Attachment_1_to_Item_No._1_-_NRIP_-_Calexco_Reach_Invitation_to_Bid_and_Specifications — Calexico City Council, August 10, 2022 (part 6 of 6)

Submit copies of solvent cement Manufacturer’s report and certification in accordance with ASTM D2564 for PVC piping.

Test Record
Transcripts
Submit test results for factory tests per foundry or test record transcript requirements.

Warranty Furnish one -year warranty from date of final acceptance B. Refer to Section 01 33 00 / 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, Certificates of Compliance, and Test Record Transcripts.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Protect piping materials from sunlight, scoring and distortion.

C. Do not allow surface temperatures on pipe and fittings to exceed 120°F.

D. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of PVC plastic pipe and fittings.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for PVC plastic pipe and fittings.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
PVC Pipe and Fittings
PVC Plastic Pipe
and Fittings ⅜”-24”
GF Harvel Plastics, Inc. Irvine, CA (800) 854-4090
Harrington Industrial Plastics, Inc. Chino, CA (909) 597-8641 Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 4

ITEM MANUFACTURER MANUFACTURER LOCATION
J.M. Eagle, Inc. Los Angeles, CA (800) 621-
4404
Accepted equal
Solvent Cement
PVC
T Christy Enterprises, Inc. Red Hot
Blue Glue, Low VOC
Anaheim, CA (714) 507-3300
IPS Corporation Weld-On 705 or
711
Gardena, CA (310) 516-0108
Accepted equal compatible with
pipe material, and CALGreen Code
and SCAQMD requirements
Adaptors and Saddles
PVC Sensor Probe
Fittings
Spears Manufacturing Company Sylmar, CA (818) 364-1611
Accepted equal
PVC Flanges Spears Manufacturing Company Sylmar, CA (818) 364-1611 Accepted equal
Bug Screens
Accepted equal
Joint Products
Nuts and Bolts,
Flange Gaskets,
and Threaded
Joint Sealants
Refer to Section 33 05 31
Identification Tape
Buried Pipe
Identification Tape
Refer to Section 33 05 26

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Materials for PVC pipe used for temperatures to 90°F, shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Pipe Standards Conform to ASTM D1785
Material Conform to ASTM D1784
Cell Class 12454
Virgin rigid PVC
Conform to NSF 14
Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 5

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Marking Mark pipe at 5’ maximum intervals.

Show Manufacturer’s name or trademark.

Mark ASTM standard complied with.

Show nominal pipe diameter.

Show wall thickness schedule.

Show material, and PVC cell classification
Size As shown on plans.

Wall Thickness Schedule 40
Color White
Painting/Coating Exterior Where
Exposed to Sunlight
or Required in Vaults
and Buildings for
Color Coding
Refer to Section 09 90 00.

C. Materials for PVC pipe joints shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Joints Restrained Style Solvent-welded socket joints except at valve connections
Provide threaded or flanged adaptors as required
for valve connections
Solvent
Cement
Material ASTM D656 primer
ASTM D2564 solvent cement
Flanges Pressures 0-150 psi Plain-faced 125 or 150 psi flanges per ANSI B16.5
Flange
Alignment
Horizontal Pipelines Boltholes shall straddle horizontal centerlines of pipe run to which flanges are attached.

Vertical Pipelines Boltholes shall straddle plant North-South and plant East-West centerlines of pipe run to which
flanges are attached.

Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 6

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Flange Bolts,
Nuts and
Washers and
Gaskets
Refer to Section 33 05 31.

A. Materials for PVC pipe fittings shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Fittings Standards Conform to ASTM D2466
Weight Use same schedule as adjacent pipe
Threads Injection molded type where required
Conform to ASTM F1498
Threaded Nipples ASTM D2464, Schedule 80 with molded threads Threaded Fittings
(Use only where
specifically allowed
on plans)
ASTM D2464 with PTFE tape
Tees and Ells Side-gated
Socket Fittings Conform to ASTM D2467
Tapping Saddles For dimensions and test performance, see ASTM D2466 and D1599
Transition Fittings Required per CPC 606.2 for transitioning between metal and PVC pipe
Material and Color Same as pipe
D. The following product design criteria, options and accessories are required:

ITEM DESCRIPTION
Design Criteria Loading H-20 (32k axle 16k wheel load)
Depth of Soil Cover Refer to Plans
E. Refer to Section 33 05 26 for requirements for identification, identification tape and warning tape for buried pipe.

Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 7
PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install PVC plastic pipe before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

B. Clean dirt and moisture from pipe and fittings. Bevel pipe ends per Manufacturer’s instructions with chamfering tool or file. Remove burrs.

3.2 Installation
A. Refer to Sections 01 73 24, and 01 73 33 / 02 05 00 for basic execution and installation requirements.

B. Refer to Section 31 23 00 / 31 23 33 for open trench requirements.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire and plumbing code requirements

3. Manufacturer’s installation and warranty requirements

4. ASTM D2855 Making Solvent-Cemented Joints with Poly(Vinyl Chloride) (PVC) Pipe and Fittings

5. ASTM F402 Safe Handling of Solvent Cements, Primers and Cleaners Used for Joining Thermoplastic Pipe and Fittings

6. ASTM F645 Selection, Design and Installation of Thermoplastic Water Pressure Piping Systems

7. ASTM D2774 Underground Installation of Thermosetting Pressure Piping

8. ASTM F1668 Construction Procedures for Buried Plastic Pipe D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. PVC plastic pipe shall be furnished and installed by Contractor at location shown on Plans and Submittals.

F. Install PVC plastic pipe to tolerances recommended by Manufacturer. Unless otherwise shown, install PVC plastic pipe true, plumb, and level using precision gauges and levels.

G. Install threaded pipe as follows:

1. Install threaded PVC pipe only where specifically called out on plans or for mating with unions.

2. Do not use threaded pipe joints for applications having pressures in excess of 100 psi.

3. Use Schedule 80 pipe or thicker for threaded applications. Do not thread Schedule 40 pipe.

4. Do not use Teflon tape as lubricant. Use paste recommended by Manufacturer such as Spears 75 thread paste.

5. Use strap wrench that will not damage pipe for tightening joints.

6. Do not tighten threaded pipe more than 2 turns beyond finger tight.

H. Provide molded transition fittings for transitions from plastic to metal or IPS pipe. Do not thread plastic pipe.

Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 8
I. Locate unions where shown and where needed for easy access and assembly of piping system.

J. Install solvent-welded PVC pipe as follows:

1. Do not solvent weld joints when ambient temperatures are below 40°F or above 90°F unless solvents specifically formulated for these conditions are used.

2. De-burr and bevel pipe surfaces to be solvent-welded.

3. Clean and dry pipe surfaces to be solvent-welded.

4. Use only solvent recommended by Manufacturers of pipe and fittings.

5. Apply solvent with non-synthetic bristle brush no less than ½ nominal size of pipe diameter.

6. Follow proper primer and cement application sequence as described in ASTM D2855.

7. Apply even coat of solvent to inside of fitting and to outside of pipe on full area to be inserted into fitting socket.

8. Insert pipe into fitting to full depth immediately after coating, and then rotate pipe 90 degrees to distribute solvent and remove air bubbles.

9. Remove excess solvent from outside of joint.

10. Each joint shall remain undisturbed for at least 30 minutes to develop handling strength.

11. Allow 24 hours drying time before pressure testing.

K. Install flanges on PVC pipe as follows:

1. Clean flange surfaces to mate with gasket, removing loose dirt, scale and detritus.

2. Inspect flange bolts and studs for proper size, threading and length.

3. Clean and lubricate bolt threads using lubricant chemically compatible with materials involved.

4. With gasket in place, align mating flange bolt holes. Make sure mating flange faces are flush against gasket prior to bolt-up.

5. Insert bolts, nuts and washers. Tighten by hand until snug.

6. Before tightening bolts beyond hand-tight, operate adjacent valves through full range of motion to ensure clear unobstructed operation of discs and other internal parts.

7. Tighten bolts in sequence by 5-lb. increments following 180° opposing sequence.

8. Flange bolt torques shall be:

FLANGE SIZE RECOMMENDED TORQUE
½” 12 ft-lb
¾” 12 ft-lb
1” 12 ft-lb
1¼” 12 ft-lb
1½” 12 ft-lb
2” 25 ft-lb
2½” 25 ft-lb
Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 9

FLANGE SIZE RECOMMENDED TORQUE
3” 25 ft-lb
3½” 25 ft-lb
4” 25 ft-lb
5” 30 ft-lb
6” 40 ft-lb
L. Provide serrated nipples where required for transition from plastic pipe to rubber hose.

M. Refer variances between Manufacturer’s installation instructions and Contract Documents to Owner’s Representative.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Completed
Piping
Systems
Completed
Piping
Systems
Hydrostatic
Test
Section 33 08 11. All fluid
containing PVC
pipe
Contractor Contractor
Installation &
Leakage
Visual inspection of
finished installation
1 inspection Owner Owner
Hydrostatic Test
to 150 psi
1 each system
as directed by
Owner
Contractor Contractor
Field
Performance
Demonstrate
compliance to
Contract Documents
and Manufacturer’s
printed literature
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate
compliance to
Contract Documents
and Manufacturer’s
printed literature
1 test Owner Contractor

3.4 Protection
A. When pipe laying is not in progress, and during noon hour and overnight, close open end of pipe with tight-fitting cap or plug to prevent entrance of foreign matter into pipe.

B. Do not use pipeline to drain water that has infiltrated into trench.

C. Maintain inside of pipe free from foreign materials and in clean and sanitary condition until acceptance by Owner.

END OF SECTION

Project Owner PVC SCHEDULE 40 PLASTIC PIPE
New River Improvement Project – Calexico 33 11 33 - 10

THIS PAGE INTENTIONALLY LEFT BLANK
Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -1
SECTION 33 12 12

RESILIENT-WEDGE GATE VALVES
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of resilient-wedge gate valves.

B. Materials, testing, and installation of resilient-wedge tapping valves.

C. Refer to Section 33 05 39 for manual valve operators D. Do not use resilient-wedge gate valves under the following circumstances:

1. For throttling service.

2. For slurry handling service.

3. For valves < 2” or > 48” diameter.

4. For working pressures >200 psi

5. For valves >4” working pressures >100 psi

6. For working pressures >150 psi

7. For pH ranges <6.5 or >8.5.

8. For temperatures < 33°F or > 125°F diameter.

9. In shallow pipelines where insufficient clearance is available for stems.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 61 00: Common Product Requirements
E. Section 01 65 00: Product Delivery Requirements
F. Section 01 66 00: Product Storage and Handling Requirements G. Section 01 73 33: Mechanical Identification
H. Section 02 05 00: Basic Civil Engineering Requirements I. Section 09 90 00: Painting and Coating
J. Section 09 96 56: Epoxy Linings and Coatings
K. Section 31 05 50: Protecting Existing Utilities
L. Section 33 08 11: Pressure Testing and Flushing of Water Utilities

1.3 System Description
A. Furnish and install complete operating valve including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and applicable building codes and standards.

B. Gate valves shall provide positive shutoff when valve is in closed position and shall provide unobstructed flow when valve is in open position.

1.4 Quality Assurance
A. Use adequate numbers of skilled workmen trained and experienced in necessary trades and crafts and completely familiar with specified requirements and methods for proper performance of Work of this section.

B. Products coming into contact with potable water shall contain no more than 0.25% lead by average weight in compliance with the Federal Reduction of Lead in Drinking Water Act and California law AB1953.

C. Factory testing shall include:

Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -2

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY

FIRST TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Resilient
Wedge Gate
Proof of Design
Test
AWWA C515 §5.1.1 1 each prototype Contractor Contractor Operation Test AWWA C515 §5.1.2.1 1 each valve Contractor Contractor Shell Test AWWA C515 §5.1.2.2 at
400 psi
1 each valve Contractor Contractor
Seat Test AWWA C515 §5.1.2.3 at
200 psi
1 each valve Contractor Contractor
Metal to
Rubber Bond
ASTM D429 1 each valve Contractor Contractor
Interior Lining Holidays and
Lining
Thickness
Refer to Section 09 96 56 1 each valve Contractor Contractor

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. API/ANSI 598 Valve Inspection and Testing

2. API/ANSI 600 Steel Gate Valves – Flanged and Butt-Welding Ends, Bolted Bonnets

3. ASME/ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings – Class 25, 125, 150 and 800

4. ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings (Including ratings for Class 150, 300, 400, 600, 900, 1500, and 2500)

5. ASME/ANSI B16.10 Face-to-Face and End-to-End Dimensions of Valves

6. ASME/ANSI B16.21 Non Metallic Flat Gaskets for Pipe Flanges

7. ASME/ANSI B16.42 Ductile Iron Pipe Flanges and Flanged Fittings, Classes 150 and 300

8. ASME/ANSI B16.47 Large Diameter Steel Flanges: 26”-60”

9. ASTM A116

10. ASTM A126 Gray Iron Castings for Valves, Flanges and Pipe Fittings

11. ASTM A217 Steel Castings, Martensitic Stainless and Alloy, for Pressure-Containing Parts, Suitable for HighTemperature Service

12. ASTM A276 Stainless Steel Bars and Shapes

13. ASTM A473 Stainless Steel Forgings

14. ASTM A536 Ductile Iron Castings

15. ASTM A582 Free Machining Stainless Steel Bars

16. ASTM A743 Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application

17. ASTM B16 Free-Cutting Brass Rod, Bar and Shapes for Use in Screw Machines

18. ASTM B62 Composition Bronze or Ounce Metal Castings (do not use for potable water wetted surfaces)

19. ASTM B98 Copper Silicon Alloy Rod, Bar, and Shapes

20. ASTM B124 Copper and Copper Alloy Forging Rod, Bar, and Shapes

21. ASTM B138 Manganese Bronze Rod, Bar, and Shapes

22. ASTM B148 Aluminum Bronze Sand Castings

23. ASTM B283 Copper and Copper Alloy Die Forgings (Hot Pressed)

24. ASTM B584 Copper Alloy Sand Castings for General Applications

25. ASTM B763 Copper Alloy Sand Castings for Valve Applications

26. ASTM D412 Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension

27. ASTM D429 Rubber Property—Adhesion to Rigid Substrates

28. ASTM D2000 Classification System for Rubber Products in Automotive Applications

29. AWWA C105 Polyethylene Encasement for Ductile Iron Pipe Systems

30. AWWA C111/ANSI A21.11 Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings

31. AWWA C213 Fusion-Bonded Epoxy Coating for Interior and Exterior of Steel Water Pipelines

32. AWWA C207 Steel Pipe Flanges

33. AWWA C213 Fusion-Bonded Epoxy Coating for Interior and Exterior of Steel Water Pipelines

34. AWWA C509 Resilient Seated Gate Valves for Water Supply Service

35. AWWA C515 Reduced Wall, Resilient Seated Gate Valves for Water Supply Service

36. AWWA C550 Protective Epoxy Interior Coatings for Valves and Hydrants

37. AWWA C606 Grooved and Shouldered Joints

38. MSS SP70 Gray Iron Gate Valves, Flanged and Threaded Ends Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -3

39. MSS SP111 Gray-Iron and Ductile-Iron Tapping Sleeves

40. NSF/ANSI 61 Drinking Water System Components – Health Effects

41. NSF/ANSI 372 Drinking Water System Components – Lead Content (Formerly NSF/ANSI 61 Annex G)

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit for valves >16” diameter per valve Shop Drawing requirements.

Product Data Submit per Product Data requirements and AWWA C509 / AWWA C515 §4.1.1.

Include valve dimensions, laying length.

Include dimensions and orientations of valve operators.

Include lining and coating data and thicknesses.

Include factory torque sheets showing torque required through opening and closure.

Installation Instructions Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance instruction requirements.

Certificate of
Compliance
Submit certified test results for leakage and hydrostatic tests Submit certified report of testing of factory-applied linings Submit affidavit of compliance with AWWA C509 / AWWA C515 Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M instructions, and Certificates of Compliance.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of resilient-wedge gate valves.

C. Refer to AWWA C509 Appendix A for additional requirements for delivery, storage, and handling of resilient-wedge gate valves.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for resilient wedge gate valves.

C. Work to be paid for under this item shall include all labor, materials, tools, and equipment to furnish and install resilient wedge gate valves of size type and class shown, including valve, actuator, thrust restraint, valve supports, valve can, riser, extension, lid, gaskets, fasteners, and any appurtenant Work as required by Contract Documents.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers for valves include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Resilient Wedge Gate
Valves (Potable Water
C509) 3”-36”
American AVK Company Series 65 2½”-12”” Minden, NV (775) 552-1400 ACIPCO American Flow Control Series 500 Birmingham, AL (800) 442-2347 Clow Valve Company / McWane “Series F-6000” 2”-12” Corona, CA (951) 735-5555 Kennedy Valve / McWane Kenseal II 2”-12” Elmira, NY (607) 734-2211 Tustin, CA (714) 832-1090
M&H Valve / McWane Style 4067 2”-12” Anniston, AL (256) 237-3521 Mueller Co. Series 2360 2”-12” Chattanooga, TN (423) 209-4800 Matco-Norca, Inc. 300 RWV Series La Palma, CA (866) 532-8306 Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -4

ITEM MANUFACTURER MANUFACTURER LOCATION
Resilient Wedge Gate
Valves (Recycled
Water)
Other manufacturers will be accepted only if wedge
coating is EPDM.

Accepted equal

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Resilient-wedge gate valves and tapping valves shall conform to AWWA C509 C. The following is being conveyed:

FLUID VISCOSITY
(77°F)

SPECIFIC

GRAVITY

TEMP FREEZING
POINT

BOILING
POINT
VAPOR
PRESS
(77°F)
pH SOLIDS

CONTENT
Groundwater 0.894cP 1.00 33-90°F 32°F 212°F 0.46
psia

6.5-

8.5 <500 ppm
Potable Water 0.894cP 1.00 33-90°F 32°F 212°F 0.46
psia

6.5-

8.5 <500 ppm
Recycled
Water

0.894cP 1.00 33-90°F 32°F 212°F 0.46
psia

6.5-

8.5 <1.0%
Stormwater 0.894cP 1.00 33-90°F 32°F 212°F 0.46
psia

6.5-

8.5 <1.0%
Wastewater 0.894cP 1.01 33-90°F 32°F 212°F 0.46
psia

6.5-

8.5 <1.0%
5% Sodium
Chloride Brine

1.037 33-90°F 25.2°F 212°F 0.33
psia

10% Sodium
Chloride Brine

1.076 33-90°F 18.7°F 212°F 0.33
psia

20% Sodium
Chloride Brine

1.155 33-90°F 6.1°F 8
D. Materials for resilient wedge gate valves for recycled water service shall be:

ITEM MATERIAL SPECIFICATION
Body, Bonnet and Yoke if
Applicable
Ductile Iron (for
pressures 0-300 psi)
Conform to ASTM A536 Grade 65-45-12 / ASTM A395
Cast Iron (for
pressures 0-150 psi)
Conform to ASTM A126 Class B / ASTM A48 Class 40
Cast Carbon Steel
(for pressures over
300 psi)
Conform to API 600
Conform to ASTM A216 Grade WCB / ASTM A27 Grade
U60-30
Stainless Steel for
Seawater or Brine
Service
Conform to API 600
Conform to ASTM A276 / ASTM A473 / ASTM A582 /
ASTM A743-CF-8M
SAE Type 316 / SAE Type 304 / SAE Type 416 / SAE Type
F310 heat-resisting
NSF Listing Parts Exposed to
Potable Water
Provide NSF 61 listed products and conform to NSF/ANSI
372 lead threshold for potable water applications.

Gate (same material as valve
body)
Ductile Iron Conform to ASTM A536 Grade 65-45-12 / ASTM A395 Cast Iron Conform to ASTM A48 / ASTM A126 Class B
Bronze Conform to ASTM B16, B62, B98, B124, B138, B148, B283, B584, or B763
Use alloy listed in AWWA C509 / C515 Table 5
Carbon Steel Conform to API 600
Conform to ASTM A216 Grade WCB / ASTM A27 Grade
U60-30
Stainless Steel Same Material as body
Wedge Resilient Coating Ethylene-Propylene
Diene Monomer
(EPDM)
Conform to ASTM D429
Peroxide cured
Vulcanized Rubber
Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -5

ITEM MATERIAL SPECIFICATION
Stem High-Strength LowZinc Bronze Conform to ASTM B16, B98, B138, B148, B283, B584, or B763
Maximum 5 / 7% zinc, 2% aluminum
Minimum tensile strength = 70,000 psi
Minimum yield strength = 40,000 psi
Elongation >15% in 2”
Visibly mark stem to show compliance with above.

Stainless Steel Conform to ASTM A276, A473, A582, or A743 SAE Type 316 / SAE Type 304 or other alloy listed in
AWWA C515 Table 6
Stem Nut High-Strength LowZinc Bronze Conform to ASTM A116 Alloy C844 or use alloy listed in AWWA C515 Table 5
Stainless Steel Conform to ASTM A276, A473, A582, or A743 SAE Type 316 / SAE Type 304 or other alloy listed in
AWWA C515 Table 6
Bonnet Bolts Stainless Steel Conform to ASTM A276 SAE Type 316 / SAE Type 304 with antiseize lubricant
Valve Seat EPDM Rubber Conform to ASTM D412
O-Rings Synthetic Rubber Conform to ASTM D2000
Flanges
Sizes 3”-48”
Working Pressures 0-150 psi
Ductile Iron Conform to ASME/ANSI B16.42 Class 150
Raised or plain faced
Cast Iron Conform to ASME/ANSI B16.1 Class 125
Raised or plain faced
Carbon Steel Conform to ASME/ANSI B16.5 Class 150
Conform to ASME/ANSI B16.47 Class 150 for flanges ≥ 26” Raised or plain faced
Stainless Steel Conform to ASME/ANSI B16.5 Class 150
Conform to ASME/ANSI B16.47 Class 150 for flanges ≥ 26” Raised or plain faced
Flanges
Sizes 3”-48”
Working Pressures 0-200 psi
Ductile Iron Conform to ASME/ANSI B16.42 Class 150 Raised or plain faced
Carbon Steel Conform to ASME/ANSI B16.5 Class 150
Conform to ASME/ANSI B16.47 Class 150 for flanges ≥ 26” Raised or plain faced
Stainless Steel Conform to ASME/ANSI B16.5 Class 150
Conform to ASME/ANSI B16.47 Class 150 for flanges ≥ 26” Raised or plain faced
Flanges
Sizes 3”-48”
Working Pressures 200-250 psi
Ductile Iron Conform to ASME/ANSI B16.42 Class 150
Raised or plain faced
Carbon Steel Conform to ASME/ANSI B16.5 Class 150
Conform to ASME/ANSI B16.47 Class 150 for flanges ≥ 26” Raised or plain faced
Stainless Steel Conform to ASME/ANSI B16.5 Class 150
Conform to ASME/ANSI B16.47 Class 150 for flanges ≥ 26” Raised or plain faced
Flange Alignment Valves Boltholes shall straddle horizontal and vertical centerlines of valve.

Flange Bolts, Nuts, and
Washers
Various Steels Refer to Section 33 05 31.

Flange Gaskets Refer to Section 33 05 31.

Push-on Joint Ends Provide where shown Conform to AWWA C111 / ANSI A21.11 and AWWA C509 / AWWA C515 §4.4.1.4.2
Mechanical Joint Ends Provide where shown Conform to AWWA C111 / ANSI A21.11 and AWWA C509 / AWWA C515 §4.4.1.4.3
Grooved Ends Provide where shown Conform to AWWA C606
Compatible with adjacent coupling
Lining Refer to Section 09 96 56.

Conform to AWWA C550 10 / 12 / 16-mil minimum DFT
Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -6

ITEM MATERIAL SPECIFICATION
Do not coat sealing areas or bronze or stainless steel parts.

Exterior Finish Coat Epoxy Refer to Section 09 90 00.

Polyethylene Encasement on
Buried Valves
Polyethylene Conform to AWWA C105
2 layers of 8-mil wrap
E. The following product design criteria, options and accessories are required for resilient-wedge gate valves for water service:

ITEM DESCRIPTION
Design Criteria Design Standard Conform to AWWA C509
Stem Seal Double O-Ring Type
Wedge Sealing surface permanently bonded and fully
encapsulated with resilient material
Thrust Bearings Low-friction torque-reduction type located both above and below stem collar.

Valves Connecting to
Mains
Provide flange on main side unless otherwise shown.

Markings Manufacturer's name or symbol, size of valve, year of manufacture, and working pressure shall be cast in valve bonnet or body.

Body shall have arrow cast in metal to show direction of opening,
Dimensions Laying Length Conform to ASME/ANSI B16.10 Table 1 (Class 125 or 150) ASME/ANSI B16.10 Table 2(Class 250 or 300)
Rated Working Pressure Suction Piping 150 psi
Discharge Piping 150 / 200 psi
Valve Actuators – Above
Ground
Operator Handwheel / 2” AWWA nut
Stem Non-rising stem / Rising stem with Outside Screw and Yoke (OS&Y) on fire valves
Position Indicator Required / Not required
Operation Valve shall open with counterclockwise operator rotation Valve Actuators - Buried Operator Enclosed gear or screwed rod type with 2” AWWA nut Stem Non-rising stem / Rising stem
Position Indicator Required / Not required
Operation Valve shall open with counterclockwise operator rotation Valve Stem Input Torque AWWA C509 Table
1 ≤200 ft-lb for valves 3”-4”
≤300 ft-lb for valves 6”-16”
Stem Nut Extension Where Required Required on valves buried 4’ or deeper.

Construction Center extension in valve well using guide.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install gate valves before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Section 02 05 00 for basic execution and installation requirements.

B. Furnished and install gate valves at location shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. AWWA C509 Appendix A §A.5 Installation, Operation, and Maintenance of ResilientWedge Gate Valves

3. Manufacturer’s installation and warranty requirements Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -7
D. Install gate valves to tolerances recommended by Manufacturer. Unless otherwise shown, install valves true, plumb, and level using precision gauges and levels.

E. Refer variances between Manufacturer’s installation instructions and Contract Documents to Owner’s Representative.

F. Buried gate valves shall be installed as follows:

1. Install and connect gate valve according to Manufacturer’s installation and warranty requirements.

2. Wrap 2 layers of 8-mil AWWA C105 polyethylene encasement around valve and flanges and secure with plastic adhesive tape wrapped around valve stem below operating nut to prevent entrance of soil. Fold overlaps twice and tape. Backfill with care to protect polyethylene.

3. Place and compact backfill to height of valve stem.

4. Place block pads under extension pipe to maintain valve box in vertical position during backfilling and repaving and to prevent extension pipe from contacting valve bonnet.

5. Mount upper slip pipe of extension in mid-position and secure with backfill around extension pipe.

6. Pour concrete ring allowing a depression so valve box cap will be flush with finished surface.

G. Refer to Section 31 05 50 for additional requirements associated with tapping existing water lines.

3.3 Field Quality Control
A. Valves shall be tested at same time connecting pipelines are pressure tested and in accordance with Contract Document sections covering testing.

B. During pressure testing, protect or isolate valves, operators, or control and instrumentation elements whose pressure rating is less than test pressure.

C. Field testing shall include:

ITEM TEST FOR

TEST STANDARD (ASTM OR

OTHER TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Gate
Valve
Installation &
Leakage
Visual inspection for drip tight finished
installation under pressure.
1 inspection Owner Owner
Pressure Test Refer to Section 33 08 11. 1 test Contractor Contractor Actuator Fully lubricate actuators before test.

Operate valve through 10 full opening and
closing cycles without sticking, or binding.

