipment operating over full operating ranges under conditions as closely resembling actual operating conditions as possible.
C. Commissioning and test activities shall follow detailed test procedures and check lists accepted by the Engineer. Test data shall be acquired using equipment as required and shall be recorded on test forms accepted by the Engineer, which include calculated tolerance limits for each step. Completion of system commissioning and test activities shall be documented by a certified report, including test forms with test data entered, delivered to the Engineer with a clear and unequivocal statement that system commissioning and test requirements have been satisfied.
D. Where feasible, system commissioning activities shall include the use of water to establish service conditions that simulate, to the greatest extent possible, normal final control element operating conditions in terms of applied process loads, operating ranges, and environmental conditions.
Final control elements, control panels, and ancillary equipment shall be tested under startup and steady state operating conditions to verify that proper and stable control is achieved using motor control center and local field mounted control circuits. Hardwired and software control circuit interlocks and alarms shall be operational. The control of final control elements and ancillary equipment shall be tested using both manual and automatic (where provided) control circuits. The stable steady state operation of final control elements running under the control of field mounted automatic analog controllers or software -based controllers shall be assured by adjusting the controllers as required to eliminate oscillatory final control element operation. The transient stability of final control elements operating under the control of field mounted, and software - based automatic analog controllers shall be verified by applying control signal disturbances, monitoring the amplitude and decay rate of control parameter oscillations (if any), and making necessary controller adjustments as required to eliminate excessive oscillatory amplitudes and decay rates.
E. Electronic control stations incorporating proportional, integral, or differential control circuits shall be optimally tuned, experimentally, by applying control signal disturbances and adjusting the gain, reset, or rate settings as required to achieve a proper response. Measured final control element variable position/speed setpoint settings shall be compared to measured final control element position/speed values at 0, 25, 50, 75, and 100 percent of span and the results checked against indicated accuracy tolerances.
3.9 TRAINING
A. Develop a Training Plan for the training requirements of Division 40 and submit it to the Engineer for approval. Coordinate with the Engineer and Owner the time and locations of each training session. Schedule the trainings for after the equipment has been pre -commissioned.
B. As part of the Training Plan, submit a resume for everyone to be providing training. Training shall be performed by qualified representatives of the equipment manufacturers and shall be specific to each piece of equipment.
C. Each training session shall include a written agenda.
D. The Contractor shall train the Owner's personnel on the maintenance, calibration and repair of instruments provided.
E. Within 10 days after the completion of each session, the Contractor shall submit the following:
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1. A list of Owner personnel who attended the training.
2. A copy of the training materials used during the session with notes, diagrams, and comments.
END OF SECTION 40 61 13
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SECTION 40 61 21 — PROCESS CONTROL SYSTEM TESTING
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes in -factory and field-testing requirements.
B. Related Sections
1. The Contract Documents are a single integrated document. As such, all Divisions and Sections are applicable. The Contractor and its Subcontractors are responsible to review all parts of the Contract Documents to provide a complete and coordinated project.
C. Complete I&C System
1. The requirements for the I&C System shall be the responsibility of a single company hereafter referred to as the Instrumentation Supplier (IS). The IS shall be responsible for all parts of this Section and Sub -Sections as well as all other related sections that may pertain to the I&C System.
2. The Contractor, through the IS and qualified electrical and mechanical installers, shall be responsible to the Owner for the implementation of a complete I&C System. The IS shall provide all necessary coordination, material, and labor such that the entire system be complete and functional. This includes but is not limited to the proper operation and monitoring of electrical power systems, process systems, mechanical equipment, instrumentation, control panels, programmable controllers, communications/networking, and SCADA system.
3. The overall I&C system design is based upon non -certified information that has been furnished by various equipment manufacturers and vendors. It is the Contractor's responsibility to include in the bid and installation all labor and material to provide a complete system based upon actual information from equipment being supplied for the project. Any changes or additions due to non -certified manufacturer or vendor information shall be provided at no additional cost to the Owner.
1.2 SUBMITTALS
A. In addition to the submittal requirements of Section 40 61 13, provide the following:
1. Test Results:
a. Pass/fail status of all digital I/O.
b. Results of analog I/O testing.
2. Miscellaneous:
a. Detailed step-by-step in -factory and field test procedure at least 6 weeks in advance of scheduled test date. Include sign -off sheets and punch list forms and description of configurations to be tested.
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b. Complete inventory of equipment to be tested at factory including make, model, and serial number. Label each piece of equipment.
c. Preventative maintenance schedule.
3. Submit in accordance with 01 33 00.
PART 2 - SERVICES
2.1 MANUFACTURER'S SERVICES
A. Manufacturer's services shall be furnished for the following equipment:
1. Vendor supplied equipment that contain programmable controllers, operator interfaces and/or instrumentation that requires site calibration.
a. Combustible Gas Analyzers
b. Magnetic Flow Meters
c. Radar Level Transmitters
B. The Contractor shall furnish the following manufacturer's services for the instrumentation listed below:
1. Perform bench calibration.
2. Oversee installation.
3. Verify installation of installed instruments.
4. Certify installation and reconfirm manufacturer's accuracy statement.
5. Oversee loop testing and pre -commissioning
6. Train the Owner's personnel.
2.2 FACTORY ACCEPTANCE TESTING (FAT)
A. The IS shall arrange for the manufacturers of the equipment and fabricators of panels and cabinets supplied under this Section to allow the Engineer and Owner to inspect and witness the testing of the equipment at the site of fabrication. Equipment shall include the cabinets, special control systems, and other pertinent systems and devices. A minimum of 10 days notification shall be furnished to the Engineer prior to testing. No shipments shall be made without the Engineer's approval.
B. For each FAT, the IS shall develop and submit a FAT Plan and Procedure Document within 10 days of the FAT. The FAT Plan and Procedure shall as a minimum shall have the following:
1. Descriptions of test methods to be performed during the FAT.
2. FAT Schedule and Procedure
3. FAT Checklists that allow for sign -off and comments for each test method and procedure.
C. Control Panel Completion Test Methods: The following test methods should be performed during the FAT for each control panel:
1. Completed Shop Drawings: Demonstrate that the control panel has been built according to the shop drawings and that the shop drawings are accurate.
2. Panel Layout: Demonstrate that the control panel has been laid out as designed and as required by Division 40.
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3. Power Distribution: Demonstrate all power distribution circuits, including but not limited to AC power circuits, UPS operation, signals and circuits and DC circuits.
4. Control Circuits: Demonstrate the correct installation of each control circuit. Using a signal generator or multi -meter, show the correct operation of each input, output, relay, barrier, buttons, switches, or any other control device. Demonstrate the proper functionality of any hard -wired interlocks that may be associated with each control circuit.
5. Panel Networking/Communications: If any form of communications is associated with the control panel, verify the proper operation of each communication port and link.
D. Control Loop Test Methods: To demonstrate that the control panel will provide its function as intended, provide the following control loop test methods. If programming for the control panel is provided by others, coordinate with the programmer to have all programming completed and tested prior to the FAT. If needed, coordinate to have the programmer present for the FAT.
1. Alarm Functions: Verify and/or simulate each alarm condition associated with each control loop.
2. Local Manual and Auto Functions: Verify and/or simulate each Local Manual and/or Auto function associated with each control loop.
3. SCADA Manual and Auto Functions: Verify and/or simulate each SCADA Manual and/or Auto function associated with each control loop.
4. Control Loop Interlocks: Demonstrate the functionality of any software interlocks that may be associated with each control loop.
E. If the FAT does not pass and needs to be repeated, the IS shall be responsible for additional per diem costs incurred by the Engineer and Owner.
F. All changes and/or corrections made during the FAT shall be noted on the checklists.
G. Following completion and approval of all FAT, provide the finalized checklists to the Engineer and as part of the equipment shop drawings.
2.3 FIELD QUALITY CONTROL
A. Allow for inspections by the Engineer and/or Owner of the I&C System at any time during the construction. Inspections shall be conducted to verify that the installation is per the requirements of the Contract Documents.
2.4 CALIBRATION
A. Devices provided under Division 40 shall be calibrated according to the manufacturer's recommended procedures to verify operational readiness and ability to meet the indicated functional and tolerance requirements.
B. Each instrument shall be calibrated at 0, 25, 50, 75, and 100 percent of span using test instruments to simulate inputs. The test instruments shall have accuracies traceable to National Institute of Standards and Testing.
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C. Instruments that have been bench -calibrated shall be examined in the field to determine whether any of the calibrations need adjustment. Such adjustments, if required, shall be made only after consultation with the Engineer.
D. Instruments which were not bench -calibrated shall be calibrated in the field to ensure proper operation in accordance with the instrument loop diagrams or specification data sheets.
E. Each analyzer system shall be calibrated and tested as a workable system after installation.
Testing procedures shall be directed by the manufacturers' technical representatives. Samples and sample gases shall be furnished by the manufacturers.
F. For each instrument calibration, provide a calibration sheet and update the corresponding TR20 Instrument Form with the new calibration data. The Calibration sheet shall include the following as a minimum:
1. Date of calibration
2. Project Name.
3. Tag Number.
4. Manufacturer, model, and serial number.
5. Calibration data including range, input, output, and measurement at each calibration point.
6. Space for comments.
7. Space for sign -off by party performing calibration.
G. A calibration and testing tag shall be attached to each piece of equipment or system at a location determined by the Engineer. The IS shall sign the tag when calibration is complete. The Engineer will sign the tag when the calibration and testing has been accepted.