Required pull on handwheel or chainwheel
shall not exceed 80 lbf
Required operating torque shall not
exceed 150 ft-lbs at any point
1 test Contractor Contractor
Actuator
Torque
No valve or actuator component shall
evidence deformity after applying the
following torques in presence of Owner’s
Representative.
4” – 240 ft-lbf
6” – 330 ft-lbf
8” – 400 ft-lbf
10” – 460 ft-lbf
12” – 550 ft-lbf
1 test Contractor Contractor
Field
Performance
Demonstrate compliance to Contract
Documents and Manufacturer’s printed
literature
1 test Contractor Contractor
Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -8

ITEM TEST FOR

TEST STANDARD (ASTM OR

OTHER TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
11-month
Warranty
Inspection
Demonstrate compliance to Contract
Documents and Manufacturer’s printed
literature
1 test Owner Contractor

END OF SECTION

Project Owner RESILIENT WEDGE GATE VAVES
New River Improvement Project – Calexico 33 12 12 -9

THIS PAGE INTENTIONALLY LEFT BLANK
Project Owner PLUG VALVES
New River Improvement Project – Calexico 33 12 16 - 1
SECTION 33 12 16

PLUG VALVES
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of plug valves.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 02 05 00: Basic Civil Engineering Requirements F. Section 09 90 00: Painting and Coating
G. Section 33 08 11: Pressure Testing and Flushing of Water Utilities

1.3 System Description
A. Furnish and install complete operating valves including appurtenant mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable standards.

B. Valves shall provide positive shutoff when valve or port is in closed position and shall permit unobstructed flow when valve or port is in open position.

C. Valves shall seat drip tight against seating pressure equal to rated design pressure of valve.

B. Factory testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY

FIRST TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
ResilientSeated Cast
Iron
Eccentric
Plug Valve
Shell Test AWWA C517 §5.2.1.1 1 each valve Contractor Contractor Seat Test AWWA C517 §5.2.1.2 1 each valve Contractor Contractor Proof of
Design
AWWA C517 §5.2.2 1 each
prototype
Contractor Contractor
Interior
Lining
Holidays and
Lining
Thickness
Refer to Section 09 96
56 1 each valve Contractor Contractor

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. API/ANSI 598 Valve Inspection and Testing

2. API/ANSI 599 Metal Plug Valves – Flanged, Threaded and Welding Ends Project Owner PLUG VALVES
New River Improvement Project – Calexico 33 12 16 - 2

3. ASME/ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings – Class 25, 125, 150 and 800

4. ASME/ANSI B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24

5. ASME/ANSI B16.10 Face-to-Face and End-to-End Dimensions of Valves

6. ASME/ANSI B16.42 Ductile Iron Flanged Fittings – Classes 150 and 300

7. ASTM A48 Gray Iron Castings

8. ASTM A126 Gray Iron Castings for Valves, Flanges and Pipe Fittings

9. ASTM A193 Alloy Steel and Stainless Steel Bolting Materials for High-Temperature Service

10. ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service

11. ASTM A536 Ductile Iron Castings

12. ASTM A743 Castings, Iron-Chromium, Iron Chromium Nickel, Corrosion Resistant for General Application

13. ASTM D1418 Rubber and Rubber Latices-Nomenclature

14. AWWA C213 Fusion-Bonded Epoxy Coating for Interior and Exterior of Steel Water Pipelines

15. AWWA C517 Resilient-Seated Cast-Iron Eccentric Plug Valves

16. AWWA C540 Power-Actuating Devices for Valves and Sluice Gates

17. AWWA C550 Protective Epoxy Interior Coatings for Valves and Hydrants

18. AWWA C606 Grooved and Shouldered Joints

19. MSS SP78 Cast Iron Plug Valves

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit per valve Shop Drawing requirements.

Product Data Submit per Product Data requirements.

Show lining and coating data and thicknesses.

Installation Instructions Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements.

Certificate of Compliance Submit certified test results for proof of design, hydrostatic and leakage tests.

Submit certified report of testing of factory-applied linings Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 01 33 00 / 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, and Certificates of Compliance.

Project Owner PLUG VALVES
New River Improvement Project – Calexico 33 12 16 - 3

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of plug valves.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for plug valves.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Eccentric Plug Valves
Eccentric Plug
Valves – Full
Rectangular Port
DeZurik / APCO / Hilton PEF 3”-18” Sartell, MN (320) 259-2000 Accepted equal
B. Valve manufacturer shall have at least 5 years’ recent continuous product history in the USA water/wastewater industry.

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Materials for eccentric plug valves shall be:

ITEM MATERIAL SPECIFICATION
Body Ductile Iron Conform to ASTM A536 Grade 65-45-12
Body Seat Nickel ⅛" welded overlay seat of >90% nickel.

Dimensions Laying Length Conform to ASME/ANSI B16.10 Table 1 (Class 125 or 150)
Short-Body
Plug Ductile Iron Conform to ASTM A536 Grade 65-45-12
Plug
Elastomer
EPDM Synthetic Rubber
(Ethylene-Propylene
Diene Monomer)
Conform to ASTM D1418
Conform to ASTM D429
Peroxide cured
Trim Stainless Steel SAE Type 316
Project Owner PLUG VALVES
New River Improvement Project – Calexico 33 12 16 - 4

ITEM MATERIAL SPECIFICATION
Bearings Stainless Steel
Sleeve Type
Conform to ASTM A743 Grade CF-8M SAE
Type 316 or
SAE Type 317L
Sintered, oil impregnated permanently
lubricated
Cover Bolts Stainless Steel Conform to ASTM A193 Grade B8M SAE Type 316
Cover Nuts Stainless Steel Conform to ASTM A194 Grade 8M SAE Type 316
Centered
Oil
Bearings
Stainless Steel Conform to ASTM A743 Grade CFBM SAE
Type 316
Stem
Packing
Seals
NBR Synthetic Rubber
(Nitrile Butadiene
Rubber) (Buna N)
Conform to ASTM D1418
Grit Seals
(Top and
Bottom)
PTFE Fluoropolymer
(Polytetrafluoroethylene)
(Teflon)
Conform to ASTM D1418
Flanges
Sizes 3”-72”
Working
Pressures
0-150 psi
Ductile Iron Conform to ASME/ANSI B16.42 Class 150
Raised or plain faced (Shall Match Adjoining
Equipment)
Flange
Alignment
Valves Boltholes shall straddle horizontal and vertical centerlines of valve.

Flange
Bolts, Nuts,
and
Washers
Various Steels Stainless Type 316
Epoxy
Lining (Iron
Surfaces of
Valves ≥ 4”)
Liquid Epoxy Refer to Section 09 96 56.

Conform to AWWA C213 and AWWA C550
16-mil minimum DFT
Do not coat sealing areas and bronze or
stainless steel parts.

Exterior
Finish Coat
Epoxy Refer to Section 09 90 00.

Project Owner PLUG VALVES
New River Improvement Project – Calexico 33 12 16 - 5
C. The following product design criteria, options and accessories are required on nonlubricated eccentric plug valves:

ITEM DESCRIPTION
Port Size Valves ≤ 36” 100% full-port (3”-36”)
Service Open/Close
Seat Seat Area Raised, with raised surface completely covered with weld to ensure plug face contacts only nickel
Seating Bidirectional
Design Do not use screwed-in seats
Eccentric
Plug
Facing Resilient faced with neoprene or hycar, suitable for use with sewage.

Seating Surface Cylindrical seating surface eccentrically offset from plug shaft center.

Shaft Seals Design Multiple V-ring type, externally adjustable and repackable without removing bonnet or actuator from
valve under pressure.

Do not use O-ring seals or non-adjustable packing.

Actuators On valves 6”-18” provide handwheel, gear actuators, and tee wrenches, extension stems, floorstands, etc.,
as shown on Plans
Gear Actuators
(Required on
valves ≥ 6”)
Enclose gearing in semi-steel housing Gearing shall
be suitable for running in lubricant. Provide seals on
shafts to prevent entry of dirt and water into actuator.

Actuator shaft and quadrant shall be supported on
permanently lubricated bronze bearings.

Position Indicator Required
Adjustable Stop Shall allow manual set of closing torque and provide seat adjustment to compensate for change in
pressure differential or flow direction change.

PART 3 - EXECUTION

3.1 Installation
A. Refer to Section 02 05 00 for basic execution and installation requirements.

B. Furnish and install plug valves at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable fire, plumbing and mechanical code requirements

3. Manufacturer’s installation and warranty requirements Project Owner PLUG VALVES
New River Improvement Project – Calexico 33 12 16 - 6
D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Install plug valves to tolerances recommended by manufacturer. Unless otherwise shown, install plug valves true, plumb, and level using precision gauges and levels.

F. Install valve so seat is opposite high-pressure side.

G. For suspended solids applications, install plug horizontal and rotating to top of valve when open.

3.2 Field Quality Control
A. Test valves at same time connecting pipelines are pressure tested. Valves, operators, or control and instrumentation elements whose pressure rating is less than test pressure shall be protected or isolated during pressure testing.

B. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Plug
Valve
Installation &
Leakage
Visual inspection for drip tight
finished installation under
pressure.
1 inspection Owner Owner
Pressure Test Refer to Section 33 08 11. 1 test Contractor Contractor Actuator Fully lubricate actuators
before test.

Operate valve through 10 full
opening and closing cycles
without sticking, or binding.

Required pull on handwheel
shall not exceed 80 lbf
Required operating torque
shall not exceed 150 ft-lbs at
any point
1 test Contractor Contractor
Field
Performance
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Owner Contractor

END OF SECTION
Project Owner CHECK VALVES
New River Improvement Project – Calexico 33 12 18 - 1
SECTION 33 12 18

CHECK VALVES
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of check valves.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 02 05 00: Basic Civil Engineering Requirements F. Section 09 90 00: Painting and Coating
G. Section 09 96 56: Epoxy Linings and Coatings
H. Section 33 08 11: Pressure Testing and Flushing of Water Utilities

1.3 System Description
A. Furnish and install complete operating check valve including appurtenant mountings or connections required for compliance with Manufacturer’s installation requirements and applicable standards.

B. Check valves shall prevent backflow of fluid when downstream pressure exceeds upstream pressure. Valves shall seat drip tight against downstream seating pressure equal to rated design pressure of valve.

B. Factory testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Swing
Check
Valve
Hydrostatic
Shell Test
AWWA C508
§5.2.1
1 each valve Contractor Contractor
Hydrostatic
Seat Leakage
Test
AWWA C508
§5.2.2
1 each valve Contractor Contractor
Interior
Lining
Holidays and
Lining
Thickness
Refer to Section
09 96 56
1 each valve Contractor Contractor

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

Project Owner CHECK VALVES
New River Improvement Project – Calexico 33 12 18 - 2

1. ASME/ANSI B1.20.1 (ANSI B2.1) Pipe Threads – NPT National Pipe Thread Taper

2. ASME/ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings – Class 25, 125, 150 and 800

3. ASME/ANSI B16.10 Face-to-Face and End-to-End Dimensions of Valves

4. ASME/ANSI B16.42 Ductile Iron Flanged Fittings – Classes 150 and 300

5. API/ANSI 594 Check Valves: Flanged, Lug, Wafer and Butt-welding

6. ASTM A48 Gray Iron Castings

7. ASTM A126 Gray Iron Castings for Valves, Flanges and Pipe Fittings

8. ASTM A193 Alloy Steel and Stainless Steel Bolting Materials for High-Temperature Service

9. ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service

10. ASTM A269 Seamless and Welded Austenitic Stainless Steel Tubing for General Service

11. ASTM A276 Stainless and Heat Resisting Steel Bars and Shapes

12. ASTM A313 Stainless Steel Spring Wire

13. ASTM A351 Castings, Austenitic, for Pressure-Containing Parts

14. ASTM A536 Ductile Iron Castings

15. ASTM A582 Free-Machining Stainless and Heat Resisting Steel Bars

16. ASTM B584 Copper Alloy Sand Castings for General Applications

17. ASTM B16 Free-Cutting Brass Rod, Bar and Shapes for Use in Screw Machines

18. ASTM B148 Aluminum-Bronze Sand Castings

19. ASTM B271 Copper-Base Alloy Centrifugal Castings

20. ASTM D2000 Rubber Products in Automotive Applications

21. AWWA C213 Fusion-Bonded Epoxy Coating for Interior and Exterior of Steel Water Pipelines

22. AWWA C508 Swing Check Valves for Waterworks Service 2”-24”

23. AWWA C550 Protective Epoxy Interior Coatings for Valves and Hydrants

24. MSS SP136 Ductile Iron Swing Check Valves

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit per valve Shop Drawing requirements. Include detail of any penetration of valve body by hinge pin showing packing gland, hinge pin gland, cap and other pieces used.

Product Data Submit per Product Data requirements.

Include lining and coating data and thicknesses.

Installation
Instructions
Submit per Installation Instruction requirements.

Project Owner CHECK VALVES
New River Improvement Project – Calexico 33 12 18 - 3

SUBMITTAL DESCRIPTION
O & M
Instructions
Submit per Operation and Maintenance Instruction requirements.

Certificate of
Compliance
Submit certified report of testing of factory-applied linings Submit affidavit of compliance with AWWA C508 for swing check valves
Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions and Certificates of Compliance.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of check valves.

C. Refer to AWWA C508 Appendix A for additional requirements for delivery, storage, and handling of swing check valves.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for check valves.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Rubber Flapper
Swing Check
Valves 2”-72”
Crispin Valve RF Series Berwick, PA (800) 247-8258
DeZurik / APCO / Hilton Series
CRF 100 2”-48”
Sartell, MN (320) 259-2000
GA Industries, Inc. Cranberry Twp, PA (724) 776-1020
Henry Pratt Company / Milliken
RD Series
Aurora, IL (630) 844-4000
Tustin, CA (714) 832-1090
Mueller Company Flexible Disc Chattanooga, TN (423) 209-4800 Val-Matic Valve and
Manufacturing Corp. Series 500
Elmhurst, IL (630) 941-7600
Accepted equal
B. Valve manufacturer shall have at least 5 years’ recent continuous product history in the USA water/wastewater industry.

Project Owner CHECK VALVES
New River Improvement Project – Calexico 33 12 18 - 4

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Materials for rubber flapper swing check valves 2”-72” shall be:

ITEM MATERIAL SPECIFICATION
Body and Cover Ductile Iron Conform to ASTM A536 Grade 65-45-12 Flapper Insert Carbon Steel Steel Disc insert and steel bar hinge EPDM Synthetic
Rubber (EthylenePropylene Diene
Monomer)
Conform to ASTM D1418, ASTM D2000
Conform to ASTM D429
Peroxide cured
Temperature Standard Class III to 300°F
Valve Lining Natural Rubber Vulcanized Hard
Cover Bolts Stainless Steel SAE Type 316 with antiseize lubricant Flanges
Sizes 6-72”
Working
Pressures 0-150
psi
Ductile Iron Conform to ASME/ANSI B16.42 Class 150
Raised or plain faced (Matching Adjacent
Equipment)
Flange Alignment Valves Boltholes shall straddle horizontal and vertical centerlines of valve.

Flange Bolts,
Nuts, and
Washers
Various Steels Stainless Type 316
Exterior Finish
Coat
Epoxy Refer to Section 09 90 00.

C. The following product design criteria, options and accessories are required:

ITEM DESCRIPTION
Rated Working
Pressure
200 psi on discharge side piping
Rubber
Flapper Swing
Check Valves
Design Valve shall consist of body, flapper and bolted
cover.

Laying Length Conform to ASME/ANSI B16.10 Table 7(Class 125 or 150)
Valve Seat Set at 45° angle to pipe centerline.

Manual Backflow
Actuator
Not required
Position Indicator Not required
Project Owner CHECK VALVES
New River Improvement Project – Calexico 33 12 18 - 5
PART 3 - EXECUTION

3.1 Installation
A. Refer to Section 02 05 00 for basic execution and installation requirements.

B. Furnish and install check valves at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable fire, plumbing, mechanical and electrical code requirements

3. Manufacturer’s installation instructions and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

3.2 Field Quality Control
A. Test valves at same time connecting pipelines are pressure tested and in accordance with sections of Contract Documents covering testing.

B. During pressure testing, protect or isolate valves, operators, or control and instrumentation elements whose pressure rating is less than test pressure.

C. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Check
Valve
Installation
& Leakage
Visual inspection for
drip tight finished
installation under
pressure.
1 inspection Owner Owner
Pressure
Test
Refer to Section 33 08

11. 1 test Contractor Contractor
Field
Performanc
e
Demonstrate
compliance to Contract
Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate
compliance to Contract
Documents and
Manufacturer’s printed
literature
1 test Owner Contractor

END OF SECTION

Project Owner CHECK VALVES
New River Improvement Project – Calexico 33 12 18 - 6

THIS PAGE INTENTIONALLY BLANK
Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 1
SECTION 33 12 25

AIR AND VACUUM VALVES FOR WASTEWATER SERVICE
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of air and vacuum valves for wastewater service, including air/vacuum valves, and combination air and vacuum valves.

1.3 System Description
A. Furnish and install complete operating air and vacuum valve including appurtenant structural and/or mechanical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building codes and standards.

B. Air and vacuum valves shall automatically exhaust large air quantities on pump start or pipeline filling and shall automatically prevent vacuum collapse of pipe.

C. Combination air and vacuum valves shall automatically release small pockets of air that accumulate at high points in system and shall allow air to enter or exit pipe to alleviate excess air or vacuum conditions in pipe.

D. Air-vacuum valves, 1”-6” shall incorporate body with flanged top cover.

B. Factory testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Air and
Vacuum
Valves
Hydrostatic
Test
AWWA C512
Section 5
“Verification”
1 each valve Contractor Contractor
Seat
Leakage
Test
AWWA C512
Section 5
“Verification”
1 each valve Contractor Contractor
Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 2

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Holidays and
Lining
Thickness
Refer to Section 09
96 56.
1 each valve Contractor Contractor

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. ASME/ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings – Class 25, 125, 150 and 800

2. ASME/ANSI B16.4 Cast Iron Threaded Fittings

3. ASME/ANSI B16.5 Pipe Flanges and Flanged Fittings: ½”-24”

4. ASME/ANSI B16.42 Ductile Iron Flanged Fittings – Classes 150 and 300

5. ASTM A240 Heat Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels

6. ASTM D6778 Classification System and Basis for Specification for Polyoxymethylene Molding and Extrusion Materials (POM)

7. AWWA C512 Air Release, Air/Vacuum and Combination Air Valves for Water Service

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit on valves ≥ 6” per valve Shop Drawing requirements.

Submit for lateral supports for valves weighing more than 30 lbs.

Product Data Submit per Product Data requirements.

Show lining and coating data and thicknesses.

Installation
Instructions
Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements Certificate of
Compliance
Submit certified test results for leakage and hydrostatic tests Submit certified report of testing of factory-applied linings Submit affidavit of compliance with AWWA C512
Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 3

SUBMITTAL DESCRIPTION
Engineering
Calculations
For valves weighing more than 30 lbs, submit Engineering Calculations supporting lateral support design showing valve support can resist moment from minimum of either:

Lateral force of 1.0 times weight of valve applied at valve center of mass.
or
Site-specific lateral forces computed per Section 01 73 24 & ASCE 7.

Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 01 33 00 / 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, Engineering Calculations and Certificates of Compliance.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instruction and warranty requirements for delivery, storage, and handling of air and vacuum valves.

1.8 Unit Prices
A. Refer to Section 01 22 00 for measurement and payment clauses for air and vacuum valves for wastewater service.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers for air and vacuum valves for wastewater applications include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Air and Vacuum
Valves for
Wastewater
Cla-Val Company Series 35WW Costa Mesa, CA (800) 942-6326 DeZurik / APCO / Hilton Series 401 Sartell, MN (320) 259-2000 Val-Matic Valve and Manufacturing
Corp.

Elmhurst, IL (630) 941-7600
Vent-O-Mat® / RF Valves Hanover, MD (410) 850-4464
Accepted Equal
Combination Air
and Vacuum
Valves for
Wastewater
Cla-Val Company Series 36WW Costa Mesa, CA (800) 942-6326 Crispin Valve Berwick, PA (800) 247-8258
DeZurik / APCO / Hilton Series 440
or 440C
Sartell, MN (320) 259-2000
Val-Matic Valve and Manufacturing
Corp. Series 800
Elmhurst, IL (630) 941-7600
Vent-O-Mat® / RF Valves Hanover, MD (410) 850-4464
Accepted Equal
Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 4
B. Valve manufacturer shall have at least 5 years’ recent continuous product history in the USA water/wastewater industry.

C. Air and vacuum valves shall be same model as combination air and vacuum valves of same size to allow valves to be interchangeable in field.

D. Acceptable Manufacturers for enclosures include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Polyethylene Air
Valve Enclosures
Armorcast Products Company Ontario, CA (909) 390-1365
Pipeline Products VCAS San Marcos, CA (760) 744-8907
Accepted Equal

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Air and vacuum valves and combination air and vacuum valves for wastewater service shall comply in function with AWWA C512
C. Materials for air and vacuum valves shall be:
item MATERIAL SPECIFICATION
Body and Cover Ductile Iron (for
pressures 0-300 psi)
Conform to ASTM A536 Grade 65-45-12
Float Stainless Steel Conform to ASTM A240 or A276 SAE
Type 316
Needles & Seats Buna N
Leverage Frame and
Linkage
Stainless Steel Conform to ASTM A240 or A276 SAE
Type 316
Body Bolts Stainless Steel SAE Type 316
Threaded Ends
Sizes ⅜”-4”
Working Pressures
0-400 psi
Ductile Iron Female-threaded
Conform to ASME/ANSI B1.20.1 (ANSI
B2.1)
Epoxy Lining (Iron
Surfaces of Valves <
4”)
Epoxy Refer to Section 09 96 56.

Conform to AWWA C213 and AWWA
C550
12-mil minimum DFT
Do not coat sealing areas and bronze or
stainless steel parts.

Exterior Finish Coat Epoxy Urethane Refer to Section 09 90 00.

Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 5
D. Materials for combination air and vacuum valves shall be:

ITEM MATERIAL SPECIFICATION
Body and Cover Ductile Iron (for
pressures 0-300 psi)
Conform to ASTM A536 Grade 65-45-12
Float Stainless Steel Conform to ASTM A240 or A276 SAE Type 316
Needles & Seats Buna N
Plug Stainless Steel Conform to ASTM A240 SAE Type 316
Leverage Frame
and Linkage
Stainless Steel Conform to ASTM A240 or A276 SAE Type
316
Body Bolts Stainless Steel SAE Type 316
Threaded Ends
Sizes ⅜”-4”
Working
Pressures 0-400
psi
Ductile Iron Female-threaded
Conform to ASME/ANSI B1.20.1 (ANSI B2.1)
Epoxy Lining
(Iron Surfaces of
Valves < 4”)
Epoxy Refer to Section 09 96 56.

Conform to AWWA C213 and AWWA C550
12 -mil minimum DFT
Do not coat sealing areas and bronze or
stainless steel parts.

Exterior Finish
Coat
Epoxy Urethane Refer to Section 09 90 00.

E. Materials for air valve enclosures shall be:

ITEM MATERIAL SPECIFICATION
Air Valve Enclosure Low-Density
Polyethylene
Bolt Down Plates Stainless Steel SAE Type 304 or SAE Type 316 F. The following product design criteria, options and accessories are required for air and vacuum valves:

ITEM DESCRIPTION
Design Use manufacturer’s standard design for wastewater applications
Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 6
G. The following product design criteria, options and accessories are required for combination air and vacuum valves:

ITEM DESCRIPTION
Design Use manufacturer’s standard design for wastewater applications Location Field tap for valve in level pipe section no closer than 18” to bell, coupling, joint, or fitting. Only factory outlets will be permitted within 18” of joint or flange.

H. The following product design criteria, options and accessories are required for air valve enclosures:

ITEM DESCRIPTION
Air Valve Enclosure Height 36” minimum
Diameter 24” minimum
Bolt Down Plates Quantity 3 minimum
PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install air and vacuum valves before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

B. Field tap for valve shall be made in level pipe section no closer than 18” to bell, coupling, joint, or fitting. Only factory outlets will be permitted within 18” of joint or flange.

3.2 Installation
A. Refer to Sections 01 73 24, and 01 73 33 / 02 05 00 for basic execution and installation requirements.

B. Furnish and install air and vacuum valves at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable fire, plumbing, and mechanical code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Install air and vacuum valves to tolerances recommended by Manufacturer. Unless otherwise shown, install air and vacuum valves true, plumb, and level using precision gauges and levels.

F. Install threaded air-vacuum wastewater valves as follows:

1. Clean threaded joints by wire brushing or swabbing.

2. Apply Teflon joint compound or Teflon tape to pipe threads before installing threaded valves.

3. If joints leak under pressure testing, remove valve, reapply compound or tape, reinstall, and retest joints. Joints shall be watertight
Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 7

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Air and
Vacuum
Valves
Installation
& Leakage
Visual inspection of finished
installation
1 inspection Owner Owner
Field
Performanc
e
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
Pressure
Test
Refer to Section 33 08 11.

Do not test valves at
pressures higher than
pressure rating of valve. If
necessary, test and observe
valves at 5 psi below rated
pressure. Then close isolation
valve beneath air and vacuum
valves during hydrostatic
testing
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Owner Contractor

END OF SECTION

Project Owner AIR-VACUUM WASTEWATER VALVES
New River Improvement Project – Calexico 33 12 25 - 8

THIS PAGE INTENTIONALLY BLANK
Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 1
SECTION 33 12 48

SEISMIC VALVE CONTROLLER AND MOTORIZED ACTUATOR
PART 1 - GENERAL

1.1 Scope of Work
A. This section involves the furnishing, installation, and testing of an electric motor, multi-turn, actuator for use with a rising stem fabricated slide gate. This section further includes the furnishing, installation and testing of a seismic valve controller.

1.3 System Description
A. Furnish and install complete operating seismic sensing device and valve control system including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building and electrical codes and standards.

B. Seismic sensing device shall measure resultant force vector of X, Y, and Z axis.

C. Seismic Valve Controller control system input control variables shall include:

ITEM VARIABLE DESCRIPTION
Input
Signals
(Digital)
Earthquake Seismic sensing device shall be factory calibrated to trigger between 0.2G to 0.6G force in time span of

1.0 second. Default setting shall be 0.3 G.

Input
(Manual)
Operation mode
(Selectors)
Manual reset
Remote reset capability (available but disabled)
Testing Device shall allow for activating test cycle either manually or remotely
Settings Trigger force – Set to 0.3G Time delay 1 second D. Seismic Valve Controller normal valve shut-down sequence shall operate as follows:

1. When seismic event triggers seismic sensing device, sensing device shall activate solenoid circuit.

2. Solenoid circuit shall activate the electric motor actuator which will then close the fabricated slide gate to isolate and protect the downstream bypass encasement piping from leakage due to potential damage of the piping. The Seismic Valve Controller will maintain the motorized actuator and slide gate in the closed position until manually reset at the local controller panel.

Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 2
E. Seismic Valve Controller control system shall be capable of outputting the following signals to SCADA:

ITEM VARIABLE DESCRIPTION
Output
Signals
(Discrete)
Power available Discrete signal
Battery OK Discrete signal
Battery Low Discrete alarm
Valve “Remote/Local” Discrete signal
Valve Open Discrete signal
Valve in Transition/Stop Discrete signal
Valve Closed Discrete signal
Valve triggered Discrete alarm
F. Furnish and install complete operating motorized actuator including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building, and electrical codes and standards.

G. Furnish and install intermediate operators of spur, helical, or bevel gears, between new electric motor actuator and new or existing geared valve operators, if needed to provide specified open/close time, and to provide proper operation of valve.

1.4 Quality Assurance
A. Provide a factory testing report which shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Valve
Actuator
Proof of Design
Test with Valve
Attached
AWWA C542 1 test on one
motor actuator
Contractor Contractor
Performance Test
with Valve
Attached
1 test on each
motor actuator
Contractor Contractor
B. Powered actuators shall be tested and adjusted on valve for which it is supplied by Valve Manufacturer, Actuator Manufacturer, or authorized distributor and service facility for actuator.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. AWWA C542 Electric Motor Actuators for Valves and Slide Gates

2. IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)

3. NEMA/ANSI 250 Enclosures for Electrical Equipment

4. NFPA 70 National Electric Code

5. Seismic Protection for Water Systems Ad-Hoc Committee - Specification for Seismic Sensing Devices Commonly Used for Water Reservoir Control Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 3

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop
Drawings
Submit for seismic valve controller under electrically controlled equipment Shop Drawing requirements.