2.5 LOOP TESTING
A. Each control loop shall have been installed according to the finalized loop drawing. Prior to the commencement of loop testing, the following pre -requisites should have been met:
1. All associated equipment, conduit and wire has been permanently installed, terminated and inspected.
2. All wiring has been properly pulled, terminated and labeled.
3. Each wire has been tested with a point-to-point test.
4. All control panels and electrical equipment have been checked out and tested as required by Division 26.
5. All instrumentation has been appropriately installed and calibrated.
6. Loop Test Forms for each loop to be tested have been created and will be available during the loop testing.
B. Each loop test shall have a Loop Test Form prepared and ready prior to each loop test. The loop test form shall have the following:
1. Loop Number and Description
2. Check -Off List with room for sign -off and dated by the IS, Programmer, and Owner's Witness as well as room for comments. The list of items to be checked off for each loop should include but is not limited to the following:
a. Each power distribution circuit.
b. Each control circuit.
c. Each alarm circuit.
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d. Each PLC input/output point.
e. Each Local Manual, Local Auto, SCADA Manual & SCADA Auto function. f. Each hard -wired and software interlock.
C. Upon completion of the above pre -requisites for loop testing, the IS shall oversee and coordinate each loop test. The IS is responsible to be present for all loop testing, whether the equipment was supplied by the IS or not. The IS is responsible to have all responsible parties associated with each loop present. This includes but is not limited to manufacturer representatives, vendor technicians, electrical installers, mechanical installers, and programmer. The IS shall coordinate with the Owner and Engineer to allow for witnessing of loop testing as deemed necessary by the Owner and Engineer.
D. Issues that arise during loop testing should be addressed and fixed immediately. If it is not feasible to immediately fix the issues, the loop testing should be re -scheduled as soon as possible to avoid delays. Any costs associated with re -testing and requiring all parties to return to the site shall in no way be incurred to the Owner.
E. Following a successful loop test, the appropriate parties should sign and date the Loop Test Forms. All Forms shall be certified and submitted to the Engineer as part of the O&M Manuals.
F. Following loop testing, in no way should any parts of the loop be modified. In no way shall any wiring be re-routed or re -terminated. If any such work occurs, all affected loops shall be re -tested at no expense to the Owner.
2.6 COMMISSIONING
A. The IS shall oversee, coordinate and be present during all commissioning activities. The IS shall be responsible for obtaining the assistance of the Contractor and Subcontractors as may be required for commissioning activities.
B. Commissioning shall commence after acceptance of wire test, calibration tests and loop tests, and inspections have demonstrated that the instrumentation and control system complies with Contract requirements. Pre -commissioning shall demonstrate proper operation of every system with process equipment operating over full operating ranges under conditions as closely resembling actual operating conditions as possible.
C. Commissioning and test activities shall follow detailed test procedures and check lists accepted by the Engineer. Test data shall be acquired using equipment as required and shall be recorded on test forms accepted by the Engineer, which include calculated tolerance limits for each step. Completion of system commissioning and test activities shall be documented by a certified report, including test forms with test data entered, delivered to the Engineer with a clear and unequivocal statement that system commissioning and test requirements have been satisfied.
D. Where feasible, system commissioning activities shall include the use of water to establish service conditions that simulate, to the greatest extent possible, normal final control element operating conditions in terms of applied process loads, operating ranges, and environmental conditions.
Final control elements, control panels, and ancillary equipment shall be tested under startup and steady state operating conditions to verify that proper and stable control is achieved using motor control center and local field mounted control circuits. Hardwired and software control circuit
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interlocks and alarms shall be operational. The control of final control elements and ancillary equipment shall be tested using both manual and automatic (where provided) control circuits. The stable steady state operation of final control elements running under the control of field mounted automatic analog controllers or software -based controllers shall be assured by adjusting the controllers as required to eliminate oscillatory final control element operation. The transient stability of final control elements operating under the control of field mounted, and software - based automatic analog controllers shall be verified by applying control signal disturbances, monitoring the amplitude and decay rate of control parameter oscillations (if any), and making necessary controller adjustments as required to eliminate excessive oscillatory amplitudes and decay rates.
E. Electronic control stations incorporating proportional, integral, or differential control circuits shall be optimally tuned, experimentally, by applying control signal disturbances and adjusting the gain, reset, or rate settings as required to achieve a proper response. Measured final control element variable position/speed setpoint settings shall be compared to measured final control element position/speed values at 0, 25, 50, 75, and 100 percent of span and the results checked against indicated accuracy tolerances.
END OF SECTION 40 61 21
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SECTION 40 61 26 — PROCESS CONTROL SYSTEMS TRAINING
PART 1 - GENERAL
1.1 SUMMARY
A. This Section includes Training requirements.
B. Related Sections
1. The Contract Documents are a single integrated document. As such, all Divisions and Sections are applicable. The Contractor and its Subcontractors are responsible to review all parts of the Contract Documents in order to provide a complete and coordinated project.
1.2 DEFINITIONS
A. The following definitions may be used throughout this section and subsections (refer to the contract drawings sheet GI -1 for instrumentation abbreviations):
1. CTC: Communications termination cabinet.
2. FAT: Factory acceptance test.
3. HMI: Human machine interface.
4. I&C: Instrumentation and control for process systems
5. IS: Instrumentation supplier.
6. LAN: Local area network.
7. LCP: Local control panel.
8. NC: Normally closed.
9. NO: Normally open.
10. OIT: Operator interface terminal.
11. PC: Personal computer.
12. PID: Control action, proportional plus integral plus derivative.
13. PLC: Programmable logic controller.
14. P&ID: Process and instrumentation diagram
15. RIO: Remote input/output
16. SCADA: Supervisory control and data acquisition.
17. SI: System Integrator.
18. UPS: Uninterruptible power supply.
19. VCP: Vendor control panel.
20. WAN: Wide area network
1.3 SUBMITTALS
A. TRAINING
1. Develop a Training Plan for the training requirements of Division 40 and submit it to the Engineer for approval. Coordinate with the Engineer and Owner the time and locations of
CITY OF BEAUMONT PROCESS CONTROL SYSTEMS TRAINING
MESA LIFT STATION UPGRADE 406126-1
each training session. Schedule the trainings for after the equipment has been pre - commissioned.
2. As part of the Training Plan, submit a resume for everyone to be providing training.
Training shall be performed by qualified representatives of the equipment manufacturers and shall be specific to each piece of equipment.
3. Each training session shall include a written agenda.
4. The Contractor shall train the Owner's personnel on the maintenance, calibration and repair of instruments provided.
5. Within 10 days after the completion of each session, the Contractor shall submit the following:
6. A list of Owner personnel who attended the training.
7. A copy of the training materials used during the session with notes, diagrams and comments.
PART 2 - EXECUTION
2.1 MAINTENANCE TRAINING
A. Cover following areas as a minimum:
1. Testing programs which can isolate faults to functional area.
2. Theory, logic flow, physical hardware awareness, and interface connections and assembly of each equipment item.
3. Diagnostic procedures using special and general-purpose test equipment. Theory, testing, and troubleshooting procedures given for special test equipment.
4. Operation of computers and peripherals.
5. Programming routines and procedures to enable students to take advantage of on-line and standby equipment for maintenance and performance verification.
6. Present short operator's course to ensure students understand operator functions and man/machine interfaces. Explain displays and printouts so students understand how information is derived, when it is presented incorrectly, and use of guidelines to differentiate between software and hardware problems.
2.2 INSTRUMENT TRAINING
A. Cover following areas as a minimum:
1. General principle of operation.
2. Calibration schedule.
3. Calibration procedure.
4. Calibration equipment required (if needed).
5. Recommended spare parts.
6. Consumable part — recommended replacement schedule (e.g. Reagents, filters, probe tips) and procedure.
7. General care and maintenance with special consideration to all instruments that may require cleaning such as pressure and level elements, etc.
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MESA LIFT STATION UPGRADE 406126-2
2.3 HMI TRAINING
A. HMI functionality.
B. How key components work; shall include, but not be limited to:
1. Entering of set points.
2. Using alarm matrix.
3. Acknowledging and clearing alarms.
END OF SECTION 40 61 26
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MESA LIFT STATION UPGRADE 406126-3
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SECTION 40 71 13 — MAGNETIC FLOW METERS
PART 1 - GENERAL
1.1 SUMMARY
A. Magnetic flow meters are used to provide continuous flow measurement of the process. The flow instrument consists of a transmitter and a flow element.
1.2 ACTION SUBMITTALS
A. Product Data:
1. Dimensional Drawings
2. Materials of Construction
3. Measurement Accuracy
4. Range and range ability
5. Enclosure Rating
6. Classification Rating
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. All submittals as required in 40 61 13.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations, and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
C. All process lower and upper ranges to be coordinated with Engineer prior to instrument submittals being submitted.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID's and as
CITY OF BEAUMONT MAGNETIC FLOW METERS
MESA LIFT STATION UPGRADE 407113-1
required in section 26 05 00. Each system shall be factory calibrated and certified prior to delivery.
PART 2 - PRODUCTS
2.1 GENERAL
A. Each process measurement system shall typically consist of a sensor and a transmitter. Where shown on the drawings, the transmitter may be utilized for multiple sensors. When a transmitter is used for multiple sensors, it shall be capable of displaying simultaneously each process measurement.
B. Each transmitter shall be equipped with means to transmit process measurement information to the plant SCADA system.
1. For hardwired signals, unless otherwise indicated on the drawings, provide the following:
a. 4-20mA output signal for each process measurement (for up to 500 Ohm loads) b. Two programmable SPDT relay outputs, rated at 5A up to 230VAC, for each process measurement
2. Where shown on the drawings, provide the following digital communications to the plant SCADA system:
a. Modbus RTU (Two -Wire RS -485)
C. Each transmitter shall be powered by 115VAC (± 10%) at 60Hz unless specifically shown on the drawings as being powered by 24VDC (± 15%). Each transmitter shall retain its programmable settings in non-volatile memory.
D. Each sensor and corresponding transmitter shall be supplied as a complete and operable system.
This includes all cabling, mounting hardware and fasteners. When installed outdoors, the transmitter shall be protected from the sun such that direct sunlight will not shine on the display.