Submit for actuator under electrically controlled equipment Shop Drawing requirements and requirements of AWWA C542.

Submit dimensional drawings for all views
Submit electrical schematic diagrams and wiring diagrams showing interconnects for power, control, monitoring, and protective circuits.

Submit for solenoid circuits under electrically controlled equipment Shop Drawing requirements.

Product Data Submit per Product Data requirements.

Show motor actuator parts and construction materials referenced by ANSI, NEMA, ASTM, SAE or CDA specification and grade.

Show motor actuator dimensions and weights
Show coatings
Installation
Instructions
Submit per Installation Instruction requirements.

O & M
Instructions
Submit per Operation and Maintenance Instruction requirements.

Include typical blank log sheets for Owner 6-month scheduled testing.

Include theory of operation of actuator and intermediate gearing.

Include complete parts list and part changeout instructions.

Include recommended list of spare parts
Include list of special tools for installation, maintenance and adjustments.

Include lubrication guide with list of recommended lubricants and lubrication frequency.

Include specifications and ordering information for replacement motors.

Submit expanded parts drawings of mechanical and electrical parts.

Certificate of
Compliance
Submit certificate of compliance with ANSI Z21 per Certificate of Compliance requirements.

Engineering
Calculations
Submit for actuator torque calculations throughout flow range per Engineering Calculations requirements.

Submit information showing relationship between operator output torque and torque limit switch settings.

Manufacturer’s
Statement of
Responsibility
Submit per Manufacturer’s Statement of Responsibility requirements.

Motor Data Show nameplate data, insulation type, output torque, voltage, phases, frequency, current at running torque, locked rotor current, duty rating.

Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 4

SUBMITTAL DESCRIPTION
Show open/close travel time, defined as time required for valve to travel from close-to-open or open-to-close. Cycle is defined as close to open and back to close. Do not use intermittent or pulsed operation to conform to specified travel time.

Test Record
Transcripts
Submit for factory tests per Test Record Transcript requirements.

Factory
Training
Certification
Submit evidence installation technicians have been factory trained on specific models installed prior to technicians performing work on valves and actuators.

Warranty Furnish 3-year parts and labor warranty from date of final acceptance.

Warranty shall include service contract for duration of warranty period.

B. Refer to Section 01 33 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, Certificates of Compliance, and Test Record Transcripts.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of seismic valve controllers.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Actuators –
Multi-turn Worm
Gear and Motor
Flo-Loc Products Model FP3200 Dana Point, CA (949) 429-1089 Engineer Approved equal
Intermediate
Gear Operator
Rotork Gears Americas IS Series
Multi-turn
Houston, TX (713) 983-7381
Engineer Approved equal
Seismic Actuator
Control Panel
Flo-Loc Products Model FL201-
1AB/PP5200-50HD
Dana Point, CA (949) 429-1089
Engineer Approved equal

2.2 Electric Motor Valve Actuator Design Criteria
A. The valve actuator shall be a multi-rotational design, capable of operating a rising stem fabricated slide gate using a wall-mount pedestal (supplied under Section 33 12 71) with intermediate multi-turn gearbox. The valve actuator shall provide 20 output rpm at a minimum output torque of 244 ft/lbs.

B. The slide gate shall be equipped with an intermediate multi-turn gearbox mounted to an operator pedestal furnished by the valve manufacturer. The multi-turn gearbox shall have the input shaft parallel to the rising stem. The multi-turn gearbox output sleeve shall be of the Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 5
removable type facilitate spindle machining to match the slide gate rising stem thread pattern.

The intermediate actuator shall not require removal or replacement in order to attach the motorized valve actuator.

C. The motorized valve actuator shall be mounted onto the slide gate’s intermediate multi-turn gearbox. The input shaft of the gearbox shall be fitted with a 2" AWWA operating nut without modification to the internal mechanism of the valve or to the valve's manual operator.

D. The motorized valve actuator shall have the capability of being readily dismounted from the multi turn gearbox and operating nut to allow manual use of a T-bar in the event of an emergency. A dedicated T-bar shall be mounted on the exterior of the Valve Actuator.

E. The motorized valve actuator shall be capable of local and remote operation of the valve from "Full Open" to "Full Close". The valve actuator shall also be capable of being position set at any range between full open and full close locally and remotely.

F. All valve position indicator status shall be at each of the following locations:

1. Valve Actuator panel (local)

2. Seismic Controller panel (panel)

3. Remote control (SCADA) (subject to I/O availability).

G. The Valve Actuator shall be capable of being from each of the following locations:

1. Valve Actuator panel (local)

2. Seismic Controller panel (panel)

3. Remote control (SCADA) (future capability not initially wired due to existing SCADA I/O limitations).

H. The Valve Actuator shall have a mechanical valve position indicator.

I. The Valve Actuator shall have a heating element to control condensation in extreme cold or humidity conditions.

J. The Valve Actuator shall have security provisions (key switch) to prevent unauthorized operation.

K. The Valve Actuator shall have the following capabilities for SCADA use:

1. Seismic Sensor Operation

2. Full Open Valve Control and Status

3. Full Closed Valve Control and Status

4. Valve in Transition/Stop Control and Status

5. Key Switch Local or Remote Status.

2.3 Valve Actuator Design and Materials
A. The Valve Actuator design must comply with AWWA C542 – Electric motor Actuators for Valves and Slide Gates.

B. The Valve Actuator shall be compact, lightweight (less than 40 Lbs.) and multi-rotational, with the necessary torque to operate the slide gate specified in Section 33 12 71 with the safety factor included.

C. The Valve Actuator shall be powered by a Direct Current Permanent Magnet motor with high starting torque, capable of dynamic braking and with ball bearing shaft and class "H" insulated, high-temperature welded commutators. The motor shall be totally enclosed, able to operate from 24VDC and shall be designed especially for battery powered operation. Motor shall be manufactured by Leeson Motors and readily available to the customer.

Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 6
D. The Valve Actuator gear box shall contain gears, shafts, bearings, and electrical components designed to withstand, without damage, a minimum of 20 times the normal torque needed to operate the valve.

E. The gears of the valve actuator shall be self-locking worm gears to eliminate backpressure movement, with bronze worm gears and hardened steel worms. All worm gears shall be made of bronze with 14½º pressure angle and with 1/2" face. All worms shall be matching and made of hardened and ground steel.

F. The Valve Actuator shall be powered by a 24VDC external battery pack with battery charging system, capable of being charged by AC or Solar.

G. The Valve Actuator shall be designed and manufactured for 100% (24 hour) continuous duty.

H. The Valve actuator shall withstand extreme operating temperatures from -10°F to +150°F and all external finishes shall contain UV protection.

I. The Valve Actuator manufacturer shall provide Start-up, Certification and Training to the purchaser.

J. The Valve Actuator shall be made from materials which are certified and traceable to the American Society of Testing Materials (ASTM).

K. The Valve Actuator shall be field-proven, with a minimum ten-year documented history of operation on various valve types and sizes with a seismic control system.

L. The valve actuator must have torque capabilities that comply with AWWA requirements and shall include a minimum 1.5 safety factor.

2.4 Seismic Controller Design Criteria
A. The Seismic Controller shall have a model SS1001 Seismic Sensor on board which meets or exceeds all Standards, Codes and Specifications set by the California Division of the State Architect (DSA) Part 12, Title 24 CCR and ANSI Z21-21.

B. The Seismic Controller shall be combined with a PP5200 Power Supply which shall consist of two 12VDC, 51Ah gel batteries connected in series to provide 24VDC to a single motorized valve actuator and the seismic controller, a battery charger and a battery charge LCD readout.

Gel batteries shall be sized in relationship to the number of turns of the valve actuator to be powered and the cycles of operation.

C. The Seismic Controller shall have circuit breakers to protect the internal circuitry of the system.

D. The Seismic Controller shall be capable of controlling one valve or system, and sending appropriate alarm signals.

E. The Seismic Controller shall provide two form-C contacts rated 10A, ½HP, 25/250VAC, 0.1A, 125VDC.

F. The Seismic Controller shall employ two high-performance solenoids for remote "Arm/Trip" operation which shall be rated 80W (inrush) and 6W (hold).

G. The Seismic Controller shall employ a pulse relay to electrically activate the "Arm/Trip" solenoids while protecting the solenoids from constant power.

H. The Seismic Controller shall provide for local and remote operation via SCADA of the Seismic Sensor's "Arm (reset)/Open-Trip/Close" functions.

I. The Seismic Controller shall provide for local (LED) status indication in a swing panel and remote status indication via SCADA of the Seismic Sensor's "Arm (reset)-Trip" functions.

J. The Seismic Controller shall provide “Arm/Open-Trip/Close” valve operation for one valve actuator.

Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 7
K. The Seismic Controller shall provide for local (LED) and remote status indication via SCADA of the valve position: “Open – In Transition/Stop – Closed”.

L. The Seismic Controller shall provide for remote status indication via SCADA of the “local” and “remote” positions of the security key switch on the valve actuator.

M. The Seismic Controller shall provide for local and remote status indication of AC Power ON function, confirming that power is available to charge the batteries.

N. The Seismic Controller shall provide for local and remote status indication of battery condition OK and Battery Low.

O. The Seismic Controller shall have a Swing Panel where all the local status indications and controls are available while isolating the internal power and wiring.

P. The Seismic Controller shall have a High Draw circuit breaker to protect the internal circuitry of the system from excessive draw required by the slide gate valve .

Q. The Seismic Controller shall be protected from the environment by a 30-in x 24-in x 10-in Stainless Steel Enclosure that meets NEMA 4X standards.

R. The Seismic Controller shall operate in a temperature range from -10° F to +150°F.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install Seismic Valve Controllers before submitting Shop Drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Section 33 05 33 and manufacturer’s recommendations for basic execution and installation requirements.

B. Furnish and install seismic valve controllers at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire, plumbing, mechanical and electrical code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Install seismic valve controllers to tolerances recommended by Manufacturer. Unless otherwise shown, install seismic valve controllers true, plumb, and level using precision gauges and levels.

F. Install actuators to tolerances recommended by Manufacturer. Unless otherwise shown, install motorized actuators true, plumb and level using precision gauges and levels.

3.3 Field Quality Control
A. Field testing shall include:

Project Owner SEISMIC VALVE CONTROLLERS AND MOTORIZED ACTUATOR New River Improvement Project – Calexico 33 12 48 - 8

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Seismic
Sensing
Device
Response to
Sinusoidal
Motion
Seismic Protection for Water
Systems Ad-Hoc Committee
– Specification §4.2
1 test Contractor Contractor
Field
Performance
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
11 month
Warranty
Inspection
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Owner Contractor
Electric
Motor
Actuators
Installation,
Noise,
Vibration,
Odors and
Heat
Visual inspection of finished
installation
1 inspection Owner Contractor
Running
Amperage
Record amperage draw for
unseating, seating, and
running conditions and
compare to rated motor FLC
1 test Contractor Contractor
Temperature
Rise
Record motor temperature
before actuator is energized
and after actuator is cycled
once. Temperature
difference shall be ≤ 50°C
1 test Contractor Contractor
Limit
Switches
Open and close valves twice
and verify position
transmitters function
properly
1 test Contractor Contractor
Field
Performance
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Owner Contractor
B. Provide services of factory-authorized representative on-site to provide:

1. Installation assistance, inspection and startup of complete Seismic Valve Controller system.

2. Field testing and adjustment.

3. Instruction of Owner’s personnel in operation and maintenance.

END OF SECTION
Project Owner STAINLESS STEEL SLIDE GATES
New River Improvement Project – Calexico 33 12 71- 1
SECTION 33 12 71

STAINLESS STEEL SLIDE GATES
PART 1 - GENERAL

1.1 Scope of Work
A. This section covers stainless steel slide gates with 4 sides sealing for submerged applications and their associated accessories for operation. The contractor shall furnish all labor, materials, equipment and incidentals required to install and field test the gates shown on the Contract Drawings and specified herein.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 02 05 00: Basic Civil Engineering Requirements F. Section 09 90 00: Painting and Coating
G. Section 09 96 56: Epoxy Linings and Coatings
H. Section 33 12 48: Seismic Valve Controller and Electric Motor Actuator

1.3 System Description
A. Furnish and install complete operating hydraulic slide gates where shown on the Drawings including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with manufacturer’s installation requirements and compliance with applicable building codes and standards.

B. Coordinate the procurement, supply, installation, and operation of the electric motor actuator and its seismic controller with Section 33 12 48: Seismic Valve Controller and Electric Motor Actuator.

1.4 Quality Assurance
A. Qualifications: The gates supplied under this section shall be standard products of a manufacturer regularly engaged in the design and manufacturing of water control gates.

B. Standards and certifications: The gates supplied under this section shall conform to all requirements of ANSI/AWWA C561-14. The slide gate manufacturer must maintain an ISO9001 certification and also a company certification for its welding operations from the CWB or AWS.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. ASTM A240 Standard Specification for Chromium and Chromium Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels and for General Applications.

2. ASTM A276 Stainless and Heat-Resisting Steel Bars and Shapes

3. ASTM A582 Standard Specification for Free-Machining Stainless Steel Bars

4. ASTM A790 Standard Specification for Seamless and Welded Ferritic / Austenitic Stainless Steel Pipe

5. ASTM B179 Standard Specification for Aluminum Alloys in Ingot and Molten Forms for Castings from All Casting Processes.

6. ASTM B584 Standard Classification System for Copper Alloy Sand Castings for General Applications

7. ASTM D2000 Standard Classification System for Rubber Products in Automotive Applications

8. ASTM D4020 Standard Specification for Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials.

Project Owner STAINLESS STEEL SLIDE GATES
New River Improvement Project – Calexico 33 12 71- 2

9. ASTM F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

10. AWWA C561 Standard Classification System for Fabricated Stainless Steel Slide Gates

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit general arrangement drawings including all parts, dimensions, details, and stainless plate thicknesses for all components. Included information on fasteners, stem, yoke, actuator pedestal, and verify coordination with electric motor actuator and seismic valve controller provider.

Product Data Submit per Product Data requirements for all items under scope of supply.

Design
Calculations
Submit for acceptance by the purchaser design calculations demonstrating compliance with the design requirements of these specifications and those of AWWA C561-14. In particular, calculations shall be submitted for the following gate components:
• Slide
• Seat contact pressure
• Frame
• Yoke
• Stem, stem connection
• Lifting nut
• Manual actuator operating force
• Electric actuator load
• Anchors
Installation
Instructions
Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements Certificate of
Compliance
Submit affidavit of compliance for fabricated-steel slide gates with AWWA C561.

Test Record
Transcripts
Submit for factory tests per Test Record Transcript requirements.

Warranty Furnish five-year warranty from date of final acceptance B. Refer to Section 01 33 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, Certificates of Compliance, and Test Record Transcripts.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. The manufacturer shall use due and customary care in preparing the gates and accessories for shipment. Self-contained frame gates shall be shipped assembled with stem and manual operator.

C. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of slide gates.

1.8 Unit Prices Bid Item 33 12 71 – Slide Gates
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

Project Owner STAINLESS STEEL SLIDE GATES
New River Improvement Project – Calexico 33 12 71- 3
PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. This specification section is based on the FONTAINE-AQUANOX Series 20 Stainless Steel Slide Gates manufactured by ISE Metal Inc. Other suitable slide gate manufacturers are indicated in paragraph 2.1 B.

B. Acceptable manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
FabricatedStainless-Steel
Slide Gates
(AWWA C561)
Fontaine Aquanox, Division of ISE
Metal, Inc.

Sherbrooke, QC (819) 769-0157
Hydrogate / Henry Pratt Denver, CO (800) 678-8228
Rodney Hunt Orange, MA (978) 633-4362
Waterman Industries, Inc. Exeter, CA (800) 445-8457
Engineer approved equal

2.2 Materials
A. Materials for fabricated-stainless-steel slide gates for normal water and wastewater service shall comply with AWWA 561 and shall be:

ITEM MATERIAL SPECIFICATION
Slide, Frame and Yoke Stainless Steel ASTM A240, grade 316L Side Seal/Guides and
Top Seal
Ultra High Molecular Weight
Polyethylene (UHMWPE)
ASTM D4020
Flush Invert Bottom
Seal
Ethylene Propylene (EPDM) ASTM D2000
Compression Cord Ethylene Propylene (EPDM) ASTM D2000
Wall Gasket Ethylene Propylene (EPDM) ASTM D2000
Bolts and Hardware Stainless Steel ASTM F593, grade 316 Stem Stainless Steel ASTM A582, grade 316
Thrust Nut and Lift Nut Aluminum Bronze or
Manganese Bronze
ASTM B505, C95800
ASTM B584, C86300
Stem Couplings Stainless Steel ASTM A582, grade 316
Stem Guide Bracket Stainless Steel ASTM A582, grade 316 Stem Guide Bushing Ultra High Molecular Weight
Polyethylene (UHMWPE)
ASTM D4020
Handwheel Cast Aluminum ASTM B179
Crank Aluminum ASTM B209, 6061-T6
Pedestal Stainless Steel ASTM F593, grade 316
Gearbox Housing Cast Iron ASTM A48 35B/40B
Square Nut Cast Aluminum ASTM B179
Stem Cover Clear PVC
Stem Cover Cap PVC
B. The following product design criteria, options and accessories are required for slide gates:

ITEM DESCRIPTION
Slide
Gates
Fluid Handled Raw Water with Polluted Runoff
Size 72-in w x 60-in h
Design Seating Head 13.0-ft min
Design Unseating Head 13.0-ft min
Operating Seating Head Normal 1.0’ to 8.0’
Actuator Mounting Pedestal Mount with Wall Bracket
Actuator Type Electric Motor with Gearbox and Seismic Controller (See Section 33 12 48 for requirements).

Stem Rising
Stem Diameter 2.14-in, 4 threads/in, 0.50 lead/turn, left hand Project Owner STAINLESS STEEL SLIDE GATES
New River Improvement Project – Calexico 33 12 71- 4

ITEM DESCRIPTION
threads
Gate Position Indicator Not Required
Guide Frame Style Anchor Bolt Wall-Mount, Open Frame
Seals Side, Invert and Top
Allowable Leakage at
Seating Pressure

0.1 gpm/ft of perimeter

2.3 Factory Tests
A. The gates shall be tested in the factory for leakage and for operating force. Leakage shall be measured at the unseating design pressure. Operating force shall be measured with the gate in vertical position, with and without the design pressure. Factory test reports shall be submitted prior to scheduled shipping of the slide gates.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install hydraulic gates and valves before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Section 33 05 33 and Manufacturer’s recommendations for basic execution and installation requirements.

B. Furnish and install gates at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building and plumbing code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Install sluice gates to tolerances recommended by manufacturer. Unless otherwise shown, install hydraulic gates and valves true, plumb and level using precision gauges and levels.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS
PAID
FOR BY
Hydraulic
Gates
Leakage Measure flow rate at
unseating pressure
1 each gate Contractor Contractor
Installation &
Leakage
Visual inspection of finished
installation
1 inspection Owner Owner
Field
Performance
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate compliance to
Contract Documents and
Manufacturer’s printed
literature
1 test Owner Contractor
B. The Contractor shall supply a detailed report of the field tests to the Engineer for review.

Project Owner STAINLESS STEEL SLIDE GATES
New River Improvement Project – Calexico 33 12 71- 5

END OF SECTION
Project Owner RUBBER DUCKBILL CHECK VALVES
New River Improvement Project – Calexico 33 12 74- 1
SECTION 33 12 74

DUCKBILL CHECK VALVES
PART 1 - GENERAL

1.1 Scope of Work
A. This section covers rubber duckbill check valves and their associated accessories for operation. The contractor shall furnish all labor, materials, equipment and incidentals required to install and field test the gates shown on the Contract Drawings and specified herein.

1.3 System Description
A. Furnish and install complete operating duckbill check valves where shown on the Drawings including appurtenant structural, mechanical or connections required for compliance with manufacturer’s installation requirements and compliance with applicable building codes and standards.

1.4 Quality Assurance
A. Qualifications: The valves supplied under this section shall be standard products of a manufacturer regularly engaged in the design and manufacturing of rubber duckbill check valves.

B. Standards and certifications: The duckbill check valve must maintain an ISO-9001 certification and also a company certification for its welding operations from the CWB or AWS.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. ASTM D2000 Standard Classification System for Rubber Products in Automotive Applications

2. ASTM D4020 Standard Specification for Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials.

3. ASTM F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit general arrangement drawings including all parts, dimensions, and details for all components
Product Data Submit per Product Data requirements for all items under scope of supply.

Design
Calculations
N/A
Installation
Instructions
Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements Certificate of
Compliance
Submit affidavit of compliance for duckbill check valves.

Project Owner RUBBER DUCKBILL CHECK VALVES
New River Improvement Project – Calexico 33 12 74- 2

SUBMITTAL DESCRIPTION
Test Record
Transcripts
Submit for factory tests per Test Record Transcript requirements.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. The manufacturer shall use due and customary care in preparing the gates and accessories for shipment. Self-contained frame gates shall be shipped assembled with stem and manual operator.

C. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of slide gates.

1.8 Unit Prices Bid Item 33 12 74 – Duckbill Check Valve A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. This specification section is based on the Series 35 Tideflex Valve manufactured by Red Valve Inc. Other suitable slide gate manufacturers are indicated in paragraph 2.1 B. Manufacturer shall have at least 15years of experience in the manufacture of duckbill style elastomeric valves.

B. Acceptable manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Rubber
Duckbill Check
Valves
Series 35 Red Valve, Inc. Carnegie, PA (412) 279-0044
Series DBF Onyx Valve Company Cinaminson, NJ (856) 829-2888 Engineer approved equal

2.2 Materials
A. Materials for rubber duckbill check valves for normal water and wastewater service shall pure gum rubber with stainless steel backup rings.

2.3 Factory Tests
A. The manufacturer shall have conducted independent hydraulic testing to determine headloss and jet velocity characteristics on a minimum of eight (8) sizes of duckbill valves ranging from 2” through 48”. The testing must include multiple constructions (stiffness) within each size and must have been conducted for free discharge (discharge to atmosphere) and submerged conditions.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install duckbill check valves before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Furnish and install valves at locations shown on Plans and Submittals.

Project Owner RUBBER DUCKBILL CHECK VALVES
New River Improvement Project – Calexico 33 12 74- 3
B. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building and plumbing code requirements

3. Manufacturer’s installation and warranty requirements C. Refer variances between above documents and Contract Documents to Owner’s Representative.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

END OF SECTION
Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 1
SECTION 33 30 31

POLYVINYL CHLORIDE (PVC) GRAVITY SEWER PIPE
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of polyvinyl chloride (PVC) gravity sewer and storm drain pipe and fittings 4”-60”.

B. For sewers 18”-30”, use ASTM F679 Poly (Vinyl Chloride) (PVC) Large-Diameter Plastic Gravity Sewer Pipe and Fittings.

C. Outdoor piping exposed to sunlight shall be painted with a coat of water-based latex paint per Section 09 90 00. Use pastel shades or white to reduce thermal expansion.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 01 73 33: Mechanical Identification
F. Section 02 05 00: Basic Civil Engineering Requirements G. Section 02 41 14: Paving Removal and Resurfacing
H. Section 03 30 00: Cast-in-Place Concrete
I. Section 22 10 00: Plumbing Piping
J. Section 31 05 50: Protecting Existing Utilities
K. Section 31 23 00: Excavation and Fill
L. Section 31 23 33: Trenching and Backfilling
M. Section 33 05 26: Utility Identification
N. Section 33 08 31: Leakage and Infiltration Testing of Gravity Sewer Pipelines O. Section 33 39 13: Pre-Cast Concrete Manholes

1.3 System Description
A. Furnish and install complete sewer pipe to limits shown on Plans including appurtenant connections in conformance with Manufacturer’s installation requirements and compliance with applicable construction safety codes and standards.

B. Pipe and fittings shall be produced by same Manufacturer.

C. Manufacturer of pipe and fittings shall employ manufacturing methods and material formulations in use for at least 5 years.

D. Owner or Owner’s Representative shall be entitled to inspect pipes and witness manufacturing process.

Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 2
E. For testing purposes, a production lot shall consist of all pipe having same lot marking number but shall not exceed 1,200’ per day.

F. Factory testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
PVC
Gravity
Sewer
Pipe
Izod
Impact
Test

0.65 ft-lb/in at 23°C per
ASTM D256 for cell
class 12454

1.5 ft-lb/in at 23°C per
ASTM D256 for cell
class 13343

1.5 ft-lb/in at 23°C per
ASTM D256 for cell
class 13364
One test on
each
production lot
or 1200’ on
sample at
least 8’ long
Contractor Contractor
Tensile
Stress at
Yield
7000 psi per ASTM
D638 for cell class
12454
6000 psi per ASTM
D638 for cell class
13343 or 13364
One test on
each
production lot
or 1200’ on
sample at
least 8’ long
Contractor Contractor
Specific
Gravity

1.0-1.2 per ASTM
D792
One test each
production lot
Contractor Contractor
Chemical
Resistance
(Pickle Jar)
Test
Sample per ASTM
D1987
Test per SSPWC
(Greenbook) §211-2
Chemical Resistance
(Pickle Jar) Test except
Weight Change
Specimens Shall
Conform to SSPWC
(Greenbook) §207-15.3
Tensile Stress and
Impact Strength after
100 days shall meet
criteria above
Weight Change per
ASTM D543 shall be

1.5% maximum
unconditioned and

1.0% maximum
conditioned
As directed Contractor Contractor

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 3

1. ASTM D256 Izod Pendulum Impact Resistance of Plastics

2. ASTM D395 Rubber Property—Compression Set

3. ASTM D412 Vulcanized Rubber and Thermoplastic Elastomers—Tension

4. ASTM D543 Resistance of Plastics to Chemical Reagents

5. ASTM D573 Rubber—Deterioration in an Air Oven

6. ASTM D638 Tensile Properties of Plastics

7. ASTM D648 Deflection Temperature of Plastics Under Flexural Load in Edgewise Position

8. ASTM D792 Density and Specific Gravity (Relative Density) of Plastics by Displacement

9. ASTM D648 Test Method for Deflection Temperature of Plastics under Flexural Load Above Ground

10. ASTM D1149 Rubber Deterioration—Cracking in an Ozone Controlled Environment

11. ASTM D1599 Short-Time Hydraulic Failure Pressure of Plastic Pipe, Tubing and Fittings

12. ASTM D1784 Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds

13. ASTM D2240 Rubber Property—Durometer Hardness

14. ASTM D2241 Poly (Vinyl Chloride) (PVC) Pressure-Rated Pipe SDR Series

15. ASTM D2321 Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications

16. ASTM D2412 Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

17. ASTM D2564 Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings

18. ASTM D2665 Poly(Vinyl Chloride) (PVC) Plastic Drain, Waste and Vent Pipe and Fittings

19. ASTM D2729 Poly(Vinyl Chloride) (PVC) Sewer Pipe and Fittings

20. ASTM D3034 Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings

21. ASTM D3212 Joints for Drain and Sewer Plastic Pipe Using Elastomeric Seals

22. ASTM D4396 Rigid Poly(Vinyl Chloride) (PVC) and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds for Plastic Pipe and Fittings Used in Nonpressure Applications

23. ASTM F477 Elastomeric Seals (Gaskets) for Joining Plastic Pipe

24. ASTM F656 Primers for Buried PVC Pipe and Fittings

25. ASTM F679 Poly (Vinyl Chloride) (PVC) Large-Diameter Plastic Gravity Sewer Pipe and Fittings

26. ASTM F1417 Installation Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air

27. ASTM F1803 Poly (Vinyl Chloride)(PVC) Closed Profile Gravity Pipe and Fittings Based on Controlled Inside Diameter

28. ASTM F1866 Poly (Vinyl Chloride) (PVC) Plastic Schedule 40 Drainage and DWV Fabricated Fittings

29. California Green Building Standards Code (CALGreen Code)

30. California Plumbing Code (CPC)

31. NSF/ANSI 14 Plastic Piping Components and Related Materials Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 4

32. SSPWC Standard Specifications for Public Works Construction (Greenbook) §207-17 PVC Gravity Pipe

33. UNI-B-5 Uni-Bell Recommended Practice for the Installation of PVC Sewer Pipe

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Product Data Submit per Product Data requirements.