E. All transmitters shall be waterproof and made from corrosion resistant materials.
F. All sensors to be immersed in liquids shall be rated for permanent submersion and shall be corrosion resistant.
2.2 FLOW PROCESS MEASUREMENT DEVICES
A. MAGNETIC FLOW METER
1. Materials
a. All mounting hardware shall be 316 stainless steel, the instrument enclosure and the spool mag shall be rated NEMA 4X, the flow sensor liner shall be hard rubber, and the electrode material shall be Hastelloy.
b. Spool size shall be as specified on the drawings.
CITY OF BEAUMONT MAGNETIC FLOW METERS
MESA LIFT STATION UPGRADE 407113-2
c. All applications with flow element below grade where no de -watering means or in submersible applications shall provide the flow element as NEMA 6P (IP-68). d. Transmitter shall be integral or remote to the flow element as shown on the P&ID's.
2. Design and fabrication
a. Utilize characterized field principle of electromagnetic induction to produce signal directly proportional to flow rate. The meter shall use a pulsed DC magnetic field excitation.
b. Provide flanged end connections per ANSI B16 rated for piping system operating and test conditions.
c. Operating pressure: 150 psi.
d. Operating temperature: 32-150°F.
e. Grounding requirements: per manufacturer requirements. Typically, inlet and outlet grounding rings of same material as electrode.
f. When the transmitter is remote to the flow element, provide cable between flow element and transmitter. Coordinate with the installer the length of the cable required. No splices in any way will be allowed.
g. Complete zero stability shall be inherent to the meter system. The system shall have a programmable low flow cutoff.
h. Empty pipe detection to prevent false measurement when pipe is empty or partially filled.
i. Forward and reverse flow measurement and totalization as well as net flow totalization.
j. 4-20mA DC isolated output into maximum 800 ohms. Signal shall be programmable to indicate forward and/or reverse flow.
k. Provide a dry contact output for flow direction indication.
1. Provide a programmable frequency output for flow totalization. m. + 0.5% accuracy for flow rates above 1 fps.
3. Acceptable Manufacturers
a. Siemens SITRANS F 5100W.
b. Endress+Hauser Promag W 400.
c. Rosemount 8700.
d. ABB WaterMaster.
CITY OF BEAUMONT MAGNETIC FLOW METERS
MESA LIFT STATION UPGRADE 407113-3
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers' recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
B. Install all transmitters five feet above floor level. Install in a location that is easily accessible and visible while as near to the sensor(s) as possible.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 40 61 21 and per the manufacturer's documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble -free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
2. Test the process measurement system for proper operation at low, mid, and high process conditions.
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration. These shall be submitted as part of the O&M manual as called for in section 40 61 13.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 40 61 26.
END OF SECTION 40 71 13
CITY OF BEAUMONT MAGNETIC FLOW METERS
MESA LIFT STATION UPGRADE 407113-4
SECTION 40 72 23 — RADAR LEVEL METERS
PART 1 - GENERAL
A. Radar level instruments are used to provide continuous noncontact level measurement of the process. The radar instrument consists of a transmitter, a radar antenna, and a receiver.
1.2 ACTION SUBMITTALS
A. Product Data:
A. Dimensional Drawings
B. Materials of Construction
C. Measurement Accuracy
D. Range and range ability
E. Enclosure Rating
F. Classification Rating
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. All submittals as required in 40 61 13.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations, and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
C. All process lower and upper ranges to be coordinated with Engineer prior to instrument submittals being submitted.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID's and as required in section 26 05 00. Each system shall be factory calibrated and certified prior to delivery.
CITY OF BEAUMONT RADAR LEVEL METERS
MESA LIFT STATION UPGRADE 407223-1
PART 2 - PRODUCTS
2.1 GENERAL
A. Each transmitter shall be equipped with means to transmit process measurement information to the plant SCADA system.
A. For hardwired signals, unless otherwise indicated on the drawings, provide the following:
a. 4-20mA output signal for each process measurement (for up to 500 Ohm loads) B. Where shown on the drawings, provide the following digital communications to the plant SCADA system:
a. Hart Protocol
B. Each radar transmitter shall be loop powered unless specifically shown on the drawings as being powered externally. Each transmitter shall retain its programmable settings in non-volatile memory.
C. Each radar transmitter shall be capable of being programmed through a Bluetooth connection.
D. Each sensor and corresponding transmitter shall be supplied as a complete and operable system.
This includes all cabling, mounting hardware and fasteners. When installed outdoors, the transmitter shall be protected from the sun such that direct sunlight will not shine on the display.
E. All transmitters shall be waterproof and made from corrosion resistant materials.
F. All sensors to be immersed in liquids shall be rated for permanent submersion and shall be corrosion resistant.
2.2 RADAR LEVEL MEASURING SYSTEM
A. The radar level measuring system shall be setup as a single loop powered transducer/transmitter assembly. For hazardous locations, the transmitter shall be rated for the area of classification that it being installed in and it shall be installed with an appropriate intrinsically safe barrier to guarantee the circuit may not normally or abnormally release sufficient electrical or thermal energy to cause ignition of a flammable or combustible atmospheric mixture.
B. All transducer/transmitter assemblies shall be rated IP68 for permanent submergence.
Transmitters shall have an LCD display and shall be programmable by Bluetooth. A remote display shall be provided if no LCD is available on the transmitter.
C. The transducer shall be encapsulated in chemical and corrosion resistant material and shall be hermetically sealed. The antenna supplied (horn or rod) shall be per the recommendation of the manufacturer. It shall be capable of operating from -40°F to 140°F.
The transducer shall be compatible with the level range as indicated on the Contract
CITY OF BEAUMONT RADAR LEVEL METERS
MESA LIFT STATION UPGRADE 407223-2
Drawings. As a minimum, the transducer shall be capable of measuring a range of 40 feet with < 0.2 -inch accuracy.
D. Coordinate with the mechanical installers the method of installing the radar system (flanged or threaded connection). It is critical that the radar level measuring system be installed according to the manufacturer's installation guidelines. Install shield sections if required. Keep the radar emission cone free of interference from pipes, beams, pouring liquids, etc. Locate the assembly away from side walls of tanks or vessels.
E. Each transmitter shall provide a 4-20mA output signal that is programmable to a user desired level range.
F. Provide a software package by the same manufacturer as the radar system that is used to commission and maintain the system. The software shall be able to configure the system, view radar echo profiles and modify the programming to suppress false echo.
G. Manufacturers:
a. Siemens
b. Vega
c. Endress + Hauser
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers' recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
B. Install all analyzers/transmitters five feet above floor level. Install in a location that is easily accessible while as near to the sensor(s) as possible.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 40 61 21 and per the manufacturer's documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble -free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
CITY OF BEAUMONT RADAR LEVEL METERS
MESA LIFT STATION UPGRADE 407223-3
A. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
B. Test the process measurement system for proper operation at low, mid, and high process conditions.
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration. These shall be submitted as part of the O&M manual as called for in section 40 61 13.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 40 61 26.
END OF SECTION 40 72 23
CITY OF BEAUMONT RADAR LEVEL METERS
MESA LIFT STATION UPGRADE 407223-4
SECTION 40 72 76 — LEVEL SWITCHES
PART 1 - GENERAL
1.1 SUMMARY
A. Level switches provide point level measurement of the process.
1.2 ACTION SUBMITTALS
A. Product Data:
1. Dimensional Drawings
2. Materials of Construction
3. Measurement Accuracy
4. Range and range ability
5. Enclosure Rating
6. Classification Rating
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. All submittals as required in 40 61 13.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations, and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
C. All process lower and upper ranges to be coordinated with Engineer prior to instrument submittals being submitted.
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID's and as
CITY OF BEAUMONT LEVEL SWITCHES
MESA LIFT STATION UPGRADE 407276-1
required in section 26 05 00. Each system shall be factory calibrated and certified prior to delivery.
PART 2 - PRODUCTS
2.1 GENERAL
A. Each level switch system shall typically consist of a sensor and an output contact.
B. Each level switch shall be equipped with means to transmit process measurement information to the plant SCADA system.
1. For hardwired signals, unless otherwise indicated on the drawings, provide the following:
a. Form C dry type contacts rated for 10A up to 250VAC.
C. Each level switch shall be supplied as a complete and operable system. This includes all cabling, mounting hardware and fasteners. When installed outdoors, the level switch shall be protected from the sun such that direct sunlight will not shine on the display.
D. All level switches shall be waterproof and made from corrosion resistant materials.
E. All sensors to be immersed in liquids shall be rated for permanent submersion and shall be corrosion resistant.
2.2 LEVEL PROCESS MEASUREMENT DEVICES
A. FLOAT SWITCHES
1. Float switches shall consist of a mechanical switch, hermetically sealed in a plastic casing, freely suspended at the desired height from its own cable. When the liquid level reaches the float switch, the casing will tilt, and the mechanical switch will change state.
2. The casing shall be constructed of polypropylene with the sheathed cable extruding from the casing. The cable shall be three conductors, made specifically for underwater use and heavy flexing service.
3. The float switch shall have a 10A resistive rating up to 250VAC.
4. Weight and buoyancy shall be such that contaminants like a cake of grease will not result in the float switch changing operating level more than one inch.
5. A NEMA 4X 316SS junction box shall be supplied for termination of the float cable(s) allowing for conventional wiring and conduit to be run from the junction box to a control panel. It shall have terminal blocks for the required number of circuits and shall accept sealed fittings.
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MESA LIFT STATION UPGRADE 407276-2
6. Float switch cables shall be suspended in a manner that provides minimum strain to the cable and will not damage it. This is typically achieved with a stainless -steel cord support grip or strain relief grip as manufactured by Kellems. When support grips are used, a stainless -steel hook shall be installed for hanging the support. All screws, fasteners, boxes, and grips shall be 316SS. In no way are any steel or galvanized steel components allowed.