Installation
Instructions
Submit per Installation Instruction requirements.

Certificate of
Compliance Type
PSM Pipe 4”-15”
Deliver with pipe an affidavit from pipe Manufacturer certifying conformance with ASTM D3034 and Contract Documents.

Include copy of test data results.

Certificate of
Compliance Pipe 18”-
30”
Deliver with pipe an affidavit from pipe Manufacturer certifying conformance with ASTM F679 and Contract Documents.

Include copy of test data results.

Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Product Data, Installation Instructions, and Certificates of Compliance.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of PVC gravity sewer pipe and fittings.

1.8 Unit Prices Bid Items 33 30 31 – PVC Gravity Sewer Pipe A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for PVC gravity sewer pipe.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Sewer Pipe
PVC Sewer Pipe,
Fittings,
Couplings, and
Gaskets 18”-30”
(ASTM F679)
JM Eagle, Inc. Los Angeles, CA (310) 693-8200
North American Pipe Corporation Houston, TX (713) 840-7473 North American Pipe Corporation
/ Westlake Chemical
Janesville, WI (608) 754-2710
Pacific Western Extruded
Plastics Company
Visalia, CA (559) 651-2100
Accepted equal
Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 5

ITEM MANUFACTURER MANUFACTURER LOCATION
Identification Tape
Buried Pipe
Identification
Tape
Refer to Section 33 05 26

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Materials for PVC solid-wall gravity sewer pipe used to temperatures of 140°F shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Pipe Standards Pipe sizes 18”-27” Conform to ASTM F679
Material Conform to ASTM D1784
Virgin rigid PVC
Additives or fillers including but not limited to
stabilizers, antioxidants, lubricants, and
colorants shall be ≤10% by weight per 100 of
PVC resin in compound.

Marking Mark pipe at 5’ maximum intervals.

Show Manufacturer or trademark.

Mark ASTM standard complied with.

Show nominal pipe diameter.

Show SDR.

Show material, and PVC cell classification.

Show coded number identifying plant, machine,
date and shift on which pipe was extruded.

Show service designation or legend.

Mark pipe with home mark on spigot to indicate
proper penetration when joint is made
Size As shown on plans.

Pipe sizes 18”-30” = T-1, unless otherwise
shown on Plans.

Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 6

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Standard Lengths 12.5’ and 20’ with option to supply up to 15% of pipe delivery in random lengths
Pipe Stiffness 115 psi per ASTM D2412
Type of Construction Solid wall with smooth interior and exterior surfaces
Color Green (Sewer) and White (Storm Drain)
Refer to Section 33 05 26
C. Materials for PVC solid-wall gravity sewer or storm drain pipe joints shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Joints on
Sewers
Type Integral bell gasketed joint meeting ASTM
D3212
Socket and spigot configurations for fittings and
couplings shall be compatible with those used
for pipe.

Joint Gasket Synthetic elastomer conforming to ASTM F477 Factory installed in belled end of pipe and
fittings
Gaskets Material Rubber or synthetic elastomer conforming to ASTM F477
Compound shall contain ≥ 50% Grade 1
synthetic rubber by volume.

Remainder of compound shall consist of
pulverized fillers free of rubber substitutes,
recycled rubber, and deleterious substances.

Gasket Age <180 days old
Initial Physical Requirements
Physical
Characteristics
Extruded or molded and cured to form dense,
homogeneous, and smooth surface free of
pitting, blisters, porosity, and other
imperfections.

Tolerance ±1/32” for any diameter or profile dimension
measured at any cross section
Tensile Strength >1500 psi per ASTM D412
Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 7

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Elongation at Break >350% per ASTM D412
Shore Durometer
Type A (Pipe
Manufacturer shall
select value suitable
for joint type.)
40-65 (applies only to sealing component of
gasket.) per ASTM D2240
Compression Set ≤16% of original deflection per ASTM D395 Method B
Physical Requirements after Accelerated Aging
Tensile Strength
after Oven Aging (96
hrs@158°F)
≥ 80% of tensile strength before aging per
ASTM D573
Increase in Shore
Durometer Hardness
after Oven Aging
≤10% increase over original Shore durometer
per ASTM D2240
Physical
Requirements after
Exposure to Ozone
Concentration
No cracks per ASTM D1149
Gasket
Splices
Quantity No more than one splice shall be permitted in
any gasket.

Splicing
Methodology
Make splice by applying suitable cement to
ends and vulcanizing splice in a full mold.

Splice Testing Elongation Test – Stretch spliced portion of gasket to 100% elongation. While gasket is
stretched, rotate gasket at least 180° each
direction to inspect to assure no separation
occurs.

Bend Test – Wrap spliced portion of unstretched gasket at least 180° but not more than 270° around rod with diameter equal to
gasket cross-section diameter. No separation
shall occur.

D. Materials for PVC solid-wall gravity sewer or storm drain pipe fittings shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Standards Pipe sizes 18”-27” Conform to ASTM F679
Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 8

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Fittings and
Couplings
Material Conform to ASTM D1784
Cell Class 12454
Virgin rigid PVC
Additives or fillers including but not limited to
stabilizers, antioxidants, lubricants, and
colorants shall be ≤10% by weight per 100 of
PVC resin in compound.

Conform to NSF 14
Markings Show Manufacturer or trademark.

Show nominal pipe diameter.

Show material, and PVC cell classification.

Show coded number identifying plant, machine,
date and shift on which pipe was extruded.

Show service designation or legend.

E. Refer to Section 33 05 26 for requirements for identification, identification tape and warning tape for buried PVC gravity sewer pipe.

F. The following product design criteria, options and accessories are required:

ITEM DESCRIPTION
Design Live Load H-20 (32k axle 16k wheel load)
Depth of Soil Cover See Plans
G. Socket and spigot configurations for fittings and couplings shall be compatible to those used for pipe.

H. Pipe not installed within 120 calendar days of latest certification test shall not be used without prior approval from Owner’s Representative.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install PVC gravity sewer pipe before submitting shop drawings or ordering materials. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

B. Grade trench bottom to line and grade to which pipe is to be laid, with allowance for pipe thickness. Dig bell holes or coupling holes of ample dimension in trench bottom at locations of each joint to facilitate joining. Remove hard spots that would prevent uniform bedding thickness. Before laying each pipe section, check grade with straight-edge and correct any irregularities found. Trench bottom shall form continuous and uniform bearing and support for pipe at every point between bell or coupling holes, except grade may be disturbed for removal of lifting tackle.

C. At each joint location dig bell (joint) holes in trench bottom and at sides to permit visual inspection of entire joint.

Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 9
D. Provide and maintain means and devices at all times to remove and dispose of all water entering trench during pipe-laying operations. Keep trench dry until pipe-laying and jointing are completed.

3.2 Installation
A. Refer to Sections 01 73 33 / 02 05 00 for basic execution and installation requirements.

B. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire and plumbing code requirements

3. Manufacturer’s installation and warranty requirements

4. ASTM D2321 Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications

5. ASTM F1668 Construction Procedures for Buried Plastic Pipe

6. UNI-B-5 Uni-Bell Recommended Practice for the Installation of PVC Sewer Pipe C. Refer variances between Manufacturer’s installation instructions, published installation standards and Contract Documents to Owner’s Representative.

D. Protect water and recycled water systems by constructing sewers with separations and materials described in Section 31 05 50.

E. Install PVC gravity sewer pipe as follows:

1. Install PVC gravity sewer pipe and fittings per ASTM D2321 and Uni-Bell Recommended Practice for the Installation of PVC Sewer Pipe and as herein specified.

2. Inspect each pipe and fitting before lowering pipe or fitting into trench.

3. Use proper care to prevent damage in handling, moving, and placing pipe. Hoist pipe with forklift, crane, backhoe or other handling equipment to prevent damage or reduction of pipe service life. Use cloth belt sling or continuous fiber rope to prevent scratching pipe.

Lower (do not drop) pipe from truck. Dropped pipe will be rejected.

4. Install PVC gravity sewer pipe and fittings to tolerances recommended by Manufacturer.

Unless otherwise shown, install PVC gravity sewer pipe and fittings at locations and grades shown on Plans using precision gauges and levels.

5. No longitudinal bending shall be allowed in installation of PVC gravity sewer pipe. Install all deflections at sewer manholes or by using joints and fittings specifically designed for use with PVC pipe of specified SDR.

6. Install pipe without break, upgrade from structure to structure, with bell ends of pipe upgrade. Install pipe to line and grade given so as to form close concentric joint with adjoining pipe and prevent sudden offsets of flow line.

7. Clean interior of pipe and fittings of all dirt and superfluous materials of all description immediately prior to installing pipe. Wipe joints clean of all dirt and foreign matter and apply accepted lubricant to mating surfaces of pipe to be joined.

8. Insert spigot end to proper depth of socket as indicated by home mark on pipe. Spigot end shall slide into bell end without displacement of rubber gasket.

9. Close open end of pipe with tight-fitting cap or plug to prevent entrance of foreign matter into pipe at all times when pipe installation is not in progress. These provisions shall apply during noon hour as well as overnight.

10. Do not use pipeline to drain water that has infiltrated into trench.

Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 10

11. Maintain inside of pipe free from foreign materials and in clean and sanitary condition until its acceptance by Owner.

12. After joint assembly. Bring bedding material up to pipe spring line. Place bedding material on each side of pipe. Do not drop rock or crushed gravel directly onto pipe. Walk and tamp bedding material into final position at pipe spring line and continue to top of pipe.

13. Then place bedding material to top of pipe zone and compact to specified pipe zone compaction.

F. Connect PVC sewer pipe to manholes using gasketed plastic manhole coupling to provide watertight connection.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Pipe Horizontal
Alignment
1” maximum
horizontal deviation
from plan alignment
Mirror each
straight
section of
pipe
Contractor Contractor
Vertical
Alignment
¼” maximum
horizontal deviation
from plan grades
Mirror each
straight
section of
pipe
Contractor Contractor
Pipe
Separations
Refer to Section 31
05 50.

All new pipe Contractor Contractor
Pressure
Test for
Leakage
and
Infiltration
Refer to Section 33
08 31
1 test per run
of pipe
Contractor Contractor
Mandrel
Test for
Obstruction
s and Pipe
Deflections
SSPWC
(Greenbook) §306-

7.8.3 (See Below)
1 test per run
of pipe
Contractor Contractor
Video
Inspection
Video entire new
alignment. Submit
copy of video to
Owner
All new pipe Contractor Contractor
Laterals Horizontal
Alignment
1” maximum
horizontal deviation
from plan alignment
Survey
location of
each lateral
Contractor Contractor
Vertical
Alignment
¼” maximum
horizontal deviation
from plan grades
Survey
location of
each lateral
Contractor Contractor
Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 11

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Sewer
System
Field
Performanc
e
Demonstrate
compliance to
Contract Documents
and Manufacturer’s
printed Literature
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate
compliance to
Contract Documents
and Manufacturer’s
printed literature
1 test Owner Contractor
B. Perform mandrel test after placement and compaction of backfill, installation of utilities, pipe testing, and prior to placing of permanent paving. Correct obstructions encountered during mandrel test at no additional cost to Owner

3.4 Cleaning
A. Prior to testing, thoroughly clean sewers from structure to structure with hydro-flush equipment or sewer scrubbing ball. Remove debris and trash from each structure. Disinfection of sewer is not required.

END OF SECTION
Project Owner PVC GRAVITY SEWER PIPE
New River Improvement Project – Calexico 33 30 31 - 12

THIS PAGE INTENTIONALLY BLANK
Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 1
SECTION 33 32 30

SELF-PRIMING PUMPS
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of factory-built self-priming pumps with a triplex configuration as indicated on the project drawings, herein specified and as necessary for proper and complete performance.

1.2 Related Work
A. Section 01 33 00: Submittal Procedures
B. Section 01 40 00: Quality Requirements
C. Section 01 65 00: Product Delivery Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 02 05 00: Basic Civil Engineering Requirements F. Section 09 90 00: Painting and Coating
G. Section 09 96 56: Epoxy Linings and Coatings

1.3 System Description
A. Furnish and install complete operating pumping units including pumps, motors and necessary appurtenances required by Contract Documents. Factory built pumps shall be individually mounted on steel bases.

B. Furnish and install anchor bolts and appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building codes and standards.

C. Principal items of equipment shall include three horizontal, self-priming, centrifugal sewage pumps, V-belt drives, motors, piping, valves. Not included in this package is the motor control panel, automatic liquid level control system, and integral wiring (by others).

D. The pump station shall be capable of parallel pump operation dependent upon the liquid level present in the wet well.

1.4 Quality Assurance
A. The pumps and pump manufacturer must be ISO 9001:2000 revision certified, with scope of registration including design control and service after sales activities.

B. Upon request from the Owner, the pump manufacturer shall prove financial stability and ability to produce the equipment within the specified delivery schedules. Evidence of facilities, equipment and expertise shall demonstrate the manufacturer's commitment to long term customer service and product support.

C. All internal passages, impeller vanes, and recirculation ports shall pass a 3" spherical solid.

Smaller internal passages that create a maintenance nuisance or interfere with priming and pump performance shall not be permitted. Upon request from the Owner or engineer, manufacturer's certified drawings showing size and location of the recirculation port(s) shall be submitted for approval.

D. Manufacturer must show proof of original product design and testing. Products violating intellectual property regulations shall not be allowed, as they may violate international law and expose the user or engineer to unintended liabilities. "Reverse-engineered" products fabricated to substantially duplicate the design of original product shall not be allowed, as they Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 2
may contain substantial differences in tolerances and material applications addressed in the original design, which may contribute to product failure.

E. The term "pump manufacturer" or "pump station manufacturer" shall be defined as the entity which designs, machines, assembles, hydraulically tests and warranties the final product. Any entity that does not meet this definition will not be considered a "pump manufacturer" or "pump station manufacturer" and is not an acceptable supplier. For quality control reasons and future pump and parts availability, all major castings of the pump shall be sourced and machined in North America.

F. Reprime Performance

1. Consideration shall be given to the sanitary sewage service anticipated, in which debris may lodge between the suction check valve and its seat, resulting in the loss of the pump suction leg, and siphoning of liquid from the pump casing to the approximate center line of the impeller. Such occurrence shall be considered normal, and the pump must be capable of automatic, unattended operation with an air release line installed.

2. During unattended operation, the pump shall retain adequate liquid in the casing to insure automatic repriming while operating at its rated speed in a completely open system. The need for a suction check valve or external priming device shall not be required.

3. Pump must reprime 18 vertical ft. at the specified speed and impeller diameter. Reprime lift is defined as the static height of the pump suction above the liquid, while operating with only one-half of the liquid remaining in the pump casing. The pump must reprime and deliver full capacity within five minutes after the pump is energized in the reprime condition.

Reprime performance must be confirmed with the following test set-up:
a. A check valve to be installed down stream from the pump discharge flange. The check valve size shall be equal (or greater than) the pump discharge diameter. b. A length of air release pipe shall be installed between pump and the discharge check valve. This line shall be open to atmosphere at all times duplicating the air displacement rate anticipated at a typical pump station fitted with an air release valve. c. The pump suction check valve shall be removed. No restrictions in the pump or suction piping will prevent the siphon drop of the suction leg. Suction pipe configuration for reprime test shall incorporate a 2 feet minimum horizontal run, a 90 degree elbow and vertical run at the specified lift. Pipe size shall be equal to the pump suction diameter.
d. Impeller clearances shall be set as recommended in the pump service manual. e. Repeatability of performance shall be demonstrated by testing five consecutive reprime cycles. Full pump capacity (flow) shall be achieved within five minutes during each cycle.
f. Liquid to be used for reprime test shall be water.

4. Certified reprime performance test results, prepared by the manufacturer, and certified by a registered professional engineer, shall be submitted for approval prior to shipment.

5. Certified Pump Performance Test
a. Tests shall be conducted in accordance with Hydraulic Institute Standards 14.6.3.4 Acceptance Grade 2B at the specified head, capacity, rated speed and horsepower.

The performance tests will validate the correct performance of the equipment at the design head, capacity and speed.

6. Factory System Test
a. All components including the pumps and motors shall be tested as a complete working system at the manufacturer's facility. Tests shall be conducted in accordance with Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 3
Hydraulic Institute Standards at the specified head, capacity, rated speed and horsepower. Factory operational test shall duplicate actual performance anticipated for the complete station.
b. Upon request from the engineer or Owner, the operational test may be witnessed by the engineer, and/or representatives of his choice, at the manufacturer's facility.

7. The manufacturer's technical representative shall inspect the completed installation, correct or supervise the correction of any defect or malfunction, and instruct operating personnel in the proper operation and maintenance of the equipment.

G. Factory testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY

FIRST TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Pump and
Motor
Assembly
Compliance
with Purchase
Order
Verify impeller, motor
rating & electrical
connections comply
with Contract
Documents
1 each pump
assembly
Contractor Contractor
Motor No-Load
Current, full
load current,
winding
resistance and
high potential

ANSI /IEEE
Standard 112
Method B and
applicable NEMA
Standards
1 each motor Contractor Contractor
Test Run to
establish
correct rotation
and mechanical
integrity
Test run 1 each pump Contractor Contractor
Self-Priming Verify self-priming
capability
1 each pump Contractor Contractor
Certified Pump
Curve
Witnessed running
test per AWWA E101
and Hydraulic
Institute Standards
Do not exceed
published HI
standards or 0.20
in/sec RMS in
absence of HI
standards.

On variable
speed pumps,
test each pump
& prepare 6-
point curves at 4
100 rpm
increments.

Contractor
(Includes
lodging &
travel
expenses for
4 personnel
from Owner’s
and/or Design
Engineer’s
offices.)
Contractor
(Includes
lodging &
travel
expenses
for 4
personnel
from
Owner’s
and/or
Design
Engineer’s
offices.)
H. Testing shall be performed after final connection of pump and motor and after completion of static and dynamic balancing.

I. Project VFD shall be tested with assembled project pump and motor to guarantee compatibility.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 4
J. If vibration levels fall outside of acceptable limits established by Hydraulic Institute or above, shut down pump and correct for vibration before further testing.

K. Witness testing shall be scheduled at least 2 days in advance of test dates.

1.5 References
A. Publications listed below form part of this specification to extent referenced in the text by basic designation only. Consult latest edition of publication unless otherwise noted.

1. American National Std. Institute (ANSI) / American Water Works Assoc. (AWWA) a. ANSI B16.1 - Cast iron pipe flanges and flanged fittings. b. ANSI/AWWA C115/A21.51 - Cast/ductile iron pipe with threaded flanges. c. ANSI 253.1 - Safety Color Code for Marking Physical Hazards. d. ANSI B40.1 - Gages, Pressure and Vacuum.
e. AWWA C508 - Single Swing Check Valves.

2. American Society for Testing and Materials (ASTM)
a. ASTM A48 - Gray Iron Castings.
b. ASTM A126 - Valves, Flanges, and Pipe Fittings.
c. ASTM A307 - Carbon Steel Bolts and Studs.
d. ASTM A36 - Structural Steel.

3. Institute of Electrical and Electronics Engineers (IEEE) a. ANSI/IEEE Std 100 - Standard Dictionary of Electrical Terms. b. ANSI/IEEE Std 112 - Test Procedure for Polyphase Induction Motors. c. IEEE Std 242 - Protection of Industrial and Control Power Systems.

4. National Electric Code (NEC) / National Electrical Manufacturers Assoc. (NEMA) a. NEC - National Electric Code.
b. NEC 701 - National Electric Code article 701.
c. NEMA Std MG1 - Motors and Generators.

5. Miscellaneous References
a. Ten-State Standards Recommended Standards for Sewage Works. b. Hydraulic Institute Std for Centrifugal, Rotary and Reciprocating Pumps. c. NMTBA and JIC Std National Machine Tool Builders Association and Joint Industrial Council Standards
d. ISO 9001International Organization for Standardization.

1.6 Submittals
A. Furnish the following submittals.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 5

SUBMITTAL DESCRIPTION
Shop
Drawings
Submit for pumps including volutes, impellers, V-belts, drive assemblies, shafts, bearings, seals, and shaft guards per equipment shop drawing requirements. Show fabrication, assembly, foundation and installation requirements. Submit catalog cuts sheets reflecting characteristics for major items of equipment, materials of construction, major dimensions, motor and v-belt drive data, pump characteristic curves showing the design duty point and other design points as specified including capacity (GPM), head (FT), net positive suction head required (NPSHr), and hydraulic brake horsepower (BHP).

Submit for motor and motor controls under electrically controlled equipment shop drawing requirements.

Show lining and coating data and thicknesses.

Submit for anchor bolts. Show placement, embedment, and edge distances as required by CBC Chapter 19. Show embedment distances and projections from concrete face.

Product Data Submit per Product Data requirements
Pump Curves Submit pretest pump curves with specified operating points marked.

Curve shall also show moment of inertia of complete pumping unit, required submergence and NPSHR
Installation
Instructions
Submit per Installation Instruction requirements.

O & M
Instructions
Submit per Operation and Maintenance Instruction requirements.

Certificate of
Compliance
Submit pump system certification per Certificate of Compliance requirements.

Submit data on self-priming maximum lift and certification that pump will prime under field conditions shown
Submit coating system and application certification per certificate of compliance requirements.

Engineering
Calculations
Submit power transmission calculations documenting:
a. Ratio of pump/motor speed.
b. Pitch diameter of driver and driven sheaves.
c. Number of belts required per drive.
d. Theoretical horsepower transmitted per belt, based on vendor's data.
e. Center distance between pump and motor shafts.
f. Arc-length correction factor applied to theoretical horsepower transmitted.
g. Service factor applied to established design horsepower. h. Safety factor ratio of power transmitted/brake horsepower required. i. Calculations for lateral force restraint of anchor bolts.

Manufacturer’s
Statement of
Responsibility
Required per Manufacturer’s Statement of Responsibility requirements.

Include statement that pumps installed comply with Contract Documents.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 6

SUBMITTAL DESCRIPTION
Test Record
Transcripts
Before shipping pumps, submit certified pump curves for factory tests per Test Record Transcript requirements. Where variable speed drives are provided, submit certified pump curves in 100 rpm increments throughout operating range of pump. Include written report stating date and location that pumps were tested and certifying that certified pump curves are accurate and comply with specifications.

Motor Data Required per motor data requirements of Section 01 33 00 / 02 05 00.

Include mounting details
Testing
procedures
Submit written test procedures in advance of field pump tests.

Warranty Furnish 5-year warranty from date of final acceptance for pumping units. Warranty shall bear appropriate serial numbers, and shall be included in O&M Manual
B. Refer to Section 01 33 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, Certificates of Compliance, Engineering Calculations, Manufacturer’s Statements of Responsibility, and Test Record Transcripts.

C. Operation and Maintenance Manuals

1. Installation shall be in accordance with written instructions provided by the pump manufacturer. Comprehensive instructions supplied at time of shipment shall enable personnel to properly operate and maintain all equipment supplied. Content and instructions shall assume operating personnel are familiar with pumps, motors, piping and valves, but lack experience on exact equipment supplied.

2. Documentation shall be specific to the pumps supplied and collated in functional sections.

Each section shall combine to form a complete system manual covering all aspects of equipment supplied by the station manufacturer. Instructions shall include the following as a minimum:
a. Functional description of each major component, complete with operating instructions. b. Calibration and adjustment of equipment for initial start-up, replacement, or as required for routine maintenance.
c. Support data for commercially available components not produced by the station manufacturer, but supplied in accordance with the specifications, shall be supported by literature from the prime manufacturer and incorporated as appendices. d. Mechanical layout drawing of the pump station and components, prepared in accordance with good commercial practice, shall provide installation dimensions and location of all pumps, motors, valves and piping.
e. Operation and maintenance instructions which rely on vendor cut-sheets and literature which include general configurations, or require operating personnel to selectively read portions of the manual shall not be acceptable. Operation and maintenance instructions must be specific to equipment supplied in accordance with these specifications.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of pumps.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 7

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for packaged sewage lift stations with duplex self-priming pumps.

1.9 Warranty
A. The pump manufacturer shall warrant all equipment to be of quality construction, free of defects in material and workmanship. A written warranty shall include specific details described below.

B. All equipment, apparatus, and parts furnished shall be warranted for sixty (60) months, excepting only those items that are normally consumed in service, such as light bulbs, oils, grease, packing, gaskets, O rings, etc. The pump manufacturer shall be solely responsible for warranty of the assembled pumping units.

C. Components failing to perform as specified by the engineer, or as represented by the manufacturer, or as proven defective in service during the warranty period, shall be replaced, repaired, or satisfactorily modified by the manufacturer.

D. Equipment supplied by others is not covered by this limited warranty. Any warranty applicable to equipment selected or supplied by others will be limited solely to the warranty provided by the manufacturer of the equipment.

E. This limited warranty shall be valid only when installation is made and use and maintenance is performed in accordance with manufacturer recommendations. A start-up report competed by an authorized manufacturer's representative must be received by manufacturer within thirty (30) days of the initial date the unit is placed into service. The warranty shall become effective on the date of acceptance by the Owner or the Owner's authorized agent.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Pumps shall be manufactured by Gorman-Rupp, no equal.

B. Pumps furnished shall operate throughout their full submitted pump curve driven by motors of horsepowers specified below or shown on Plans. Pumps requiring larger motor than specified or shown are unacceptable in absence of written statement from Owner electrical infrastructure, drives and switchgear can support larger motor.

2.2 Unit Base
A. Each pumping unit shall be mounted on a steel base plate. The base plate shall be comprised of a structural assembly that includes a perimeter flange and reinforcements. Base plate shall be fabricated of steel not less than 1/4" thick. Perimeter flange and reinforcements shall be designed to prevent flexing or warping under operating conditions. Base plate and/or flange shall be drilled for hardware used to secure unit base to concrete pad as shown on the contract drawings. Unit base shall contain provisions for lifting the complete pump unit during shipping and installation.

2.3 Pump Design
A. Pumps shall be horizontal, self-priming centrifugal type, designed specifically for handling raw, unscreened, domestic sanitary sewage. Pump solids handling capability and performance criteria shall be in accordance with requirements listed in this specification.

B. The manufacturer of the pumps must be ISO 9001:2000 revision certified, with scope of registration including design control and service after sales activities.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 8

2.4 Materials
A. Pump Casing: Casing shall be cast iron Class 30 with integral volute scroll. Casing shall incorporate following features:

1. Mounting feet sized to prevent tipping or binding when pump is completely disassembled for maintenance.

2. Fill port coverplate, 3-1/2" diameter, shall be opened after loosening a hand nut/clamp bar assembly. In consideration for safety, hand nut threads must provide slow release of pressure, and the clamp bar shall be retained by detente lugs. A Teflon gasket shall prevent adhesion of the fill port cover to the casing.

3. Casing drain plug shall be at least 1-1/4" NPT to insure complete and rapid draining.

4. Liquid volume and recirculation port design shall be consistent with performance criteria listed in this specification.

5. Aggressive Self-Cleaning Wear Plate:
a. A replaceable wear plate shall be self-cleaning design ensuring that debris is cleared away and does not collect on the impeller vanes.
b. The nature of the conveyed medium poses significant challenges to the continuous operation of the pump. Of particular concern is the clogging of the impeller by debris in the pumped medium including but not limited to long rags, fibers, and like debris which are able to wrap around the impeller vanes, stick to the center of the vanes or hub, or lodge within the spaces between the impeller and the housing. c. The aggressive self-cleaning wear plate shall have integral laser cut notches and grooves in combination with a "tooth" designed to disturb and dislodge any solids which might otherwise remain on the impeller in dynamic operation. Wearplate is designed to constantly and effectively clear the eye of the impeller without the use of blades or cutters.