7. The float cable length shall be long enough for easily removing the float from the water for testing and long enough to reach its termination junction box.
8. If the float switch is to be installed in a classified area, an appropriate intrinsically safe barrier shall be utilized to guarantee the circuit may not abnormally create an ignition.
9. Manufacturers:
a. Flygt ENM-10.
b. Or Approved Equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers' recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 40 61 21 and per the manufacturer's documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble -free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
2. Test the process measurement system for proper operation at low, mid, and high process conditions.
CITY OF BEAUMONT LEVEL SWITCHES
MESA LIFT STATION UPGRADE 407276-3
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration. These shall be submitted as part of the O&M manual as called for in section 40 61 13.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 40 61 26.
END OF SECTION 40 72 76
CITY OF BEAUMONT LEVEL SWITCHES
MESA LIFT STATION UPGRADE 407276-4
SECTION 40 73 13 — PRESSURE AND DIFFERENTIAL PRESSURE GAUGES PART 1 - GENERAL
1.1 SUMMARY
A. Pressure and differential pressure gauges provide continuous pressure measurement of the process for local indication.
1.2 ACTION SUBMITTALS
A. Product Data:
1. Dimensional Drawings
2. Materials of Construction
3. Measurement Accuracy
4. Range and range ability
5. Enclosure Rating
6. Classification Rating
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. All submittals as required in 40 61 13.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations, and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
C. All process lower and upper ranges to be coordinated with Engineer prior to instrument submittals being submitted.
CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE GAUGES MESA LIFT STATION UPGRADE 407313-1
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID 's and as required in section 26 05 00. Each system shall be factory calibrated and certified prior to delivery.
PART 2 - PRODUCTS
2.1 GENERAL
A. All gauges shall be waterproof and made from corrosion resistant materials.
2.2 PRESSURE PROCESS MEASUREMENT DEVICES
A. General
1. All inline pressure instruments shall be supplied with isolation ball valve and bleed needle valve for each measurement point. Valve materials shall be selected based upon the properties of the liquid or gas and the atmosphere.
2. Unless otherwise indicated on the Contract Drawings, pressure process measurement devices shall measure process pressure relative to atmospheric pressure (gauge pressure).
3. Pressure process measurement devices which are to measure differential pressure shall have the appropriate inlet and outlet ports and isolation and bleed valves for each port.
4. All pressure instrumentation shall be properly mounted, ideally in locations that are easily accessible and viewable. Supply all appropriate mounting poles, plates, and accessories such that each instrument is properly supported and mounted.
B. Pressure Gauges
1. Pressure gauges shall be 4-1/2 inches in diameter with white laminated dials and black graduations. Windows shall be shatterproof glass acrylic. Gauges shall have a blowout disc and be encased in phenolic, steel, or cast iron. Measuring element shall be a stainless - steel bourdon tube with welded, stress -relieved joints. Socket shall have wrench flats.
Movement shall be rotary geared stainless -steel material. Gauges shall perform as a liquid - filled gauge in a dry gauge and fight against vibration and pulsations. Gauges shall be calibrated to read in applicable units. Accuracy shall be plus and minus 1/2 percent range to 150 percent of the working pressure or vacuum of the pipe or vessel to which they are connected.
2. Acceptable Manufacturers
a. Ashcroft 1279.
b. Or Approved Equal.
CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE GAUGES MESA LIFT STATION UPGRADE 407313-2
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers' recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 40 61 21 and per the manufacturer's documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble -free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems.
B. Update the TR20 instrument forms following testing and calibration. These shall be submitted as part of the O&M manual as called for in section 40 61 13.
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 40 61 26.
END OF SECTION 40 73 13
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CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE GAUGES MESA LIFT STATION UPGRADE 407313-4
SECTION 40 73 36 — PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES PART 1 - GENERAL
1.1 SUMMARY
A. Pressure and differential pressure switches are used to prove a process condition for interlocking or alarming.
1.2 ACTION SUBMITTALS
A. Product Data:
1. Dimensional Drawings
2. Materials of Construction
3. Measurement Accuracy
4. Range and range ability
5. Enclosure Rating
6. Classification Rating
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. All submittals as required in 40 61 13.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations, and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
C. All process lower and upper ranges to be coordinated with Engineer prior to instrument submittals being submitted.
CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES MESA LIFT STATION UPGRADE 407336-1
1.5 DELIVERY, STORAGE, AND HANDLING
A. Deliver the process measurement equipment as a complete system. Each system shall be properly tagged and identified with its corresponding instrument tag as shown on the P&ID 's and as required in section 26 05 00. Each system shall be factory calibrated and certified prior to delivery.
PART 2 - PRODUCTS
2.1 GENERAL
A. Each pressure switch shall be equipped with contacts shall be rated for a minimum of 5 Amps at 120 VAC.
B. Each pressure switch shall be supplied as a complete and operable system. This includes all cabling, mounting hardware and fasteners. When installed outdoors, the pressure switch shall be protected from the sun such that direct sunlight will not shine on the display.