6. Rotating Assembly: A rotating assembly, which includes impeller, shaft, mechanical shaft seal, lip seals, bearings, sealplate and bearing housing, must be removable as a single unit without disturbing the pump casing or piping. Design shall incorporate following features:
a. Sealplate and bearing housing shall be cast iron Class 30. Separate oil filled cavities, vented to atmosphere, shall be provided for shaft seal and bearings. Cavities must be cooled by the liquid pumped. Three lip seals will prevent leakage of oil. b. The bearing cavity shall have an oil level sight gauge and fill plug check valve. The clear sight gauge shall provide easy monitoring of the bearing cavity oil level and condition of oil without removal of the fill plug check valve. The check valve shall vent the cavity but prevent introduction of moist air to the bearings. c. The seal cavity shall have an oil level sight gauge and fill/vent plug. The clear sight gauge shall provide easy monitoring of the seal cavity oil level and condition of oil without removal of the fill/vent plug.
d. Double lip seal shall provide an atmospheric path providing positive protection of bearings, with capability for external drainage monitoring. e. Impeller shall be ductile iron, two-vane, semi-open, non-clog, with integral pump out vanes on the back shroud. Impeller shall thread onto the pump shaft and be secured with a lockscrew and conical washer.
f. Shaft shall be AISI 4140 alloy steel unless otherwise specified by the engineer, in which case AISI 17-4 pH stainless steel shall be supplied.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 9
g. Bearings shall be anti-friction ball type of proper size and design to withstand all radial and thrust loads expected during normal operation. Bearings shall be oil lubricated from a dedicated reservoir. Pump designs which use the same oil to lubricate the bearings and shaft seal shall not be acceptable.
h. Shaft seal shall be oil lubricated mechanical type. The stationary and rotating seal faces shall be tungsten titanium carbide alloy. Each mating surface shall be lapped to within three light bands flatness (35 millionths of an inch), as measured by an optical flat under monochromatic light. The stationary seal seat shall be double floating by virtue of a dual O-ring design; an external O-ring secures the stationary seat to the sealplate, and an internal O-ring holds the faces in alignment during periods of mechanical or hydraulic shock (loads which cause shaft deflection, vibration, and axial/radial movement). Elastomers shall be viton. Cage and spring to be stainless steel. Seal shall be oil lubricated from a dedicated reservoir. The same oil shall not lubricate both shaft seal and shaft bearings. Seal shall be warranted in accordance with requirements listed in this specification.
i. Pusher bolt capability to assist in removal of rotating assembly. Pusher bolt threaded holes shall be sized to accept same capscrews as used for retaining rotating assembly.

7. Adjustment of the impeller face clearance (distance between impeller and wearplate) shall be accomplished by external means.
a. Clearances shall be maintained by a four-point external shimless coverplate adjustment system, utilizing a four collar and four adjusting screw design allowing for incremental adjustment of clearances by hand as required. Each of the four points shall be lockable to prevent inadvertent clearance increases or decreases due to equipment vibration or accidental operator contact. The four point system also allows for equal clearance gaps at all points between the impeller and wear plate.

Requirement of realignment of belts, couplings, etc., shall not be acceptable.

Coverplate shall be capable of being removed without disturbing clearance settings.

Clearance adjustment systems that utilize less than four points will not be considered. b. There shall be provisions for additional clearance adjustment in the event that adjustment tolerances have been depleted from the coverplate side of the pump. The removal of stainless steel shims from the rotating assembly side of the pump shall allow for further adjustment as described above
c. Clearance adjustment which requires movement of the shaft only, thereby adversely affecting seal working length or impeller back clearance, shall not be acceptable.

8. Suction check valve shall be molded Neoprene with integral steel and nylon reinforcement.

A blow-out center shall protect pump casing from hydraulic shock or excessive pressure.

Removal or installation of the check valve must be accomplished through the coverplate opening, without disturbing the suction piping. Sole function of check valve shall be to save energy by eliminating need to reprime after each pumping cycle. Pumps requiring a suction check valve to assist reprime will not be acceptable.

9. Spool flanges shall be one-piece cast iron, class 30 fitted to suction and/or discharge ports. Each spool shall have one 1-1/4" NPT and one 1/4" NPT tapped hole with pipe plugs for mounting gauges or other equipment.

B. Drain Kit: Pumps to be supplied with a drain kit for ease of maintenance. The kit to contain 10 foot length of reinforced plastic hose with a female quick connect fitting at one end, and factory installed drain fittings in each pump. Fittings include a stainless steel pipe nipple, stainless steel bushing, stainless steel gate valve and aluminum male quick connect fitting.

C. Automatic Air Release Valves

1. An automatic air release valve shall be furnished for each pump designed to permit the escape of air to the atmosphere during initial priming or unattended repriming cycles.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 10
Upon completion of the priming cycle or repriming cycle, the valve shall close to prevent recirculation. Valves shall provide visual indication of valve closure, and shall operate solely on discharge pressure. Valves which require connection to the suction line shall not be acceptable.

2. All valve parts exposed to sewage shall be constructed of cast iron, stainless steel, or similar corrosion resistant materials. Diaphragms, if used, shall be of fabric reinforced neoprene or similar inert material.

3. A cleanout port, three inches in diameter, shall be provided for ease of inspection, cleanout, and service.

4. Valves shall be field adjustable for varying discharge heads.

5. Connection of the air release valves to the station piping shall include stainless steel fittings.

D. Gauge Kit

1. A gauge kit shall be supplied for each pump. Suction pressure must be monitored by a glycerin-filled compound gauge, and discharge pressure by a glycerin-filled pressure gauge. Gauges to be at least 4 inches in diameter, graduated in feet water column. Rated accuracy shall be 1% of full scale reading. Compound gauge shall be graduated -34 to +34 feet water column minimum. Pressure gauge to be graduated 0 to 140 feet water column minimum.

2. Gauges to be factory mounted on a resilient panel with frame assembly secured to pumps or piping. Gauge installations shall be complete with all hoses and stainless steel fittings, including a shutoff valve for each gauge line at the point of connection to suction and discharge pipes.

E. Supports

1. Contractor must insure all pipes connected to the pump station are supported to prevent piping loads from being transmitted to pumps or station piping. Pump station discharge force main piping shall be anchored as shown on the contract drawings.

F. Drive Unit

1. Pump motors shall be 50 HP, horizontal ODP, 1800 RPM, NEMA design B with cast iron frame with copper windings, induction type, with normal starting torque and low starting current characteristics, suitable for continuous service. The motors shall not overload at the design condition or at any head in the operating range as specified.

G. Drive Transmission

1. Power to pumps transmitted V-belt drive assemblies. The sheave/belt combination shall provide the speed ratio needed to achieve the specified pump operating conditions.

2. Each drive assembly shall utilize at least two V-belts providing minimum a combined safety factor of 1.5. Single belt drives or systems with a safety factor of less than 1.5 are not acceptable. Computation of safety factors shall be based on performance data published by the drive manufacturer.

3. Precise alignment tolerances of the drive assemblies shall be achieved by means of a belt/sheave laser alignment system resulting in the reduction of vibration, accelerated wear, and premature failure.

4. The pump manufacturer shall submit power transmission calculations which document the following:
a. Ratio of pump/motor speed.
b. Pitch diameter of driver and driven sheaves.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 11
c. Number of belts required per drive.
d. Theoretical horsepower transmitted per belt, based on vendor's data. e. Center distance between pump and motor shafts.
f. Arc-length correction factor applied to theoretical horsepower transmitted. g. Service factor applied to established design horsepower. h. Safety factor ratio of power transmitted/brake horsepower required.

5. Belt Guards
a. Pump drives to be enclosed on all sides by a guard constructed of fabricated steel or combination of materials including expanded, perforated, or solid sheet metal. No opening to a rotating member shall exceed 1/2 inch.
b. Guards must be completely removal without interference from any unit component, and shall be securely fastened and braced to the unit base. c. Metal to be free from burrs and sharp edges. Structural joints shall be continuously welded. Rivet spacing on panels shall not exceed five inches. Tack welds shall not exceed four inch spacing.
d. The guard shall be finished with one coat of gray W.R. non lift primer and one coat of orange acrylic alkyd W.R. enamel in accordance with section 3, Color Definitions of ANSI 253.1; Safety Color Code for Marking Physical Hazards.

H. Finish

1. Pumps shall be cleaned prior to coating using an approved solvent wipe or phosphatizing cleaner. The part must thoroughly dry before paint application. Open joints shall be caulked with an approved polyurethane sealant. Exposed surfaces shall be applied with one coat of Tnemec Series 69 Polymide Epoxy Primer and one finish coat of Series 73 Aliphatic Acrylic Polyurethane for a total dry film thickness of 4-6 mils. Finish coat shall be semi-gloss white for optimum illumination and enhancement. The coating shall be corrosion, moisture, oil, and solvent resistant when completely dry. The factory finish shall allow for over-coating and touch-up for 6 months after coating. Thereafter, it will generally require sanding to accept a topcoat or touch-up coating. See Product Data Sheet for additional information.

I. Pump Performance Criteria

1. Pumps must be designed to handle raw, unscreened, domestic sanitary sewage. Pumps shall have 10" suction connection, and 10" discharge connection. Pumps shall be Gorman-Rupp model T10A-B. Each pump shall be selected to perform under following operating conditions:

ITEM
ONE
PUMP

TWO PUMPS

IN PARALLEL
Primary Design Point - Capacity (Gpm) 1,800 3,500
Primary Design Point - Total Dynamic Head (Ft) 58 58
Shut Off Head (Ft) 85 85
Design Point 2 Reduced Speed – Capacity (Gpm) 1,600 -
Design Point 2 Reduced Speed – Total Dynamic Head (Ft) 33 - Design Point 3 – Capacity (Gpm) 2,900 4,500
Design Point 3 – Total Dynamic Head (Ft) 36 50
Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 12
ITEM
ONE
PUMP

TWO PUMPS

IN PARALLEL
Maximum Pump Speed (Rpm) 1,150 1,150
Total Dynamic Suction Lift (Ft) 16 16
Maximum Repriming Lift (Ft) 18 18
Maximum Static Suction Lift (Ft) 13.5 13.5
Total Discharge Static Head (Ft) 26.5 26.5
NPSHA (FT) 17 17
J. The following product design criteria, options and accessories are required for pump motors:

ITEM DESCRIPTION
Motors Motor Type Squirrel cage induction
Motor Horsepower
and rpm
Station 50 horsepower – 1800 rpm
Frequency 60 Hz / 60Hz maximum with VFD drive
Efficiency Premium Efficiency
Duty Continuous Duty
Drive V-belt drive
Temperature Rise NEMA Design B Rated for Operation at 50°C (122°F) Insulation Class F
Service Factor 1.15
Fill Air filled. Do not use oil filled motors
Overtemperature
Protection Motor
Windings
Provide automatic reset normally closed thermal
overloads in each phase of motor windings
Vibration
Transducer
Provide vibration transducer that provide vibration
alarm and shutdown contacts when the pump/motor
vibration exceed setpoint limits
Other
Requirements
Insulate and brace windings for full voltage operation.

Motor nameplate horsepower shall not be exceeded
anywhere on pump curve without notice given in
submittal.

Dynamic balancing Dynamically balance, test and ship pumps and motors as a unit.

Motor
Bearings
Bearing Life ANSI/ABMA 9 L10 of 100,000 hours
Lubrication Grease lubricated, prelubricated at factory Bracing Brace and lock bearings to prevent shaft movement Motor
Enclosure
Enclosure Watertight
Material Cast iron
Lifting Eye Include lifting eye of adequate strength to lift entire Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 13

ITEM DESCRIPTION
pump and motor assembly
Motor
Blower
Contract Documents are based on pump Manufacturer not requiring blower to increase heat exchange efficiency.

If motor manufacturer recommends blower be provided for each pump motor, submit proposed revisions to drawings to accommodate blowers in accordance with shop drawing requirements described above.

Where blower and appurtenant work is required by motor Manufacturer, provide at no additional cost to Owner.

K. Motors on VFD-driven pumps shall be compatible with VFD drives throughout expected range of operating speeds.

L. The following product design criteria, options and accessories are required for pump v-belt drives:

ITEM DESCRIPTION
V-belt Drive
Transmission
Number of V-belts 2 minimum
Minimum combined
safety factor

1.5 Speed ratio As needed to achieve pump operating conditions.

Submit calculations as described under
Submittals above.

Guard Cover over Rotating
Parts
Fabricated sheet steel
Guards must be completely removal without
interference from any unit component, and shall
be securely fastened and braced to unit base
Metal to be free from burrs and sharp edges.

Cover Fastening Guards must be completely removal without interference from any unit component, and shall
be securely fastened and braced to unit base
Structural joints shall be continuously welded.

Rivet spacing on panels shall not exceed 5”. Tack
welds shall not exceed 4” spacing.

Finish Finished with one coat gray W.R. non-lift primer and one coat orange acrylic alkyd W.R. enamel in
accordance with section 3, Color Definitions of
ANSI 253.1; Safety Color Code for Marking
Physical Hazards.

M. Paint pumps per Section 09 90 00.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install pumps before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

B. Before shipping, check motor and control data plates for compatibility to site voltage. Install and test station ground prior to connecting line voltage to station control panel.

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 14

3.2 Installation
A. Refer to Section 02 05 00 for basic execution and installation requirements.

B. Furnish and install pumps and motors at location shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire, plumbing and electrical code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Pumps shall be furnished and installed by Contractor at location shown on Plans and Submittals.

F. Install pumps to tolerances recommended by Manufacturer. Unless otherwise shown, install pumps true and level using precision gauges and levels.

G. Install, level, align, and lubricate pump station as indicated on project drawings. Installation must be in accordance with written instructions supplied by Manufacturer at time of delivery.

H. Suction pipe connections including fasteners at pipe connections shall be vacuum tight.

I. Install pipe with supports and thrust blocks to prevent strain and vibration on pump station piping.

J. Install and secure service lines (level control, air release valve or pump drain lines) as required in wet well.

K. Verify motor and control data plates for compatibility to site voltage. Install and test station ground prior to connecting line voltage to station control panel.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Pumps Self-Priming
Capability
Remove suction check
valves and test with clean
water. Tests shall be
witnessed by and certified
by pump supplier’s factory
authorized representative
5 successive
reprime
cycles each
pump
Contractor Contractor
Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 15

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
6-hour Field
Performance
Test to
Demonstrate
Compliance to
Contract
Documents
and
Manufacturer’s
Printed
Literature
Hydraulic Institute
Standards. Tests shall be
witnessed by pump
supplier’s factory
authorized representative
who shall certify that
installed pumping system
complies with Contract
Documents and
Manufacturer’s warranty
requirements and that no
drive equipment is
overloaded.

One 6-hour
test each
pump
Contractor
(including
test water)
Contractor
72-hour
System
Demonstration
Refer to Section 01 79 00
6-hour field performance
tests may be part of 72-
hour system
demonstration.
1 for pumping
system
Contractor Contractor
Installation,
Noise,
Vibration,
Odors, Heat
and Leakage
Visual inspection of
finished installation
1 inspection Owner Contractor
Running
Amperage
Record amperage draw
and compare to rated
motor FLC
1 test Contractor Contractor
11-month
Warranty
Inspection
Demonstrate compliance
to Contract Documents
and Manufacturer’s printed
Literature
1 test Owner Contractor
35-month
Warranty
Inspection
Demonstrate compliance
to Contract Documents
and Manufacturer’s printed
Literature
1 test Owner Contractor
B. Provide services of factory authorized Manufacturer’s representative on-site to witness and inspect startup of pump operation. Before startup, check equipment for proper lubrication, alignment, rotation, freedom from excessive vibration. Factory authorized Manufacturer’s representative shall notify Contractor and Owner of irregularities of installation which might render Manufacturer’s warrantee null and void.

C. Conduct field performance test in presence of Owner’s Representative and Owner’s personnel after at least 24 hours of field operation have occurred to burn in system.

D. If field performance tests show excessive vibration or fail to demonstrate compliance with requirements of Contract Documents or certified curves furnished, Owner shall have right to either:

Project Owner SELF-PRIMING PUMPS
New River Improvement Project – Calexico 33 32 30 - 16

1. Decline acceptance of failing pumps and require Contractor to replace them or

2. Deduct agreed upon allowance for Owner’s incremental cost of additional power from payment due Contractor.

3.4 Field Training of Owner’s Personnel
A. In addition to above, provide services of pump Manufacturer’s factory-authorized representative on-site for at least 8 man-hours (travel time excluded) to provide classroom instruction of Owner’s personnel in proper recommended lubrication, operation and maintenance procedures as well as procedures for proper lockout out of each energy sources.

B. The following handouts shall be provided by Manufacturer’s factory-authorized representative to attendees during classroom instruction:

1. Listing of actions (or inactions) by Owner which would render Manufacturer’s warranty null and void.

2. Written description of proper lubrication procedures.

3. Written list of required scheduled maintenance including recommended service intervals to ensure warrantee remains valid and to ensure equipment remains functional.

4. Written description of procedures for lockout of each energy source.

3.5 Spare Parts
A. Furnish the following spare parts:

QUANTITY PART
3 Pump mechanical seal (complete with shaft sleeve).
6 Cover Plate O-rings
6 Rotating assembly O-rings
3 Set impeller clearance adjustment shims
3 Extra fuse of any type used
1 each pump Duplicate nameplate

END OF SECTION
Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 1
SECTION 33 42 19

CENTRIFUGALLY CAST FIBERGLASS-REINFORCED POLYMER MORTAR (CCFRPM) PIPE PART 1 - GENERAL

1.1 Work Included
A. Materials and installation of centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe and riser sections (manholes) per the Plans.

1.3 System Description
A. Furnish and install centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe and 48-inch diameter riser sections as shown on Plans including appurtenant fittings and connections in conformance with Manufacturer’s installation requirements and in compliance with applicable construction safety codes and standards.

B. Owner or Owner’s Representative shall be entitled to inspect pipes and witness manufacturing process and shall be given a minimum of a 21-day notice.

C. Factory testing of centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR

OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Centrifugally
Cast
FiberglassReinforced
Polymer
Mortar
(CCFRPM)
Gravity Pipe
7”-144”
AWWA
C950
Verification
Testing
AWWA C950
Section 5
Verification
Per AWWA
C950
Contractor Contractor
Hydrostatic
Leak Test
ASTM D3754 or
AWWA C950
Section 5
Verification and
Table 7
All pipe,
couplings and
fittings
Contractor Contractor
Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 2

ITEM TEST FOR

TEST STANDARD
(ASTM OR

OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Stiffness
Test
AWWA C950
Section 5
Verification and
Tables 8 and 9
Per AWWA
C950
1 pipe for
each 100
lengths
Contractor Contractor
Hoop
Tensile
Strength
AWWA C950
Section 5
Verification and
Table 10
Per AWWA
C950
1 pipe for
each 100
lengths
Contractor Contractor
Axial
Tensile
Strength
AWWA C950
Section 5
Verification and
Table 11
Per AWWA
C950
1 pipe for
each 100
lengths
Contractor Contractor
Beam
Strength
AWWA C950
Section 5
Verification and
Table 12 and 13
Per AWWA
C950
1 pipe for
each 100
lengths
Contractor Contractor
D. Delivered pipe and risers shall be homogeneous throughout, uniform in color, free from cracks, holes, delaminations, foreign inclusions, blisters, or other defects of such nature, degree or extent that in Owner’s Representative’s opinion the serviceability and performance of the constructed pipe might be compromised.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings (Including ratings for Class 150, 300, 400, 600, 900, 1500, and 2500)

2. ASTM D3754 ‘Fiberglass’ (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer and Industrial Pressure Pipe 8”-144”

3. ASTM D3567 Determining Dimensions of ‘Fiberglass’ (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Fittings

4. ASTM D3268 Chemical Resistance of ‘Fiberglass’ (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition

5. ASTM D4161 “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric Seals

6. ASTM D2412 External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

7. ASTM F477 Elastomeric Seals (Gaskets) for Joining Plastic Pipe

8. AWWA C950 Fiberglass Pressure Pipe 1”-156”
Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 3

1.6 Submittals
A. Furnish the following submittals:

SUBMITTAL DESCRIPTION
Line Layout Submit per piping Shop Drawing requirements.

Include legible plan and profile diagram of pipe lay diagram , layout schedule, fabrication details and dimensional checks.

Layout schedule shall show order of installation, length and location of each pipe section and special, station and elevation of pipe invert at all changes in grade, and all data on curves and bends for both horizontal and vertical alignment.

Layout schedule to include locations of all tee bases for 48-inch diameter risers (manholes) and identify riser segments if not homogeneous. SN ratings of risers to be the same as the 72-inch diameter pipe.

Do not manufacture pipe until shop drawings are approved.

Product Data Submit per Product Data requirements.

Submit for pipe, couplings, fittings, and gaskets.

Certificate of
Compliance
Submit per certificate of compliance requirements.

Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Product Data and Certificates of Compliance.

1.7 Delivery, Storage and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of plastic pipe and fittings.

A. Use proper care to prevent damage in transporting, handling, and placing pipe.

1. Unload pipe by mechanical means such as crane, backhoe or forklift, or by textile slings and skids, as recommended by Manufacturer.

2. In using skids, prevent pipes from striking other pipe.

3. Do not drop pipe from truck.

4. Do not use chains or cables.

5. Contractor shall secure a proper staging area, on City-owned property, and secure pipe and materials. Multiple staging areas along the pipe may be utilized with the City’s permission to minimize handling of the pipe. Contractor shall properly protect all materials delivered to the site.

1.8 Unit Prices Bid Items 33 42 19 – Centrifugally Cast Fiberglass-Reinforced Polymer Mortar (CCFRPM) Pipe
A. Refer to Section 01 22 00 for measurement and payment clauses for centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe and fittings.

Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 4
PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers include:

ITEM MANUFACTURER

MANUFACTURER

LOCATION
CCFRPM Pipe and Fittings
Centrifugally Cast
FiberglassReinforced Polymer
Mortar (CCFRPM)
Pipe 8”-144”
Flowtite (Thompson Pipe
Group)
Rialto, CA (909) 822-0200
HOBAS Pipe USA, Inc. Houston, TX (800) 856-7473
Accepted equal
Identification Tape
Buried Pipe
Identification Tape
Refer to Section 33 05 26

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

B. Flows from the New River will be conveyed by this piping system.

C. Materials for centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Centrifugally
Cast
FiberglassReinforced
Polymer
Mortar
(CCFRPM)
Pipe and
Fittings 8”-
144”
Manufacturing
Standards
Conform to ASTM D3754 for force mains
Design Standards Conform to AWWA M45
Material Type Centrifugally-Cast Fiberglass-Reinforced
Polymer Mortar Pipe - Type I, Liner 2 Grade 3
per ASTM D3754 rated for pressure sewer
service
Markings Mark pipe at 5-foot maximum intervals.

Show Manufacturer or trademark.

Mark ASTM or AWWA standard complied with.

Show type and grade of pipe and liner
Show design pressure
Show nominal pipe diameter.

Show stiffness number or SN, SN 72 min.

Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 5

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Show coded number identifying plant,
machine, date and shift on which pipe was
extruded.

Show proper location of pipe or special by
reference to layout schedule
Size As shown on Plans
Pressure Class (PN) 50 PSI
Minimum Wall
Thickness

1.59 inches
Maximum Long-Term
Deflection
5% of Diameter
Wall Thickness As required to conform to pressure class Standard Lengths 20’ with tolerance of +1” or -4” unless otherwise specified or required for bends or
special joints
Short pipe lengths for small radii curves and
short pits shall be nominal sections of 10’ or
other even division of 20’.

Furnish at least 85% of total footage of each
size and class of pipe, excluding special order
lengths, in standard length sections.

Pipe Ends Square to pipe axis with maximum tolerance of ±¼” or 0.5% of nominal diameter, whichever is
greater
D. Resin additives such as curing agents, pigments, dyes, fillers, thixotropic agents, etc., when used, shall not detrimentally affect performance of pipe and fittings.

E. Materials for centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe joints and couplings shall be:

MATERIAL/

COMPONENT

STANDARDS/

CHARACTERISTICS SPECIFICATION/REQUIREMENT
Joints FWC Coupling Meet performance requirements of ASTM D4161 (Rated for 2 X Class Pressure)
Pressure Rating 50 PSI
Gaskets Material Conform to ASTM F477
Nitrile (NBR)
Gasket Age <180 days old
Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 6
F. Flanges, elbows, reducers, tees, wyes, laterals, and other fittings shall be capable of withstanding operating conditions of pipe. Fittings may be contact molded or manufactured from mitered sections of pipe joined by glass-fiber-reinforced overlays.

G. At time of manufacture, each lot of pipe and fittings shall be tested and inspected for defects.

Pipes shall be capable of withstanding test pressure of twice maximum rated pressure without leaking or cracking.

H. The following product design criteria, options and accessories are required:

ITEM DESCRIPTION
Design Criteria Loading H-20 (32k axle 16k wheel load)
Depth of Soil Cover Refer to Plans
I. Refer to Section 33 05 26 for requirements for identification, identification tape and warning tape for buried centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe.

PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pressure pipe and fittings before submitting shop drawings or ordering.

Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

B. Prior to installing pipe, grade and prepare trench bottom to provide uniform bearing throughout entire length of each joint of pipe. Dig bell holes of ample dimension in trench bottom at locations of each joint to facilitate joining. Form flat or semi-circular trench bottom conforming to grade to which pipe is to be installed.

C. Dewater trench so trench bottom and bedding material are dry.

D. Prior to installing pipe, a registered geotechnical engineer shall certify that the trench subgrade and bedding is suitable for pipe installation.

E. Minimum trench width at crown of pipe shall be per Plans.

3.2 Installation
A. Refer to Sections 01 73 33 / 02 05 00 for basic execution and installation requirements.

B. Refer to Section 31 23 00 / 31 23 33 for open trench requirements.

C. Furnish and install pipe and risers at locations shown on Plans and Submittals.

D. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable plumbing and mechanical code requirements

3. Manufacturer’s installation and warranty requirements E. Refer variances between above documents and Contract Documents to Owner’s Representative.

F. Pipe Joining:

1. Connect joints in accordance with pipe Manufacturer’s recommendations. Thoroughly clean ends of pipe and couplings.

2. Apply joint lubricant to pipe ends and elastomeric seals of couplings. Use only lubricants approved by pipe Manufacturer.

Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 7

3. Allowable joint deflections for joints shall not exceed 50% of Manufacturer’s recommendation.

4. Connection of centrifugally cast fiberglass-reinforced polymer mortar (CCFRPM) pipe to manways, access structures and the like shall be water-tight.

5. Place warning tape over pipe per Section 33 05 33 for “River Pipeline” and the plans.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Leakage
and
Infiltration
No leakage nor
infiltration will be
accepted (0 gpm).

All pipe &
joints
Contractor Contractor
Individual
Joint
Testing
Each joint shall be
individually pressure
tested with air with a
portable tester to 5
psi maximum.

All joints Contractor Contractor
Closed
Circuit
Television
Inspection
Complete video log
or closed circuit
television inspection
following hydrostatic
or leakage test
All pipe Owner Contractor
11-Month
Warranty
Inspection
Demonstrate
compliance to
Contract Documents
and Manufacturers
printed Literature
1 test Owner Contractor
B. Individual joint testing shall be conducted as follows. Each joint shall be individually air tested to a maximum of 5 psi. Once pressure stabilizes at 3 psi minimum, test shall commence for 5 minutes minimum with no drop in pressure. If joint fails to hold minimum pressure for 5 minutes, Contractor shall remedy and re-test as necessary.

3.4 Cleaning
A. Before testing, thoroughly clean each pipe to remove trash, debris, soil, and other foreign objects from pipe. Remove debris and trash from each manway.

3.5 Protection
A. Protect installed pipe during removal of tunnel access shafts, sheeting, shoring, hoses, and other equipment and machinery used during installation of pipe and backfill and compaction operations.

B. When pipe laying is not in progress, and during noon hour and overnight, close open end of pipe with tight-fitting cap or plug to prevent entrance of foreign matter into pipe.

C. Do not use pipeline to drain water that has infiltrated into trench.

D. Maintain inside of pipe free from foreign materials and in clean and sanitary condition until acceptance by Owner.

Project Owner CCFRPM PIPE
New River Improvement Project – Calexico 33 42 19 - 8

END OF SECTION

THIS PAGE INTENTIONALLY BLANK
Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 1
SECTION 40 63 43
PROGRAMMABLE LOGIC CONTROLLERS (PLCs), PUMP CONTROLLER AND SCADA RTU PART 1 - GENERAL

1.1 Work Included
A. Materials, installation and testing of pump controllers, and SCADA RTU (Remote Terminal Unit)
B. The Trash Screen PLC shall be programmed by the Trash Screen manufacturer for interface with SCADA RTU as shown on the SCADA Termination Panel wiring diagram. All as-built PLC, HMI and controller application programs shall be delivered to the customer in the DVD format.

C. The Pump Back System pump controller shall be programmed to control the pumps and the pump station status signals will be sent to the SCADA RTU as shown on the pump control panel wiring diagram and the SCADA Termination Panel wiring diagram.

D. The SCADA RTUs will be programmed and configured by Mission Communication Company.

1.2 Related Work
A. Section 01 01 02: Sequence of Operation
B. Section 01 22 00: Unit Prices
C. Section 01 33 00: Submittal Procedures
D. Section 01 40 00: Quality Requirements
E. Section 01 61 00: Common Product Requirements
F. Section 01 64 50: System Integrators
G. Section 01 66 00: Product Storage and Handling Requirements H. Section 02 05 00: Basic Civil Engineering Requirements I. Section 26 05 10: Common Work Results for Electrical J. Section 26 05 19: Low-Voltage Electrical Power Conductors and Cables K. Section 27 13 23 Outdoor Fiber-Optic Cable Systems
L. Section 40 67 00: Control System Equipment Panels and Racks

1.3 System Description
A. Provide new PLC hardware, software, and PLC programming to provide fully functional SCADA system.

B. Provide PLC, including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and applicable codes and standards.

C. Provide necessary PLC parts to provide complete operating system, including I/O (analog and discrete), communications and interface modules, bases, power supply, adapters, software, programming cable, and other cabling and hardware as needed to provide fully functioning system conforming to Contract Documents.

D. Provide PLC programming for new equipment as required to implement process control logic.

E. Provide the pump controller, the SCADA RTU per the plan and specification.

F. Provide comprehensive documentation of the program logic for all PLCs, RTUs and controllers, as required in Section 3.

Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 2
G. Logic Configuration shall be:

1. Logically set out in modular format to follow process flow.

2. Have analogs scaled to Owner units (e.g gpm, psi etc.) and annotate with units where used in program.

3. Be designed so after power loss and subsequent power restore to processor, or program recompile, setpoints and presets maintain values in effect prior to power loss or program recompile.

1.4 Quality Assurance
A. Use adequate numbers of skilled workers trained and experienced in necessary trades and crafts and completely familiar with specified requirements and methods for proper performance of Work of this section.

B. Factory testing shall include:

ITEM
TEST
FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Programmable
Logic
Controllers,
Pump
Controller and
SCADA RTUs
Operatio
n
Demonstrate
compliance to
Contract
Documents and
Manufacturer’s
printed literature
1 test each
PLC, Pump
Controller and

SCADA RTU
Contractor Contractor
C. Equipment shall be UL listed.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. NEMA/ANSI 250 Enclosures for Electrical Equipment

2. NFPA 70 National Electric Code (NEC)

1.6 Submittals
A. Furnish the following submittals with bid or within 72 hours following bid opening. Failure to submit required information on time will cause bid to be considered non-responsive and rejected.

SUBMITTAL DESCRIPTION
Equipment
Qualifications
Submit documentary evidence of 3 California installations where equipment has been in satisfactory operation for at least 5 years.

Programming
Subcontractor
Qualifications
Submit documentary evidence subcontractor has been in business in California for at least 5 years
Submit name of proposed onsite foreman along with documentary evidence proposed onsite foreman has worked in such capacity in employ of subcontractor at least 3 years and has completed at least 3 installations of product.

Submit evidence of subcontractor’s factory authorization by product Manufacturer to install product
Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 3
B. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop
Drawings
Submit for PLC, Pump Controller and SCADA RTU under electrically controlled equipment Shop Drawing requirements.

Prior to factory test, submit updated PLC, Pump Controller and SCADA RTU Input/Output List
Prior to factory test, submit comprehensively annotated PLC, Pump Controller and SCADA RTU logic diagrams
Submit color hardcopies of HMI graphics developed by System Integrator for this project, including pop-up windows. Prior to animation, submit sketches of proposed screens to Owner for acceptance.

Incorporate comments and submit revised sketches.

Product Data Submit for hardware and software products per Product Data requirements.

Factory Test
Record
Transcripts
Submit for factory tests per Test Record Transcript requirements.

O & M
Instructions,
PLC, Pump
Controller and

SCADA RTU
Program
Descriptions,
and Logic
Documentation
Submit per Operation and Maintenance Instruction requirements O&M manuals shall be organized by tabs for hard copies, and organized by bookmarks for electronic PDF books.

Provide equipment manuals and annotated PLC programming code.

Submit preliminary copy of documentation with factory test procedure submittal.

Logic documentation shall maximize use of documentation facilities integrated into concept programming environment.

Use mnemonic signal and variable names reflecting signal or variable function.

Make use of allowable number of characters in signals and variables to facilitate understanding by Owner’s personnel.

Provide title and short English description at start of each strategy explaining purpose and function of logic that follows
For each subsection of logic within strategies, provide annotation explaining to another programmer function of logic to help user understand intent of logic.

Provide title, revision number, date, and page number on every page of logic documentation.

Submit both hard and electronic Record Drawing documentation with final O&M Manual submittal.

Original Disks
and Software
Backups
Submit original disks or similar hard media for standard Manufacturer’s software supplied.

Submit electronic back-up copies of all “Record Drawing” software configured by PCS system integrator.

Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 4

SUBMITTAL DESCRIPTION
Submit record of device hardware/software configuration settings, including IP addresses used.

Software
License
Provide non-exclusive, fully paid perpetual license naming Owner as authorized to use software furnished.

Software and licensing shall become Owner’s property, including configuration and application programming software, developer keys, PLC programming code and logic (including source code files), and OIU software and program files.

Provide unlimited license for application software developed or configured by system integrator or PCS subcontractor. License shall grant Owner right to:

Use, duplicate, and modify software in any manner in whole or in part Use software in any quantity with any equipment type and for any purpose
Make back-up copies of all software.

Software
Updates
Provide Owner with free software updates and technical support for Manufacturer’s furnished software for duration of warranty period.

Upgrades and patches shall be installed by PCS integrator. Schedule upgrades with Owner.

PCS Integrator shall test system after upgrade.

Warranty Furnish one year warranty from date of final acceptance.

C. Refer to Section 01 33 00 for definition of requirements for Shop Drawings, Product Data, O&M instructions, and Factory Test Record Transcripts.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of programmable logic controllers.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for programmable logic controllers.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Programmable
Logic Controller
Including I/O
Modules
Allen-Bradley / Rockwell Automation
SLC 5
Milwaukee, WI (414) 382-2000
No Exceptions
Programming
Software
Allen-Bradley / Rockwell Automation Milwaukee, WI (414) 382-2000 No Exceptions
Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 5

ITEM MANUFACTURER MANUFACTURER LOCATION
Pump Controller Motor Protection Electronics, Inc. Apopka, FL (407) 299-3825 SCADA RTU Mission Communication (877) 993-1911
B. Equipment furnished shall operate through its full operating range powered by amperages specified or shown on Plans. Equipment requiring larger amperage than specified or shown is unacceptable, absent written statement from Owner electrical infrastructure and switchgear can support increased amperage.

2.2 Materials
A. Refer to Section 01 61 00 for basic requirements for products and materials.

B. Materials for programmable logic controllers shall be:

ITEM MATERIAL SPECIFICATION
PLC Compact Logix Per Trash Screen Manufacturer
Pump
Controller
SC2000 3 analog outputs, triplex controller, variable speed control, door mounted with gasket.

SCADA RTU Model M850 Nema 1, indoor, wall mounting with 8 points DI expansion module and 4 points AI expansion module.

C. The following product design criteria, options and accessories are required:

ITEM DESCRIPTION
Environment Field Temperature Range 34°F-120°F
Equipment Temperature Rating 0°F-185°F
Humidity 0-95% non-condensing
Lightning Protection Provide on-board lightning protection with on-board spare fuses.

Physical and
Displays
Front Panel Status Indication
DIN Rail Mountable
RAM ≥ 512 MB
Flash Memory ≥ 64 GB
PLC Processor Speed ≥ 1 GHz
PLC I/O Base Provide bases matched to I/O
module complete with fuse protection
A. The following electrical design criteria are required for equipment specified in this section:

ITEM DESCRIPTION
Electrical Work NEC Article 505
Classification
Nonhazardous
Enclosures – Indoor
Dry Locations
NEMA 250 Enclosure
Rating
NEMA 12 – Industrial Use
Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 6

ITEM DESCRIPTION
Enclosures – Indoor
Damp Locations
NEMA 250 Enclosure
Rating
NEMA 12 – Industrial Use
Enclosures – Outdoor
or Wet Locations
NEMA 250 Enclosure
Rating
NEMA 4X – Watertight, CorrosionResistant, Stainless steel Enclosures – Class I
Division 2 Dry Well
Locations
NEMA 250 Enclosure
Rating
NEMA 7 – Explosion Proof, Rated for
Class I Locations
Enclosures Construction Lockable
With powdercoat epoxy finish on steel
surfaces
Color ANSI 49 gray
Power Supply PLC As shown on plans
Battery Backup Required
Instruments As shown on plans
PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install programmable logic controllers before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

B. Examine areas and conditions under which Work of this section will be performed. Correct conditions detrimental to timely and proper completion of Work.

C. Provide onsite engineering assessments and evaluations of each remote site to design new PLC control panels for direct replacement of existing PLC control panels. This includes identifying and engineering required power requirements, I/O assignments, and control panel layouts/dimensions as needed.

3.2 Installation
A. Refer to Section 01 73 00 for basic execution and installation requirements.

B. PCS Integrator shall program PLC such that it will communicate as specified with both local and Central HMI.

C. Furnish and install programmable logic controllers at locations shown on Plans and Submittals.

D. The following installation standards shall be followed:

1. Applicable OSHA regulations.

2. Other applicable electrical code requirements

3. Manufacturer’s installation and warranty requirements E. Refer variances between above documents and Contract Documents to Owner’s Representative.

F. Provide close coordination with Owner to maintain operations during system cutover.

Coordinate site shutdowns with and obtain acceptance from Owner prior to bringing a site offline.

G. Connect field wiring as follows:

Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 7

1. Connect field wiring to field terminals. Do not connect field wires directly to PLC Input/Output modules.

2. Install wiring from PLC Input/Output modules to field terminals for spare module inputs and outputs.

H. Tune closed loop controllers as follows:

1. Tune PID controllers by adjusting proportional and integral gain parameters to provide a first over shoot of 10-15%, and to provide a short settling time.

2. Where cascade loops are used, tune innermost loop first, then loop outside it.

3. To provide stability ensure closed loop response of outer loops are 5 to 8 times slower than inner loops.

4. After final tuning each loop, document closed-loop response.

5. Provide trend graphs showing loop response to 5% change in setpoint, and 5% upset in controlled variable.

6. Provide title for each graphic and note tuning parameters used on each sheet.

7. Submit annotated loop response graphics with O&M Manual.

I. Programming logic shall be local to each PLC site.

1. Do not use master PLC control algorithms where one PLC exerts control over entire system.

2. Remote site PLCs shall be provide local control, even where Central PLC fails.

3. Shared signals amongst sites may not be available for process control if communications links fail. PLC program shall be able to select secondary process control variables available on site, (eg local pressures where reservoir level signals are lost) via operatorselected setpoint and/or automatic selection. Automatic control selection shall have enable/disable setpoints to prevent automatic swap or selection of process control variable.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
PLCs Installation Visual inspection of finished
installation
1 inspection Owner Owner
HMI
Demonstration
Test
Demonstrate local HMI
communicates with PLC, and
PLC updates HMI with current
operational values
Conduct programming
workshops with Owner to
ensure control logic, operations
scheme, sequence algorithms,
control loops, and
programming (PLC and
SCADA) are captured and
programmed into system.

Programming efforts shall
1 test each
PLC
Contractor Contractor
Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 8

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
replicate existing operational
needs of each site, plus,
incorporate new
instrumentation signals and
controls. Programming shall
also account for wireless I/O
signals (via I/O interface or
radio interface) for nearby sites
requiring signal interface tie-in
into system or tail-end link I/O
signals.

Communications
Demonstration
Test
Demonstrate radio
communication between site
and SCADA Central is
operational and reliable.

Owner personnel will lead test
with assistance of system
integrator and representative
from radio supplier.

Allow 8 hours for test and
provide qualified technician
familiar with PLC and HMI for
test duration.
1 test each
PLC
Contractor Contractor
Field
Performance
Demonstrate Work conforms to
Contract Documents and
Manufacturer’s printed
literature
1 test each
PLC
Contractor Contractor
11-month
Warranty
Inspection
Confirm Work conforms to
Contract Documents and
Manufacturer’s printed
literature
1 test each
PLC
Owner Contractor
B. Provide services of factory-authorized representative on-site for at least 2 man-days (travel time excluded) to provide:

1. Installation assistance, inspection and turn-key startup of complete programmable logic controller and SCADA system, including upgrades to existing systems and new hardware and software.

2. Field integration, point testing, demonstration testing and adjustment.

3. Instruction of Owner’s personnel in operation and maintenance.

Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 9

3.4 Spare Parts
A. Furnish the following spare parts:

QUANTITY PART
1 PLC module/base for each type PLC module furnished. Include power supply, processor, and communications cards.
1 Spare PLC I/O points of each type installed in cabinet.

END OF SECTION

Project Owner PROGRAMMABLE LOGIC CONTROLLERS
New River Improvement Project – Calexico 40 63 43 - 10

THIS PAGE INTENTIONALLY BLANK
Project Owner CONTROL SYSTEM EQUIPMENT, PANELS, AND RACKS New River Improvement Project – Calexico 40 67 00 - 1
SECTION 40 67 00

CONTROL SYSTEM EQUIPMENT PANELS AND RACKS
PART 1 - GENERAL

1.1 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 01 73 24: Seismic Restraint
F. Section 26 05 10: Common Work Results for Electrical G. Section 26 05 19: Low-Voltage Electrical Power Conductors and Cables H. Section 26 05 26: Grounding and Bonding for Electrical Systems I. Section 26 05 33: Raceway and Boxes for Electrical Systems J. Section 26 05 47: Cabinets and Enclosures
K. Section 26 08 00: Commissioning of Electrical Systems L. Section 26 27 26: Wiring Devices
M. Section 40 63 43: Programmable Logic Controllers
N. Section 40 90 20: Control System Descriptions

1.2 Description
A. Work Included: This Section covers control panels shown on Electrical or Instrumentation Drawings, or as specified in either Division 16 or 17, and sets standards for packaged unit panels.

1.3 Reference Standards
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. NEMA ICS 1 General Standards for Industrial Controls and Systems.

2. NEMA ICS 2 Standards for Industrial Control Devices, Controllers and Assemblies.

3. NEMA ICS 4 Terminal Blocks for Industrial Control Equipment and Systems.

4. NEMA ICS 6 Enclosures for Industrial Controls and Systems.

5. UL508 Industrial Control Equipment

1.4 Submittals
A. Furnish Control System Hardware Submit in accordance with Section 26 05 47.

B. Technical Manuals: Submit technical manuals specified in Section 26 05 47.

1.5 Certification
A. UL Label:

1. Each control panel and terminal cabinet shall bear UL label except as noted in following paragraph. UL label shall apply to enclosure, specific equipment supplied with enclosure, and installation and wiring of equipment within and on enclosure. If required for UL labeling, provide ground fault interrupters, isolation transformers, fuses, and other Project Owner CONTROL SYSTEM EQUIPMENT, PANELS, AND RACKS New River Improvement Project – Calexico 40 67 00 - 2
necessary equipment, even though such equipment is not indicated on Drawings.

Fabricator shall be an accepted UL listed manufacturer.

2. Control panel enclosures containing instruments mounted through enclosure walls or door shall meet requirements for UL labeling as above, but no UL label is required. This exception applies only if UL Recognized instruments for intended purpose are not made.

1.6 Product Delivery and Handling
A. Ship assembled control panels in sections that facilitate handling and field installation.

PART 2 - PRODUCTS

2.1 General
A. Environmental Suitability:

1. Ventilation shall be provided to prevent internal panel temperatures from exceeding 105°F.

Provide heat calculations for each control panel to determine cooling requirements.

2. Provide louvers near bottom and top of door. 80-mesh screens shall cover insides of louvers.

3. Provide thermostatically controlled fan in each enclosure when louvers cannot dissipate heat or cause sufficient flow to panel areas. Ventilation fans shall be low acoustic type suitable for control rooms. Provide removable cleanable or disposable dust filter for each remote site enclosure.

B. Control panel controls shall be 120VAC. Control conductors shall be provided in accordance with indicated requirements.

C. Safety Requirements: Arrange electrical supply to each control panel to be disconnected by a local 15-amp thermal magnetic circuit breaker, except for necessary foreign circuits. Isolate sources of foreign voltage by providing disconnecting or pull-apart terminal blocks or disconnect operable from control panel front. Each control panel shall be provided with identified terminal strips for connection of external conductors. Provide sufficient terminal blocks to connect 25% additional conductors for future use.

D. Discrete outputs from control panel shall be provided by electrically isolated contacts rated for 5 amps at 120VAC. Analog inputs and outputs shall be isolated 4-20 mA signals with power supply.

E. Mount nameplate on outside of door of enclosure as shown.

F. Clean and sandblast control panels per SSPC-SP-6 (Commercial Blast) after which surfaces shall receive prime coat Amercoat 185 or accepted equal, 3-mils DFT, for total thickness of prime plus finish system of 6 mils. Finished color of outside surfaces shall be selected by Owner’s Representative, unless otherwise indicated. Interior of control panel, back-panel, and side-panels shall have white finish coat.

2.2 Control Panel Materials
A. The following requirements apply to front and rear face of panel, both sides and edges of flanges, and periphery of holes or cut-outs.

1. Grind high spots, butts, and rough spots smooth.

2. Sand or sandblast surfaces to smooth, clean bright finish.

3. Remove traces of oil with solvent.

4. Apply first primer coat immediately.

B. Structural shapes and strap steel shall conform to ASTM A283 – Low and Intermediate Tensile Strength Carbon Steel Plates, Grade C.

Project Owner CONTROL SYSTEM EQUIPMENT, PANELS, AND RACKS New River Improvement Project – Calexico 40 67 00 - 3

1. Bolting Material: Commercial quality carbon steel bolts, nuts, and washers shall be ½” diameter with UNC threads. Use carriage bolts for attaching end plates. Remaining bolts shall be hex end machine bolts. Nuts shall be hot pressed hex, American Standard, heavy.

Use standard wrought washers for foundation bolts and attachments to building structures.

Other bolted joints shall have SAE standard lock washers.

C. Panels shall be of sufficient size to enclose instruments designated as “panel-mounted” plus ample interior clearance to allow for installation, general servicing, and maintenance of instruments. Elevations and horizontal spacing shall be subject to Owner’s Representative’s acceptance.

2.3 Control Panel Electrical Requirements
A. Wiring Duct: Wiring duct shall be manufactured of Noryl and shall be of restricted slot design, white in color. Panduit or accepted equal. Size shall be based on actual wiring requirements.

Duct shall be cut for precision fit. Covers shall be accessible. Analog signals shall be run in separate ducts.

B. Cable Ties: Cable ties shall be self-locking with stainless steel locking cables. Do not use adhesive backed type mounting bases.

C. Terminal Blocks: Terminal blocks shall be DIN rail mounted, 20A, and 300VAC. Terminals shall be complete with marking tags. Terminals shall be ABB (Entrelec) Series MA 2,5/5; or equal.

D. Fuse Terminal Blocks: Fuse terminal blocks shall be same profile, but different color as feed through terminal blocks, and shall have blown fuse light indicator. Fuse terminal blocks shall be ABB (Entrelec) Series MA 4/8.SF, or equal.

E. Wiring Methods: Wiring methods and materials for panels shall conform to NEC requirements for General Purpose (no open wiring) unless otherwise shown.

F. Signal and Control Circuit Wiring:

1. Wire type and sizes: machine tool wire, UL-listed Type MTW, and shall be rated 600VAC.

Wires for instrument control circuits and alarm input circuits shall be #14 AWG. Other wires, including shielded cables, shall be #16 AWG minimum.

2. Wire Insulation Refer to Section 26 05 19 for insulation colors.

3. Signal Cable – Non Computer Use:
a. Signal wire shall be twisted pair or triads in conduit or troughs. Cable shall be constructed of #18 AWG copper signal wires with THWN or THHN insulation. b. Provide copper drain wire for bundle with wrap of aluminum polyester shield. Overall bundle jacket shall be PVC.

4. Industrial Ethernet Cable:
a. Shielded (STP) Ethernet Cable shall be used to connect PLCs and radios to Industrial Ethernet Switches. Refer to Section 26 05 19 for requirements.

5. Wire Marking: Refer to Section 26 05 19 for wire marking requirements.

6. Flexible conduit is not acceptable except when accepted by Owner’s Representative in writing.

7. Conduit fittings shall be Crouse-Hinds cast fittings or accepted equal.

8. Panels shall be provided with 2 separate ground bars, one for power ground and one for signal ground. Provide ground bars with tapped holes to accommodate ground connections from various devices in panel. Provide insulator kit for signal ground bar.

Connect signal shield grounds within panel to signal ground bar. Suggested ground bar and insulator kit: Square D Part #PK12GT and #PKGTAB.

Project Owner CONTROL SYSTEM EQUIPMENT, PANELS, AND RACKS New River Improvement Project – Calexico 40 67 00 - 4

9. For case grounding, panel shall be provided with a ¼” by 1” copper ground bus complete with solderless connector for one #4 AWG bare stranded copper cable. Copper cable shall be provided by Contractor and connected to system ground loop.

G. Panel Lights and Receptacles: Panels shall be internally lighted by LED lamps, provided with guards and toggle switch located convenient to each access door. One duplex GFI type receptacle shall be provided in each panel section. Lights and receptacles shall be wired to outgoing terminal blocks for dedicated 120VAC, 60 Hertz, single-phase supply.

H. Power Supply Wiring:

1. Unless otherwise indicated, instruments and motor controls shall operate on 115VAC, 60 Hz circuits.

2. When instruments do not come equipped with integral fuses, provide fuses as required for protection of individual instruments against fault currents. Fuses shall be mounted on back of panel in fuse holder, and each fuse shall be identified by service name tag. Fuses shall be manufactured by Bussmann Manufacturing Division, Type KAW TRON or accepted equal.

I. 24VDC Power Supply: Panels shall be equipped with linear 24VDC power supply for driving current loops and other D.C. powered equipment. It shall be solidly mounted, labeled and located in plain view oriented for ease of maintenance. Unit shall be sized based on 200% of load requirements of equipment furnished. 24VDC power supply shall be manufactured by Power One or accepted equal.

J. DIN Rail Mount Circuit Breakers: Circuit breakers shall be 115VAC, single pole as manufactured by Allen Bradley Series 1492-CB1; or accepted equal.

K. Push Buttons, and Indicating Lights:

1. Push Button Contacts:
a. Provide one normally open and one normally closed contact. b. Type: Double break, silver contacts with moveable contact blade providing scrubbing action.
c. Type: Double break, silver contacts with moveable contact blade providing scrubbing action.

2. Uninterruptible Power Supplies: Powerware, or accepted equal.

2.4 Spare Parts
A. Submit necessary spare parts of components required to maintain system. Prior to final acceptance of work, provide spare parts listing of necessary spare parts and quantities for review by Owner’s Representative. Spare parts shall include, but not be limited to:

DESCRIPTION QUANTITY
24 VDC Power Supply 1
B. Deliver to Owner spare parts upon final acceptance of Work. Do not use spare parts as replacement parts during warranty period.

PART 3 - EXECUTION

3.1 Installation
A. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Electrical Code Article 409 “Industrial Control Panels” Project Owner CONTROL SYSTEM EQUIPMENT, PANELS, AND RACKS New River Improvement Project – Calexico 40 67 00 - 5

3. Other applicable building, fire and electrical code requirements

4. Manufacturer’s installation and warranty requirements B. Installation, testing, calibration, validation, startup and instruction shall conform to Section 40 90 10.

C. Install each control panel level and plumb, and secure per Section 01 73 24. Doors shall swing freely and close tightly.

D. Provide 3”-high concrete pad for each field-mounted, freestanding control panel. Provide 3 ½”-high I-beam kick panel for each control-room mounted, freestanding panel.

E. Repair damage to structure, components or finish to satisfaction of Owner’s Representative.

Clean nameplates.

F. Exercise care after installing control panels to keep out foreign matter, dust, dirt, debris, or moisture. Use protective sheet metal covers, canvas, heat lamps, etc., as needed to ensure equipment protection.

G. For metal panels mounted on concrete walls or floors, install ⅛” shims, and paint back sides and bottom of panels with Mobil Hi-Build Bituminous Coating 35-J-10; Koppers Bitumastic Super Tank Solution; or accepted equal. Film thickness shall be 10-mils minimum.

END OF SECTION
Project Owner CONTROL SYSTEM EQUIPMENT, PANELS, AND RACKS New River Improvement Project – Calexico 40 67 00 - 6

THIS PAGE INTENTIONALLY BLANK
Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 1
SECTION 40 71 13

MAGNETIC FLOW METERS
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of magnetic flow meters 12” and larger.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 02 05 00: Basic Civil Engineering Requirements F. Section 09 90 00: Painting and Coating
G. Section 09 96 56: Epoxy Linings and Coatings
H. Section 26 05 10: Common Work Results for Electrical I. Section 33 05 16: Precast Concrete Utility Structures J. Section 33 05 32: Flange Insulating Kits and Threaded Insulated Bushings K. Section 33 08 11: Pressure Testing and Flushing of Utilities L. Section 40 90 10: Common Work Results for Instrumentation and Control M. Section 40 90 20: Control System Descriptions

1.3 System Description
A. Electromagnetic-type flow instruments using Faraday’s law of induction to measure flow volume computed based on pipe’s diameter (i.e., Flowrate proportional to induced voltage).

Factory-calibrated transmitter.

B. Flow meters shall measure and transmit flow data for process record keeping, variable monitoring, and control.

C. Furnish and install complete operating flow meter including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building, plumbing, and electrical codes and standards.

D. Flow meter instrument output variables shall include:

ITEM VARIABLE DESCRIPTION
Output Signals (Analog) Rate of flow 4-20mA
Output Signals (Discrete) Rate of flow HART
Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 2

1.4 Quality Assurance
A. Factory testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Flow
Meter
Wet Calibration Hydraulic Institute
Standards
1 each meter Contractor Contractor
Interior
Lining
Holidays and
Lining Thickness
Refer to Section 09 96

56. 1 each meter Contractor Contractor
Meter Accuracy of Flow
Measurement
AWWA M6 as directed Contractor Contractor

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings (Including ratings for Class 150, 300, 400, 600, 900, 1500, and 2500)

2. AWWA C207 Steel Pipe Flanges for Waterworks Service

3. AWWA C213 Fusion-Bonded Epoxy Coating for Interior and Exterior of Steel Water Pipelines

4. AWWA C550 Protective Epoxy Interior Coatings for Valves and Hydrants

5. AWWA M6 Water Meters – Selection, Installation, Testing and Maintenance

6. NEMA/ANSI 250 Enclosures for Electrical Equipment

7. NFPA 70 National Electric Code

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit per pipeline equipment Shop Drawing requirements Submit for transducers under electrically controlled equipment Shop Drawing requirements
Product Data Submit per Product Data requirements
Show lining and coating data and thicknesses.

Installation
Instructions
Submit per Installation Instruction requirements
O & M Instructions Submit per Operation and Maintenance Instruction requirements Certificate of
Compliance
Submit certificate of factory testing for meter accuracy and capacity.