C. All pressure switch shall be waterproof and made from corrosion resistant materials.
2.2 PRESSURE PROCESS MEASUREMENT DEVICES
A. General
1. All inline pressure instruments shall be supplied with isolation ball valve and bleed needle valve for each measurement point. Valve materials shall be selected based upon the properties of the liquid or gas and the atmosphere.
2. Unless otherwise indicated on the Contract Drawings, pressure process measurement devices shall measure process pressure relative to atmospheric pressure (gauge pressure).
3. Pressure process measurement devices which are to measure differential pressure shall have the appropriate inlet and outlet ports and isolation and bleed valves for each port.
4. All pressure instrumentation shall be properly mounted, ideally in locations that are easily accessible and viewable. Supply all appropriate mounting poles, plates, and accessories such that each instrument is properly supported and mounted.
B. Pressure Switches
1. For unclassified locations, pressure switches shall be housed in a NEMA 4X enclosure.
For classified locations, pressure switches shall be housed in a NEMA 7 enclosure.
2. Gauge and Differential pressures switches shall be diaphragm -actuated, dual adjustable, with SPDT snap action switch. Contacts shall be rated for a minimum of 5 Amps at 120 VAC. The dead band shall be adjustable up to 60 percent of full scale. Set points shall fall between 20 and 80 percent of the adjustable range. The diaphragm shall be Buna-N, unless
CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES MESA LIFT STATION UPGRADE 407336-2
otherwise indicated, and the lower housing shall be brass with a 1/4 -inch bottom sensing connection, unless otherwise indicated.
3. Acceptable Manufacturers
a. Ashcroft Series B (Gauge) and D (Differential).
b. Or Approved Equal.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment and materials specified in this section shall be installed, connected, and tested in accordance with the manufacturers' recommendations and as required by these specifications and contract drawings. Contractor shall coordinate with other trades to insure proper connection to piping and other mechanical equipment.
B. Install all pressure switches five feet above floor level. Install in a location that is easily accessible while as near to the sensor(s) as possible.
3.2 CALIBRATION AND COMMISSIONING
A. A manufacturer representative shall field calibrate the process measurement system as required by section 40 61 21 and per the manufacturer's documented calibration procedure. The system shall be calibrated to the proper ranges as required by the Owner and the Engineer. Where analog signals are connected to local or remote monitoring equipment, verify that the calibrated ranges and scaling of the local and remote indicators are correct.
B. Prior to final acceptance of the work, the Contractor shall certify the equipment and installation included under this section to be free of defects, and suitable for trouble -free operation.
3.3 FIELD QUALITY CONTROL
A. Tests and Inspections:
1. Visually inspect the installation of the process measurement systems. Verify that the incoming power is within the required range. Verify the functionality of all output signals and communications connections.
2. Test the process measurement system for proper operation at low, mid, and high process conditions.
B. Document data for each measurement and for system calibration. Update the TR20 instrument forms following testing and calibration. These shall be submitted as part of the O&M manual as called for in section 40 61 13.
CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES MESA LIFT STATION UPGRADE 407336-3
3.4 TRAINING
A. Provide a minimum of four hours of training for each type of process measurement system provided. Provide training in accordance with section 40 61 26.
END OF SECTION 40 73 36
CITY OF BEAUMONT PRESSURE AND DIFFERENTIAL PRESSURE SWITCHES MESA LIFT STATION UPGRADE 407336-4
SECTION 40 73 63 — DIAPHRAGM SEALS
PART 1 - GENERAL
1.1 SUMMARY
A. Diaphragm seals provide a means to measure pressure while keeping the pressure sensing device isolated from the process. These are commonly used for services that would plug the small passages in the pressure sensing device.
1.2 ACTION SUBMITTALS
A. Product Data:
1. Dimensional Drawings
2. Materials of Construction
3. Measurement Accuracy
4. Range and range ability
5. Enclosure Rating
6. Classification Rating
B. Instrumentation TR20 forms.
1.3 INFORMATIONAL SUBMITTALS
A. All submittals as required in 40 61 13.
1.4 QUALITY ASSURANCE
A. Equipment to be furnished under this section shall be the product of firms regularly engaged in the design and manufacturing of this type of equipment. Manufacturer shall assume responsibility for, and guarantee performance of equipment furnished. However, this shall not be construed as relieving the Contractor from responsibility for the proper installation and functionality of the work.
B. Examine the Contract Documents and verify that instruments being provided are compatible with the physical and process conditions associated with the instrument. This includes compatibility with liquids, gases, pressures, temperatures, flows, materials, locations, and mounting requirements. Provide all necessary accessories to the instrument for a complete and operable system.
C. All process lower and upper ranges to be coordinated with Engineer prior to instrument submittals being submitted.
CITY OF BEAUMONT DIAPHRAGM SEALS
MESA LIFT STATION UPGRADE 407363-1