Test Record
Transcripts
Submit for factory tests per Test Record Transcript requirements.

Warranty Furnish 3-year warranty from date of final acceptance Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 3
B. Refer to Section 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, Certificates of Compliance, and Test Record Transcripts.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage and handling of magnetic flow meters.

1.8 Unit Prices Bid Item 40 71 13 – Magnetic Flow Meters A. Refer to Section 01 22 00 for measurement and payment clauses for magnetic flow meters.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers for in-plant magnetic flow meters include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Magnetic
Flow
Meters
ABB
McCrometer Inc. / Water Specialties
“Ultramag”
Hemet, CA (800) 220-2279
Rosemount Inc. / Emerson “Model
8705”
Chanhassen, MN (952) 906-8888
Tustin, CA (714) 832-1090
Sparling Instruments LLC. “Tigermag” El Monte, CA (800) 800-3569 Owner Standard - No Exceptions
Features Option Manufacturer’s Code
Process
Connection
Class 150 Carbon
Steel Flange ASME
B16.5
A1K
Electrodes Flush-Mounted

1.4435/316L
0 Calibration Flow 0.2% B
Operation
Language Display
English AA
Application
Package
Heartbeat
Verification +
Monitoring
EB
Firmware Version 01.00zz
EtherNet/IP
77 Marking 1xTAG-stainless
steel label
Z1
B. Flow indicators, totalizers, and transmitters, where shown shall be manufactured by same Manufacturer as flow sensing equipment and shall be fully compatible with equipment furnished.

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 4
B. Materials for magnetic flow meters shall be:

ITEM MATERIAL SPECIFICATION
Metering Tube
1”-12”
Cast Carbon Steel (for
pressures 0-400 psi)
Conform to ASTM A216 Grade WCB
Dimensions Laying Length Verify fit in available area
Electrodes Stainless Steel SAE Type 316L
Grounding
Ring
Stainless Steel SAE Type 316L
Flanges
Sizes 2½”-54”
Working
Pressures 0-
150 psi
Carbon Steel Conform to AWWA C207 Class D, or ANSI
/ASME 16.5 Class 150
Plain faced
Flange
Alignment
Meters Boltholes shall straddle horizontal and
vertical centerlines of meter.

Flange Bolts,
Nuts, and
Washers
Stainless Steel SAE Type 316
Flange
Gaskets

Liner Fusion-Bonded Epoxy Refer to Section 09 96 56.

Conform to AWWA C213 and C550 12 mil
minimum DFT
Do not coat bronze or stainless steel parts.

Exterior Finish
Coat
Epoxy Urethane Refer to Section 09 90 00.

Nameplate Stainless Steel SAE Type 316
Fabricated
Steel Spool
Spool Provide fabricated spool piece for
replacement of each flowtube size wherever
no bypass piping is provided.

C. The following product options and accessories are required:

ITEM DESCRIPTION
Meter Fluid Metered Treated Wastewater Effluent
Diameter See plans
Flow Range at
Rated Accuracy
Meter Size Recommended
Flow Range at
Rated Accuracy
(0.98fps-32.8fps)
Factory-Set
Flow Range
(0.13fps-8.20
fps)
12” meter 350-10,600 gpm 45-2,400 gpm
Turndown
Ratio
33 62.5
Repeatability ±0.1% of reading ±0.02 in/s
Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 5

ITEM DESCRIPTION
Accuracy within
Rated Flow Range
±0.5%
Calibration 2-point
Fluid Temperature
Range
32-90°F
Maximum Operating
Pressure
150 psi
Maximum Pressure
Drop
1 psi at 17 fps
Electrodes Removable for inspection and cleaning without removing flowmeter from line
Indicator /
Totalizer
Indicator Units Gallons per minute – Range from zero to full factory setting
Indicator Direction Forward-only
Empty Pipe Sensing zero return with electrodes dry
Totalizer Units 1000 gal
Totalizer Direction Forward-only
Output Signal None
Electrical and
Cable
Connections
Manual Disconnect Field mount disconnect to input power and electronics within 2’ of transmitter
Cable from Flowtube
to Transmitter
Shielded cable assembly of sufficient length to
connect flowtube element output to transmitter
Connection Remote Mounted Transmitter with terminal blocks for flowtube wires.

Cable from
Transmitter to PLC
2#18 Shielded cable, Length as required in field
plus 10’
Coil extra cable in PLC
Grounding for
Unlined and
Ungrounded
Conductive Pipe
Minimum #9AWG braided copper ground wire from
grounding lugs spanning flange to meter to
grounding lugs spanning flange to earth ground
Stray Current
Isolation
Flange Insulating Kit Refer to Section 33 05 32
Human
Interface
LCD Display Backlit 4 lines with 16 characters per line 3 totalizers (7-digit + 7 digit overflow)
Standard supporting software
Register Hermetically sealed register with register test hand Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 6
D. The following electrical design criteria are required for equipment specified in this section:

ITEM DESCRIPTION
Electrical Work NEC Article 505 Classification Nonhazardous Enclosures – Indoor
Dry Locations
NEMA 250 Enclosure Rating NEMA 12 – Industrial Use
Enclosures –
Outdoor or Wet
Locations
NEMA 250 Enclosure Rating NEMA 4X – Watertight, CorrosionResistant, Stainless steel Enclosures Construction Lockable
Type 316 Stainless Steel
IEC 60529 Enclosure Rating
for Underground Equipment
IP 65 water jet
Indicator/Totalizer
Mounting
Local Mount Integral mounted on flowmeter in
polycarbonate housing
Remote Mount Location as shown on Plans
Power Supply Flow Meter 120VAC – 1 phase – 60Hz
PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install magnetic flow meters before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Section 02 05 00 for basic execution and installation requirements.

B. Furnish and install flowmeters at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire, plumbing and electrical code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Install magnetic meter with electrodes located at ends of a horizontal diameter (9 o’clock and 3 o’clock positions) to ensure continued electrode immersion when air bubbles are present in metered fluid.

F. Install remote mount transmitter at the pump control panel door.

G. Electrically isolate meter from adjacent piping and fittings to prevent stray-current interference.

H. On meters 3” and larger, provide 1” outlet or service saddle and corporation stop on spool at least 2 pipe diameters downstream from meter. Coordinate location of tap with Owner’s Representative.

Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 7
I. Construct grounding rod, and ground magnetic meter in conformance with Manufacturer’s installation instructions.

J. Finished installation shall be compatible with Owner’s existing flow measurement and telemetry facilities.

3.3 Field Quality Control
A. Field testing will include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER TEST

STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Magnetic
Meter
Installation &
Leakage
Visual inspection of finished
installation
1 inspection Owner Owner
Hydrostatic
Pressure
Test
Refer to Section 33 08 11. 1 each meter
tube
Owner Contractor
Accuracy Owner reserves right to either
test meter in shop before
placing meter in service or
test in field using test tap to
be furnished by Contractor.

As directed Owner Contractor
Field
Performance
Demonstrate Work conforms
to Contract Documents and
Manufacturer’s printed
literature
1 test Contractor Contractor
Integration
with Owner’s
Telemetry
Confirm successful operation
with telemetry.

As directed Contractor Contractor
11-month
Warranty
Inspection
Confirm accuracy of
registration and compatibility
with telemetry.

Confirm Work conforms to
Contract Documents and
Manufacturer’s printed
literature
As directed Owner Contractor

3.4 Adjusting and Cleaning
A. Provide services of Manufacturer’s representative as needed for startup, inspection and necessary adjustments as needed to integrate new flowmeter into existing telemetry network.

END OF SECTION
Project Owner MAGNETIC FLOW METERS
New River Improvement Project – Calexico 40 71 13 - 8

THIS PAGE INTENTIONALLY BLANK
Project Owner ULTRASONIC AND SUBMERSIBLE LEVEL METERS
New River Improvement Project – Calexico 40 72 13 - 1
SECTION 40 72 13

ULTRASONIC AND SUBMERSIBLE LEVEL METERS
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of ultrasonic level instruments.

1.3 System Description
A. Furnish and install complete operating ultrasonic level instrument including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building codes and standards.

B. Ultrasonic and submersible level instrument control system output variables shall include:

ITEM VARIABLE DESCRIPTION
Output Signals (Analog) Level 4-20mA signal

B. Ultrasonic level instrumentation shall be UL listed.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. NFPA 70 National Electric Code (NEC)

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit per mechanical equipment Shop Drawing requirements.

Submit for ultrasonic level instruments under electrically controlled equipment Shop Drawing requirements.

Project Owner ULTRASONIC AND SUBMERSIBLE LEVEL METERS
New River Improvement Project – Calexico 40 72 13 - 2

SUBMITTAL DESCRIPTION
Product Data Submit per Product Data requirements.

Installation Instructions Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements
Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions and O&M Instructions.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of ultrasonic level instruments.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for ultrasonic level-sensing systems.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers for ultrasonic level instruments include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Ultrasonic
Level
Sensor
Endress + Hauser, Inc. Greenwood, IN (714) 674-9520
Siemens Milltronics Washington, DC (800) 743-6367
Approved equal
Ultrasonic
Level
Controller /
Transmitter
Endress + Hauser, Inc. Greenwood, IN (714) 674-9520
Siemens Milltronics Hydroranger 200 Washington, DC (800) 743-6367 Accepted equal
B. Acceptable Manufacturers for submersible level instrumentation include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Submersible
Level
Controller –
(Pressure
Type)
GE Druck
Dwyer Instrument, Mercoid
Accepted equal
C. Ultrasonic level indicators, transmitters, and controllers where shown shall be manufactured by same Manufacturer as ultrasonic level sensing equipment and shall be fully compatible with equipment furnished.

2.2 Materials
A. Refer to Section 02 05 00 for basic requirements for products and materials.

Project Owner ULTRASONIC AND SUBMERSIBLE LEVEL METERS
New River Improvement Project – Calexico 40 72 13 - 3
B. The following electrical design criteria are required for ultrasonic equipment specified in this section:

ITEM DESCRIPTION
Enclosures –
Outdoor or
Wet Locations
NEMA 250 Enclosure
Rating
NEMA 4X – Watertight, CorrosionResistant, Stainless steel NEMA 3R – Rainproof, Sleet-Resistant
As shown on plans
Transmitter/
Controller
Remote Mount 4-20 MA output, mounted inside the pump
control panel,
See plans
Power Supply Ultrasonic Level Controller 120VAC – 1 phase – 60Hz C. The following electrical design criteria are required for submersible level equipment specified in this section:

ITEM DESCRIPTION
Enclosures –
Outdoor or
Wet Locations
NEMA 250 Enclosure
Rating
NEMA 4X – Watertight, CorrosionResistant, Stainless steel Transmitter/
Controller
Submersible 2-wires, 4-20 ma, 0-20 FT range
Power Supply 24VDC
PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install ultrasonic and submersible level instruments before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Sections and, 01 73 24 / 02 05 00 for basic execution and installation requirements.

B. Furnish and install ultrasonic level instruments at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire, plumbing and electrical code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

Project Owner ULTRASONIC AND SUBMERSIBLE LEVEL METERS
New River Improvement Project – Calexico 40 72 13 - 4
E. Install ultrasonic level instruments to tolerances recommended by Manufacturer. Unless otherwise shown, install ultrasonic level instruments true, plumb, and level using precision gauges and levels.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Ultrasonic Level
Instrumentation
Installation &
Leakage
Visual inspection of
finished installation
1 inspection Owner Owner
Field
Performance
Demonstrate
compliance to
Contract Documents
and Manufacturer’s
printed Literature
1 test Contractor Contractor
Integration
with Owner’s
Telemetry
Verify successful
operation with
telemetry.

As directed Contractor Contractor
11-month
Warranty
Inspection
Demonstrate
compliance to
Contract Documents
and Manufacturer’s
printed literature
1 test Owner Contractor

3.4 Adjusting and Cleaning
A. Provide services of Manufacturer’s representative as needed for startup, inspection and necessary adjustments as needed to integrate new ultrasonic level instruments into existing telemetry network.

END OF SECTION
Project Owner LEVEL SWITCHES
New River Improvement Project – Calexico 40 72 76 - 1
SECTION 40 72 76

LEVEL SWITCHES
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of level switches.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 01 73 33: Mechanical Identification
F. Section 01 73 24: Seismic Restraint
G. Section 26 05 10: Common Work Results for Electrical H. Section 40 90 20: Control System Descriptions

1.3 System Description
A. Furnish and install complete operating level instrument including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and compliance with applicable building codes and standards.

B. Level instrument control system output variables shall include:

ITEM VARIABLE DESCRIPTION
Output Signals (Discrete) Level Alarm High Level / Low Level

B. Level instrumentation shall be UL listed.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. NFPA 70 National Electric Code (NEC)

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit per mechanical equipment Shop Drawing requirements.

Submit for level instruments under electrically controlled equipment Shop Drawing requirements.

Product Data Submit per Product Data requirements.

Project Owner LEVEL SWITCHES
New River Improvement Project – Calexico 40 72 76 - 2

SUBMITTAL DESCRIPTION
Installation Instructions Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions and O&M Instructions.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of level instruments.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for level switches.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers for wet well float switches include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Float Switch Flygt ENM-10 Plainville, CT (855) 877-9666 Accepted equal
B. Acceptable Manufacturers for meter vault float switches include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Float
Switch
Gems Sensors, Inc. LS-3 with slosh shield Plainville, CT (855) 877-9666 Accepted equal

2.2 Materials
A. Refer to Section 33 05 33 for basic requirements for products and materials.

B. Treated wastewater effluent is being measured.

C. Materials for wet well and meter vault float switches shall be:

ITEM MATERIAL SPECIFICATION
Stem Polypropylene SAE Type 316
Float Polypropylene Conform to ASTM D1418, ASTM D2000
Temperature Standard Class II to 230°F
Slosh Shield Lucite
Project Owner LEVEL SWITCHES
New River Improvement Project – Calexico 40 72 76 - 3
D. The following electrical design criteria are required for equipment specified in this section:

ITEM DESCRIPTION
Electrical Work NEC Article 505 Classification Nonhazardous Enclosures – Outdoor
or Wet Locations
NEMA 250 Enclosure Rating NEMA 4X – Watertight,
Corrosion-Resistant, Stainless
steel
Power Supply Level Controller and Sensor 120VAC – 1 phase – 60Hz PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install level instruments before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Sections 33 05 33 for basic execution and installation requirements.

B. Furnish and install level instruments at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Applicable building, fire, plumbing and electrical code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

E. Install level instruments to tolerances recommended by Manufacturer. Unless otherwise shown, install level instruments true, plumb, and level using precision gauges and levels.

3.3 Field Quality Control
A. Field testing shall include:

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST

TEST PAID
FOR BY

RETESTS

PAID FOR
BY
Level
Switches
Installation &
Leakage
Visual inspection of
finished installation
1 inspection Owner Owner
Field
Performance
Demonstrate compliance
to Contract Documents
and Manufacturer’s
printed Literature
1 test Contractor Contractor
Integration with
Owner’s
Telemetry
Verify successful
operation with telemetry.

As directed Contractor Contractor
11-month
Warranty
Inspection
Demonstrate compliance
to Contract Documents
and Manufacturer’s
printed literature
1 test Owner Contractor
Project Owner LEVEL SWITCHES
New River Improvement Project – Calexico 40 72 76 - 4

3.4 Adjusting and Cleaning
A. Provide services of Manufacturer’s representative as needed for startup, inspection and necessary adjustments as needed to integrate new level instrumentation into existing telemetry network.

END OF SECTION
Project Owner PRESSURE AND FLOW INSTRUMENTS
New River Improvement Project – Calexico 40 73 00 - 1
SECTION 40 73 00

PRESSURE AND FLOW INSTRUMENTS
PART 1 - GENERAL

1.1 Work Included
A. Materials, testing, and installation of pressure instruments.

1.2 Related Work
A. Section 01 22 00: Unit Prices
B. Section 01 33 00: Submittal Procedures
C. Section 01 40 00: Quality Requirements
D. Section 01 66 00: Product Storage and Handling Requirements E. Section 01 73 24: Seismic Restraint
F. Section 26 05 10: Common Work Results for Electrical G. Section 40 90 20: Control System Descriptions

1.3 System Description
A. Furnish and install complete operating pressure and flow instrumentation to provide continuous pressure monitoring where shown, including appurtenant structural, mechanical and/or electrical mountings or connections required for compliance with Manufacturer’s installation requirements and applicable standards.

B. Pressure and flow meter instrument output variables shall include:

ITEM VARIABLE DESCRIPTION
Output signals (Analog) Pressure 4-20mA signal
Output signals (Discrete) Pressure High Level
Output signals (Discrete) Flow Low Flow

B. Pressure and flow instrumentation shall be UL listed.

1.5 References
A. Reference publications below form part of this specification to extent referenced and are referred to within text by basic designation only.

1. ASME/ANSI B16.5 Steel Pipe Flanges and Flanged Fittings (Including ratings for Class 150, 300, 400, 600, 900, 1500, and 2500)

2. ASME/ANSI B40.100 Pressure Gauges and Attachments

3. AWWA C207 Steel Pipe Flanges

4. California Plumbing Code (CPC)

5. NEMA/ANSI 250 Enclosures for Electrical Equipment

6. NFPA 70 National Electric Code
Project Owner PRESSURE AND FLOW INSTRUMENTS
New River Improvement Project – Calexico 40 73 00 - 2

1.6 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit per equipment Shop Drawing requirements Submit for pressure instruments under electrically controlled equipment Shop Drawing requirements
Product Data Submit per Product Data requirements
Installation Instructions Submit per Installation Instruction requirements O & M Instructions Submit per Operation and Maintenance Instruction requirements Warranty Furnish one-year warranty from date of final acceptance B. Refer to Section 02 05 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, and O&M instructions.

1.7 Delivery, Storage, and Handling
A. Refer to Sections 01 65 00 / 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of pressure instruments.

1.8 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

B. Refer to Section 01 22 00 for measurement and payment clauses for pressure instruments.

PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable Manufacturers for stem-mount pressure gauges include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Pressure
Gauges –
Stem-Mounted
Bourdon Tube
Type
Ashcroft Series 1259 Stratford, CT (800) 328-8258
Global Water Instrumentation / Xylem
PG200
College Station, TX (800) 876-
1172
Kobold Instruments Pittsburgh, PA (800) 998-1020
Marsh Bellofram Corporation Newell, WV (304) 387-1200
Marshall Instruments Inc. (Mastergauge) Anaheim, CA (714) 632-8565 United Electric Controls Watertown, MA (617) 926-1000
U.S. Gauge Company (Ametek) Sellersville, PA (215) 355-6900 Wika USA / Ryan Herco Lawrenceville, GA (888) 945-
2872
Accepted Equal
Project Owner PRESSURE AND FLOW INSTRUMENTS
New River Improvement Project – Calexico 40 73 00 - 3
B. Acceptable Manufacturers for pressure switches include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Pressure
Switches
Ashcroft Series B461B Stratford, CT (800) 328-8258
Barksdale Inc. / Crane Vernon, CA (323) 589-6181
Kobold Instruments Pittsburgh, PA (800) 998-1020
Plast-O-Matic Riverside, CA (951) 686-2852
SOR, Inc. Lenexa, KS (913) 888-2630
United Electric Controls Series 400 Watertown, MA (617) 926-1000 Accepted Equal
C. Acceptable Manufacturers for pressure transmitters include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Pressure
Transmitters
Rosemount 3051T
E+H Cerabar PMP51
Accepted Equal
D. Acceptable Manufacturers for flow switches include:

ITEM MANUFACTURER MANUFACTURER LOCATION
Flow Switch Fluid Components International San Marcos, CA (760) 744-6950 Accepted Equal
E. Pressure sensors, indicators and transmitters where shown shall be fully compatible with equipment furnished.

2.2 Materials
A. Materials for stem-mount pressure instruments and insertion flow sensors shall be:

ITEM MATERIAL SPECIFICATION
Bourdon
Tube Type
Gauge
Case SAE Type 316 Stainless
Steel
Process-Wetted
Materials
(Bourdon Tube)
SAE Type 316 Stainless
Steel
Window Acrylic
Sleeve Pure Gum Rubber
Fill Fuid None
Chemical
Gauge
Corrosion
Guards
Case PVC Conform to ASTM
D1784 Cell Class 12454
Diaphragm PTFE
Pressure
Indicators
Case SAE Type 316 Stainless
Steel
Project Owner PRESSURE AND FLOW INSTRUMENTS
New River Improvement Project – Calexico 40 73 00 - 4

ITEM MATERIAL SPECIFICATION
Process-Wetted
Materials
SAE Type 316 Stainless
Steel
Pressure
Switches
Case SAE Type 316 Stainless
Steel
Diaphragm Buna N
B. Materials for insertion flow sensors shall be:

ITEM MATERIAL SPECIFICATION
Liquid Flow
Switch
Case Nema 4X, Model FLT93,
120VAC Power Supply,
SPDT alarm output.

Process-Wetted
Materials
SAE Type 316 Stainless
Steel
C. The following product design criteria, options and accessories are required:

ITEM DESCRIPTION
Pressure Gauges
– Stem-Mounted
Bourdon Tube
Type
Style Dry type with dampers, stem-mounted
Comply with ASME/ANSI B40.100
Calibrated Pressure Range 0-150 psi unless otherwise shown on Plans.

Accuracy within Flow
Range
±0.1%
Fluid Metered Treated Wastewater Effluent
Fluid Temperature Range 32-90°F
Stem Connection ½” NPT
Indicator Units 0-150 psi
Dial Size 4”
Readout Single readout in psi
Pressure Switch Sensing Element Diaphragm-actuated
Adjustment Range 0-150 psi unless otherwise shown on
Plans.

Process Connection ½” NPT
Switch Single-adjustment
Automatic reset type
Contacts SPDT / DPDT
Rated for at least 5 amps at 120VAC
Pressure
Transmitter
Sensing Element Analog pressure sensor with hardware
required to allow insertion and removal
without system shutdown.

Calibrated Pressure Range 0-150 psi unless otherwise shown on Plans.

Project Owner PRESSURE AND FLOW INSTRUMENTS
New River Improvement Project – Calexico 40 73 00 - 5

ITEM DESCRIPTION
Accuracy within Flow
Range
±0.1%
Span Continuously Adjustable
Fluid Metered Treated Wastewater Effluent
Fluid Temperature Range 32-95°F
Maximum Operating
Pressure
150 psi
Process Connection ½” NPT
Zero Adjustment Required
Damping Adjustment Required
Indicator Integral with transmitter
Single readout scaled in psi
Output Signal 4-20mA
D. The following electrical design criteria are required for equipment specified in this section:

ITEM DESCRIPTION
Electrical Work NEC Article 505
Classification
Nonhazardous
Enclosures – Outdoor
or Wet Locations
NEMA 250
Enclosure Rating
NEMA 4X – Watertight, CorrosionResistant, Stainless steel Indicator Mounting Local Mount See plans
Power Supply Pressure
Instruments
24 VDC at control panel for pressure
transmitter
120VAC – 1 phase – 60Hz for pressure
switches
PART 3 - EXECUTION

3.1 Preparation
A. Make field measurements needed to install pressure instruments before submitting shop drawings or ordering. Make minor changes in dimensions and alignments as needed to avoid utilities or structural conflicts.

3.2 Installation
A. Refer to Sections 33 05 00 00 for basic execution and installation requirements.

B. Furnish and install pressure instruments at locations shown on Plans and Submittals.

C. The following installation standards shall be followed:

1. Applicable OSHA and Cal OSHA regulations

2. Other applicable building, fire and plumbing code requirements

3. Manufacturer’s installation and warranty requirements D. Refer variances between above documents and Contract Documents to Owner’s Representative.

3.3 Field Quality Control
A. Field testing shall include:

Project Owner PRESSURE AND FLOW INSTRUMENTS
New River Improvement Project – Calexico 40 73 00 - 6

ITEM TEST FOR

TEST STANDARD
(ASTM OR OTHER

TEST STANDARD) FREQUENCY
FIRST
TEST

PAID FOR
BY

RETESTS

PAID FOR
BY
Pressure
Instruments
Installation &
Leakage
Visual inspection of
finished installation
1 inspection Owner Owner
Field
Performance
Demonstrate
compliance to Contract
Documents and
Manufacturer’s printed
Literature
1 test Contractor Contractor
Integration
with Owner’s
Telemetry
Verify successful
operation with
telemetry.

As directed Contractor Contractor
11-month
Warranty
Inspection
Demonstrate
compliance to Contract
Documents and
Manufacturer’s printed
literature
1 test Owner Contractor

3.4 Adjusting and Cleaning
A. Provide services of Manufacturer’s representative as needed for startup, inspection and necessary adjustments as needed to integrate new pressure instrumentation into existing telemetry network.

END OF SECTION
Project Owner INSTRUMENTATION AND CONTROLS
New River Improvement Project – Calexico 40 90 00 - 1
SECTION 40 90 00

INSTRUMENTATION AND CONTROLS
PART 1 - GENERAL

1.01 SECTION INCLUDES
A. Work Included:

1. Provide all tools, equipment, materials, and supplies and be responsible for all labor required to complete the installation, startup and operational testing of a complete and operable Instrumentation and Control (I&C) System as indicated on the Drawings and as specified herein.

2. Provide all the necessary equipment components and interconnections along with the services of manufacturers' engineering representatives necessary to ensure the City receives a completely integrated and operational I&C system as herein specified.

3. Provide all terminations for wiring at field mounted instruments, equipment enclosures, alarm, and status contacts.

4. Provide all Instrumentation and Control wire required for a fully functioning Instrumentation and Controls System as shown on the Drawings except for wire specifically specified in Division 26.

5. Furnish and install MCC and provide all terminations for power and control wiring, control cables, and fiber optic cables to terminate in control panels at terminal blocks, switches, Ethernet connections, etc. Check and confirm continuity of field wiring, control cables, and fiber optic cables between instruments, variable frequency drives, and control panels.

6. Furnish and install instruments, control panels, variable frequency drives, software, wiring including fiber optic type, and all other instrumentation and control components specified in Divisions 26, 40, 43, and 46 for a complete operational control system.

7. System integration, to include the following, will be performed by the City or contractors and consultants working directly for the City. a Prepare and load SCADA programming
b Provide and install I/O Concentrator and other SCADA and communications equipment on the SCADA backplanes, as required. c Perform startup of SCADA and communications portions of project B. Work Specified in Other Divisions:

1. Division 26 Work, including all instrumentation and controls conduit, and only that wire specified in Division 26. Refer to Division 26 Specifications for specific requirements for wire, conduit, grounding, and other electrical equipment.

Project Owner INSTRUMENTATION AND CONTROLS
New River Improvement Project – Calexico 40 90 00 - 2

1.02 REFERENCE STANDARDS
A. American National Standard Institute (ANSI) Publications:

Y14.15a Drafting Practice
C62.1 Surge Arrestors
B. Instrumentation Society of America (ISA) Publications:

S5.4 Instrument Loop Diagrams
S20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves

1.03 RESPONSIBILITIES
A. Provide all engineering, documentation, labor, and materials required to resolve signal, power, or functional incompatibilities between the wiring and cable points of termination in the RTU and interfacing devices. This includes all interface to existing instruments and equipment.

B. As a minimum, the Contractor shall perform the following work:

1. Prepare analog and digital hardware submittals

2. Procure hardware

3. Fabricate panels

4. Perform factory tests on panels

5. Perform bench calibration and verify calibration after installation

6. Oversee and certify installation

7. Oversee, document, and certify loop testing

8. Oversee, document, and certify system commissioning

9. Conduct the performance test

10. Prepare Owner's Manuals

11. Conduct training classes

12. Prepare record drawings
C. Integration of the I/O concentrators/Trash Screen PLC/SCADA system with instrumentation and control devices being provided under other sections:

1. Resolve signal, power, or functional incompatibilities and communication incompatibilities between the points of termination at the VFD/Control Panels and interfacing devices.

1.04 SUBMITTALS
A. General: It is incumbent upon the Contractor to coordinate the work specified in these Sections so that a complete instrumentation, communication networks and control system for the facility will be provided and will be supported by accurate shop and record Project Owner INSTRUMENTATION AND CONTROLS
New River Improvement Project – Calexico 40 90 00 - 3
drawings. As a part of its responsibility the Contractor shall prepare and submit complete and organized shop drawings, as specified herein. Interface between instruments, existing control panels, motor control centers, starters, control valves, flowmeters, chemical feeders and other equipment related to the instrumentation and control system shall be included in the shop drawing submittal.

1. In these Contract Documents all systems, meters, instruments, and other elements are represented schematically, and are designated by numbers, as derived from criteria in Instrument Society of America Standard ANSI/ISA S5.1.

The Contractor shall assign nomenclature and instrument tags on their submittal drawings. ANSI nomenclature and numbers shall be employed exclusively throughout shop drawings, data sheets, computer programming and similar materials. Any other symbols, designations, and nomenclature unique to the manufacturer's standard methods shall not replace those prescribed above.

2. Should an error be found in a shop drawing during installation or startup of equipment, the correction, including any field changes found necessary, shall be noted on the drawing and submitted finally "as-built" prior to acceptance of the project.

3. The Contractor shall respond to all comments on shop drawing resubmittals made by the City either by making the noted correction or stating why it was not revised. Any resubmittal received by the City, which do not contain responses to the City's previous comments, shall be returned to the Contractor marked "rejected." No further review by the City shall be performed until the Contractor responds to these comments.

4. AutoCAD drawings and 2 hard copies are to be submitted to CITY.

B. Submittals:

1. Control System Hardware: This submittal to include instrumentation and control panels shall be included in a singular, all-inclusive submittal which shall include but not be limited to:
a A complete index appearing in the front of each bound submittal volume.

Labeled tags shall separate system groups.
b Panel, and cabinet layout drawings shall be prepared and they shall include the following information:
(1) Front, side, and plan views to scale.
(2) Dimensions.
(3) Arrangement (interior and exterior).
(4) Mounting information, including conduit entrance locations. (5) Finish data.
(6) Tag number and functional name of items mounted in and on panel, console and cabinet.
(7) Nameplate legend which includes text, letter size, and colors to be used
c Installation, mounting, and anchoring details for all components and assemblies, including access requirements and conduit connection or entry details.

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d Panel wiring diagrams shall be prepared and integrate the field wiring.

They shall include the following information:
(1) Name of panel.
(2) Wiring sizes and types.
(3) Terminal strip numbers and wiring number
(4) Functional name and manufacturer's designation for items to which wiring is connected.
(5) Electrical control schematics in accordance with ANSI standards. e Field wiring diagrams shall be prepared and be integrated with the panelwiring diagram. They shall include the following information:
(1) Wire and piping sizes and types to existing and new field devices. (2) Conduits in which wiring is to be located.
(3) Panel termination strip numbers.
(4) Location, functional name, and manufacturer's designation of items to which wiring and piping are connected.
f Drawings showing schematic diagrams for control circuits. Complete details on the circuit interrelationship of all devices within and outside each Control Panel shall be submitted using schematic control diagrams.

The diagrams shall show numbered terminals on components together with the unique number of the wire to be connected to each terminal. The diagrams shall also show terminal assignments from all primary measurement devices, such as flowmeters, and to all final control devices, such as samplers, pumps, valves and chemical feeders. The Contractor shall furnish all necessary equipment suppliers' shop drawings to facilitate inclusion of this information for the System Integrator. g Interface with existing control and monitoring system. This shall include any and all modifications made to existing measurement and control circuits, equipment and wiring, that are at the site but not indicated on the plan drawings, as applicable to this project. The plans primarily indicate new field devices and not necessarily extension of existing field wiring. It is the responsibility of the Contractor to ascertain actual field conditions of the existing circuits, equipment and wiring. The City will provide to the Contractor copies of all drawings and data the City can find showing such existing conditions. The City makes no representation as to the completeness or correctness of any such drawings and data and cannot guarantee that complete or partial data exists for any of the facilities included in this contract. Lack of such drawings or detail shall not alleviate the contractual responsibility to ascertain and implement interfaces and modifications to existing measurement and control circuits, equipment and wiring. The existence of the electrical drawings reflecting existing control and monitoring functions within these contract documents are for guidance only and do not relieve the Contractor from meeting the requirements stated herein.
h Complete and detailed bills of materials: A bill of material list, including quantity, description, manufacturer, and part number, shall be submitted for each field mounted device or assembly, cabinet assemblies and Project Owner INSTRUMENTATION AND CONTROLS
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subassemblies. Bills of material shall include all items within an enclosure.
i Data sheets for each component, together with a technical product brochure or bulletin: The data sheets shall show:
(1) Component functional description used herein and on the Drawings;
(2) Manufacturer's model number or other product designation; (3) Project system or loop of which the component is a part; (4) Project location or assembly at which the component is to be installed;
(5) Requirements for electric supply (if any);
(6) Special requirements or features, such as specifications for ambient operating conditions.
(7) Features and options which are furnished.
j A list of recommended spare parts covering items which are furnished under this Contract with the name, address, and phone number of manufacturer and manufacturer's local service representative of these parts.

2. Report Submittal: Six (6) sets of sample reports shall be supplied to the Owner for review. The submittal shall include a short description of the methods and procedures to be performed by operators to print the reports including the automatic reporting capabilities.

3. Test Reports: The Contractor shall provide reports detailing the results of tests performed on the system including the Field Functional Test Report. Three (3) sets shall be provided of each report.

4. Start-up Test Procedure Submittal: The Start-up Test Procedure Submittal shall be included in a singular all inclusive package which shall include but not be limited to:
a The proposed procedures to be followed during start-up of the Control System and its components.
b The forms and checklists needed to document the completion of a successful start-up.

5. Technical Manuals: Four (4) final sets of technical manuals shall be supplied for the City in accordance with Section 01 33 00 and two (2) additional final sets shall be supplied for the City, as a condition of acceptance of the project. Two sets shall consist of 1 or more volumes, each of which shall be bound in a standard size, 3-ring, loose-leaf, vinyl plastic hard cover binder suitable for bookshelf storage. Binder ring size shall not exceed 3 inches. The other four sets will be recorded on CD ROM in PDF format.
a Initially, 3 sets of these manuals shall be submitted to the Owner for review after return of favorably reviewed shop drawings and data required herein. Following the City's review, one set will be returned to the Contractor with comments. The sets shall be revised and/or amended as Project Owner INSTRUMENTATION AND CONTROLS
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required and the requisite final sets shall be submitted to the City 15 days prior to startup of systems. The City will distribute the copies. b In addition to updated shop drawing information reflecting actual existing conditions, each set of technical manuals shall include installation, connection, operating, calibration, set points (e.g., pressure, pump control, time delays, etc.) adjustment, test, troubleshooting, maintenance and overhaul instructions in complete detail. This shall provide the City with comprehensive information on all systems and components to enable operation, service, maintenance and repair. Exploded or other detailed views of all instruments, assemblies and accessory components shall be included together with complete parts lists and ordering instructions.
c This manual shall be provided prior to project acceptance. d Security Manual: The Contractor shall furnish a document identifying all security access codes (username, passwords) assigned in the as-built system. This document shall be provided as a separate item. e This manual shall be provided prior to project acceptance. f As Built Shop Drawings: Shop drawings shall be updated to reflect actual as-built conditions.
g This manual shall be provided prior to system acceptance.

6. Record Drawings: The Contractor shall keep current a set of complete schematic diagrams that shall include all field and panel wiring. These drawings shall include all of the hardwired signals shown on the P&ID drawings. One set of drawings electronically formatted in AutoCAD (DWG) and two hard copies shall be submitted to CITY after completion of all field functional tasks but prior to acceptance of the completed work by the City.

1.05 QUALITY ASSURANCE
A. Standard of Quality: The Contractor shall provide equipment of the types and sizes specified which has been demonstrated to operate successfully. Provide equipment which is new and of recent proven design.

1.06 DRAWINGS
A. Drawings: The Instrumentation Drawings are diagrammatic; exact locations of instrumentation products shall be determined in the field by the City. Except where special details are used to illustrate the method of installation of a particular piece or type of equipment or material, the requirements or descriptions in this Specification shall take precedence in the event of conflict.

1. Locations of equipment, inserts, anchors, motors, panels, pull boxes, manholes, conduits, stub-ups, fittings, power and convenience outlets, and ground wells are approximate unless dimensioned; verify locations with the City prior to installation. Field verify scaled dimensions on Drawings.

2. Review the Drawings and Specification Divisions of other trades and perform the instrumentation work that will be required for the installations.

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3. Should there be a need to deviate from the Instrumentation Drawings and Specifications, submit written details and reasons for all changes to the City for favorable review.

4. Resolution of varying interpretations of the Contract Documents shall conform to

5. The Drawings provide details of installation and supersede the manufacturer's recommendation where a conflict exists.

1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. Box, crate, or otherwise enclose and protect instruments and equipment during shipment, handling, and storage. Keep all equipment dry and covered from exposure to weather, moisture, corrosive liquids and gases or any element that could degrade the equipment. Protect painted surfaces against impact, abrasion, discoloration, and other damage. Notify the City in writing in the event that any equipment or material is damaged. Obtain prior favorable review by the City before making repairs to damaged products

1.08 WARRANTY REQUIREMENTS
A. Correction of Defects: The Contractor shall correct all defects in the contractor-supplied Control System upon notification from the City for a period of one year from the date of Acceptance Test Completion. Mechanical corrections shall be completed within 5 days of notification. Programming issues shall be corrected within 24 hours and submit updated program to City.

PART 2 - PRODUCTS

2.01 MATERIALS AND STANDARD SPECIFICATIONS
A. Provide instruments, equipment and materials suitable for service conditions and meeting standard specifications such as ANSI, ASTM, ISA, and SAMA. The intent of this Specification is to insure instruments and equipment are of a uniform quality and manufacture throughout the plant. All instruments in the plant of the same type shall be made by the same manufacturer.

2.02 NAMEPLATES
A. For each piece of equipment, provide a manufacturer's nameplate showing their name, location, the pertinent ratings and the model designation.

B. Identify each piece of equipment and related controls with a rigid laminated engraved phenolic nameplate. Engrave nameplates with the inscriptions indicated on the Drawings and, if not so indicated, with the equipment name. Securely fasten nameplates in place using two stainless steel screws or, where favorably reviewed by the City, with epoxy cement. Where no inscription is indicated on the Drawings, furnish nameplates with an appropriate inscription furnished by the City upon prior request by the Contractor.

Section 011003 Coordination.

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C. Each control device, including pushbuttons, control switches, and indicating lights, shall have an integral legend plate or nameplate indicating the device function. These shall be inscribed as indicated on the Drawings or as favorably reviewed by the City.

D. Provide CAUTION or SAFETY nameplates to alert operators of special conditions that may result in faulty equipment operations. Devices containing batteries that must be replaced periodically must be clearly identified. Nameplates are not required if the device senses and displays a low battery warning.

2.03 NAME TAGS
A. All instrumentation and equipment items or systems shall be identified by name tags.

Field equipment shall be tagged with the assigned instrumentation tag number listed in the Instrument Schedule.

B. Name tags shall be stainless steel with engraved or stamped black characters of 3/16-inch minimum height. Tags shall be attached to equipment with a tag holder and stainless steel band with a worm screw clamping device. Use 20-gauge stainless steel wire where banding is impractical. For field panels or large equipment cases use stainless steel screws; however, such permanent attachment shall not be on an ordinarily replaceable part.

2.04 FIELD-MOUNTED EQUIPMENT
A. All instrument and control equipment mounted outside of protective structures shall be equipped with suitable surge arresting devices to protect the equipment from damage due to electrical transients induced in the interconnecting lines from lightning discharges or nearby electrical devices. Protective devices used on 120 Vac inputs to field mounted equipment shall be secondary valve surge protectors conforming to the requirements of ANSI C62.1.

2.05 EQUIPMENT OPERATING CONDITIONS
A. All equipment shall be rated for normal operating performance with varying operating conditions over the following minimum ranges:

1. Electrical Power: 120 Vac ±10%, 60 Hz, unregulated, except where specifically stated otherwise on the Drawings or in the Specifications, or when two-wire, loop-powered devices are specified.

2. Field Instruments:
a Outdoor Areas:

Ambient Temperature: +15°F to +120°F
Ambient Relative Humidity: 5% to 100%
Weather: Rain, and ice
b Indoor Unheated Areas:

Ambient Temperature: +40°F to +120°F
Ambient Relative Humidity: 5% to 95%, non-condensing
c Indoor Environmentally Controlled Areas:

Ambient Temperature: +60°F to +104°F
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Ambient Relative Humidity: 10% to 90%, non-condensing

2.06 EQUIPMENT LOCATIONS
A. Provide equipment and materials suitable for the types of locations in which they are located as defined under Division 26. All equipment specified for field mounting shall be weatherproof and splash proof as a minimum. If electrical or electronic components are contained within the equipment, they shall be housed in NEMA 4X gasketed cases unless noted otherwise on the Drawings.

2.07 CURRENT TECHNOLOGY
A. All meters, instruments, and other components shall be the most recent field-proven models marketed by their manufacturers at the time of submittal of the shop drawings unless otherwise required to match existing equipment.

2.08 LOOP ACCURACY
A. The accuracy of each instrumentation system or loop shall be determined as a probable maximum error; this shall be the square-root of the sum of the squares of certified "accuracies" of the designated components in each system, expressed as a percentage of the actual span or value of the measured variable. Each individual instrument shall have a minimum accuracy of plus and minus 0.5 percent of full scale and a minimum repeatability of plus and minus 0.25 percent of full scale unless otherwise indicated.

Instruments which do not conform to or improve upon these criteria are not acceptable.

2.09 SIGNAL ISOLATORS, CONVERTORS, AND CONDITIONERS
A. Ensure that input-out signals of all instruments and control devices are compatible.

Provide signal isolators and converters as necessary to obtain the required system performance. Mount the devices in the field at point of application. Provide items as manufactured by AGM or equal.

2.10 ANALOG SIGNAL INDICATED UNITS
A. For all instruments with local or remote indicators, provide indicators scaled in actual engineering units, i.e., gallons per minute, feet, psi, etc., rather than 0 to 100%, unless noted otherwise on the Drawings or Instrument Schedule.

2.11 SIGNAL TRANSMISSION
A. Analog:

1. Signal transmission between electric or electronic instruments shall be 4-20 mA and shall operate at 24 Vdc. Signal output from all transmitters and controllers shall be current regulated and shall not be affected by changes in load resistance within the unit's rating.

2. Nonstandard transmission systems such as impulse duration, pulse rate, and voltage regulated will not be permitted except where specifically noted in the Instrument Schedule or shown on the Drawings. When transmitters with Project Owner INSTRUMENTATION AND CONTROLS
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nonstandard outputs do occur, their output shall be converted to 4-20 mA prior to transmission.

B. Discrete: All alarm and status signals shall be 120 Vac unless specified otherwise.

Ethernet and fiber optic transmissions shall be allowed to the extent shown on the Drawings.

2.12 PAINTING
A. Factory paint all instruments and equipment except where installed in pipelines. Where instrument panels are installed adjacent to electrical control panels provided under Division 26, provide instrument panels of identical color to that of electrical control panels. Paint as required in Division 9 for structural supports, brackets, etc. Repair damaged factory paint to satisfaction of the City. Feathering, priming and painting shall produce a reasonable match to the surrounding paint work.

2.13 FASTENERS
A. Fasteners for securing equipment to walls, floors and the like shall be 316 stainless steel. When fastening to existing walls, floors, and the like, provide capsule anchors, not expansion shields. Size capsule anchors to meet load requirements. Minimum size capsule anchor bolt is 3/8-inch.

2.14 INSTRUMENT CALIBRATION
A. Each field instrument shall be calibrated at 0%, 25%, 50%, 75% and 100% of span using test instruments to simulate inputs and read outputs that are rated to an accuracy of at least 5 times greater than the specified accuracy of the instrument being calibrated.

Such test instruments must have accuracies traceable to the National Institute of Standards and Technology (NIST).

B. Submit a written report to the City on each instrument. This report shall include a laboratory calibration sheet or the manufacturer's standards calibration sheet on each instrument and calibration reading as finally adjusted within tolerances.

C. The Contractor may, at his option, choose to perform calibration on an instrument by acquiring the services of an independent test lab, or by obtaining the required test instruments and performing the calibration.

2.15 NOT USED

2.16 BINDERS
A. Submittals shall be furnished separately bound in a "D" standard size, 3-ring with gap free D-ring, loose-leaf, vinyl plastic, heavy duty, hard cover binder suitable for bookshelf storage. Binder ring size shall not exceed 3 inches.

2.17 ELECTRONIC MEDIA
A. Manuals and Drawings shall be provided in hardcopy and electronic format. As-built Documents shall be provided in MS Word, Adobe Acrobat (pdf) or AutoCAD (DWG) Project Owner INSTRUMENTATION AND CONTROLS
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format on CD – ROMs. The Contractor shall provide vendor manuals electronically and include these manuals on the CD set. The CD shall be organized to simplify user browsing.

PART 3 - EXECUTION

3.01 PROCESS CONTROL SYSTEM
A. Control Philosophy and Loop Functional Descriptions are described in Section 40 96 15 which is hereby incorporated by reference.

3.02 MOUNTINGS
A. Mount and install equipment as indicated. Mount field instruments on pipe mounts or other similar means in accordance with suppliers' recommendation. Where mounted in control panels, mount according to requirements of that section.

B. Equipment specified for field mounting shall be suitable for direct pipe mounting or surface mounting, surface-mounted indicators and equipment with calibration adjustments or requiring periodic inspection shall be mounted not lower than 3 feet-6 inches nor higher than 6 feet above walkways, platforms, catwalks, and the like.

C. Note that applicable specifications require detail drawings showing seismic sway bracing design and anchorage requirements for their equipment. Seismic zone requirements are specified in Division 1.

D. All devices shall be accessible to operators for servicing, operating, reading, etc. Provide permanent platforms to assure devices are continuously accessible.

E. HMI shall be mounted at 60” from the finish floor to the center of HMI.

3.03 FIELD WIRING
A. Ring out signal wiring prior to termination and perform surge withstand tests where required. Verify wire number and terminations are satisfactory as designated on the Loop Diagrams. Verify all terminations are tight and shields are uniformly grounded at one location.

3.04 ELECTROMAGNETIC INTERFERENCE (EMI)
A. Construction shall proceed in a manner which minimizes the introduction of noise (RFI/EMI) into the I&C System.

B. Cross signal wires and wires carrying ac power or control signals at right angles.

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C. Separate signal wires from wires carrying ac power or switched ac/dc control signals within control panels, terminal cabinets, telemetry equipment, multiplexer cabinets, and data loggers as much as possible. Provide the following minimum separations within such equipment unless indicated otherwise on the Drawings:

Power Wiring CapaCity Separation
(Inches)
120 volts ac or 10 amps 12
240 volts ac or 50 amps 18
480 volts ac or 200 amps 24
4,160 volts ac or 800 amps 48

3.05 SIGNAL GROUNDING
A. Proper grounding of equipment and systems in this Division is critical, since computer and associated networks and peripherals are involved. The Drawings and Division 26 specify safety grounding for all equipment in this Division.

B. A single-point grounding system for instrument signals is required for all instrument panels. This instrument single point grounding system does not use building steel or conduit systems for its ground path.

1. Ground all signal shields, signal grounds, and power supplies at an isolated signal bus within each instrument panel, rack, or enclosure. The shields at the far ends of these signal cables must be disconnected (floated) from any ground to prevent ground loops.

2. Do not connect the rack or enclosure frames to the signal grounding buses.

3. Connect each isolated signal ground bus within each panel using a stranded, insulated copper wire of size 6 AWG or larger directly to a system ground rod installed per the Drawings.

3.06 PREPARATION
A. Ensure that installation areas are clean and that concrete or masonry operations are completed prior to installing instruments and equipment. Maintain the areas in a broomclean condition during installation operations.

B. Panels shall be protected during construction to prevent damage to front panel devices and prevent dust accumulation in the intervals. Other protective measures (lamp, strip heaters, etc.) shall be included as weather conditions dictate.

3.07 CALIBRATION
A. General: All devices provided under Divisions 40, 43, and 46 shall be calibrated according to the manufacturer's recommended procedures to verify operational readiness and ability to meet the indicated functional and tolerance requirements.

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B. Calibration Points: Each instrument shall be calibrated at 0, 25, 50, 75, and 100% of span using test instruments to simulate inputs. The test instruments shall have accuracies traceable to National Institute of Testing Standards.

C. Bench Calibration: Instruments which have been bench-calibrated shall be examined in the field to determine whether any of the calibrations are in need of adjustment. Such adjustments, if required, shall be made only after consultation with the City.

D. Field Calibration: Instruments which were not bench-calibrated shall be calibrated in the field to insure proper operation in accordance with the instrument loop diagrams or specification data sheets.

E. Analyzer Calibration: Each analyzer system shall be calibrated and tested as a workable system after installation. Testing procedures shall be directed by the manufacturers' technical representatives. All samples and sample gases shall be furnished by the manufacturers.

F. Calibration Sheets: Each instrument calibration sheet shall provide the following information and a space for sign-off on individual items and on the completed unit:

1. Project name

2. Loop number

3. Tag number

4. Tag name

5. Manufacturer

6. Model number

7. Serial number

8. Calibration range

9. Calibration Data: Input, output, and error at 10 percent, 50 percent, and 90 percent of span

10. Switch setting, contact action, and deadband for discrete elements

11. Space for comments

12. Space for sign-off by System Integrator and date

13. Test equipment used and associated serial numbers

14. Space for sign-off by City I&C technician with date G. Calibration Tags: A calibration and testing tag shall be attached to each piece of equipment or system at a location determined by the City. The Contractor shall have the System Integrator sign the tag when calibration is complete. The City will sign the tag when the calibration and testing has been accepted.

3.08 LOOP TESTING
A. General: Individual instrument loop diagrams per ISA Standard S5.4 – Instrument Loop Diagrams, expanded format, shall be submitted to the City for review prior to the loop Project Owner INSTRUMENTATION AND CONTROLS
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tests. The Contractor shall notify the City of scheduled tests a minimum of 30 days prior to the estimated completion date of installation and wiring of the PCIS. After the City's review of the submitted loop diagrams for correctness and compliance with the specifications, loop testing shall proceed. The loop check must be witnessed by the City.

B. Control Valve Tests: All control valves, cylinders, drives and connecting linkages shall be stroked from the operator interface units as well as local control devices and adjusted to verify proper control action, hand switch action, limit switch settings, torque settings, remote control actions, and remote feedback of valve status and position. Control valve actions and positioner settings shall be checked with the valves in place to insure that no changes have occurred since the bench calibration.

C. Interlocks: All hardware and software interlocks between the instrumentation and the motor control circuits control circuits of variable-speed controllers and packaged equipment controls shall be checked to the maximum extent possible.

D. Instrument and Instrument Component Validation: Each instrument shall be field tested, inspected, and adjusted to its indicated performance requirement in accordance to its Manufacturer's specifications and instructions. Any instrument which fails to meet any Contract requirement, or, in the absence of a Contract requirement, any published manufacturer performance specification for functional and operational parameters, shall be repaired or replaced.

E. Loop Validation: Controllers and electronic function modules shall be field tested and exercised to demonstrate correct operation. All control loops shall be checked under simulated operating conditions by impressing input signals at the primary control elements and observing appropriate responses of the respective control and monitoring elements, final control elements, and the graphic displays associated with the PLC.

Actual signals shall be used whenever available. Following any necessary corrections, the loops shall be retested. Specified accuracy tolerances for each analog network are defined as the root-mean-square-summation of individual component accuracy requirements. Individual component accuracy requirements shall be as indicated by Contract requirements or by published manufacturer accuracy specifications, whenever Contract accuracy requirements are not indicated. Each analog network shall be tested by applying simulated analog or discrete inputs to the first element of an analog network.

For networks which incorporate analog elements, simulated sensor inputs corresponding to 0, 25, 50, 75, and 100% of span shall be applied, and the resulting element outputs monitored to verify compliance to calculated root-mean-square-summation accuracy tolerance requirements. Continuously variable analog inputs shall be applied to verify the proper operation and setting of discrete devices. Provisional settings shall be made on controllers and alarms during analog loop test. All analog loop test data shall be recorded on test forms which include calculated root-mean-square-summation system accuracy tolerance requirements for each output.

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F. Loop Validation Sheets: The Contractor shall prepare loop confirmation sheets for each loop covering each active instrumentation and control device except simple hand switches and lights. Loop validation must verify the contract data into the SCADA. Loop confirmation sheets shall form the basis for operational tests and documentation. Each loop confirmation sheet shall cite the following information and shall provide spaces for sign-off on individual items and on the complete loop by the System Integrator:

1. Project name

2. Loop number

3. Tag number, description, manufacturer and model number for each element

4. Installation bulletin number

5. Specification sheet number

6. Loop description number

7. Adjustment check

8. Space for comments

9. Space for loop sign-off by System Integrator and data

10. Space for sign-off and date by both System Integrator and City.

G. Loop Certification: When installation tests have been successfully completed for all individual instruments and all separate analog control networks, a certified copy of all test forms shall be retained by the Contractor.

3.09 FIELD FUNCTIONAL TESTING
A. General: Field functional testing shall commence after acceptance of all wire test, calibration tests and loop tests, and all inspections have demonstrated that the instrumentation and control system complies with all Contract requirements. Field functional testing shall demonstrate proper operation of all systems with process equipment operating over full operation ranges under conditions as closely resembling actual operation conditions as possible.

B. Field functional Test Procedures and Documentation: All field functional testing activities shall follow detailed test procedures and check lists accepted by the City. All test data shall be acquired using equipment as required and shall be recorded on test forms accepted by the City, which include calculated tolerance limits for each step. Completion of all system field functional testing activities shall be documented by a certified report, including all test forms with test data entered and retained by the Contractor.

C. Operational Validation: Where feasible, system field functional testing activities shall include the use of water to establish service conditions that simulate, to the greatest extent possible, normal final control element operation conditions in terms of applied process loads, operation ranges, and environmental conditions. Final control elements, control panels, and ancillary equipment shall be tested under start-up and steady-state operation conditions to verify that proper and stable control is achieved using motor control center and local field mounted control circuits. All hardwired and software control circuit interlocks and alarms shall be operational. The control of final control element and ancillary equipment shall be tested using both manual and automatic (where provided) Project Owner INSTRUMENTATION AND CONTROLS
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control circuits. The stable steady-state operation of final control elements running under the control of field mounted controllers as required eliminating oscillatory final control element operation. The transient stability of final control elements operation 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.

D. Loop Tuning: All 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 % of span and the results checked against indicated accuracy tolerances.

E. Field Functional Test Validation Sheets: Field functional testing shall be documented on a test form as follows:

1. For functions which can be demonstrated on a loop-by-loop basis, the form shall include:
a Project name
b Loop number
c Loop description
d Tag number, description, manufacturer and data sheet number for each component.
e Specification page and paragraph of function demonstrated f Description of function
g Space for sign-off and date by both the System Integrator and City.

F. Field Functional Test Certification: The Contractor shall submit an instrumentation and control system field functional test completion report which shall state that all Contract requirements have been met and shall include a listing of all instrumentation and control system maintenance and repair activities conducted during the field functional testing.

Acceptance of the instrumentation and control system field functional testing must be provided in writing by the City before the acceptance testing may begin. Final acceptance of the control system shall be based upon plant completion as stated in the

3.10 ON-SITE SUPERVISION
A. The Contractor shall furnish the services of an on-site resident engineer to supervise and coordinate installation, adjustment, testing, and start-up of the Process Control System. The resident engineer shall be present during the total period required to affect a complete operation system. A team of engineering personnel shall be on site to check all equipment, perform the tests indicated in this Section, and furnish startup services.

Specifications.

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3.11 ACCEPTANCE TEST
A. General: Subsequent to Field Functional Test and instrument calibration, verifying substantial completion of field installation and start-up, the system will be given a final 30-day acceptance test. The 30-day test must be successfully completed, including resolution of punch-list items generated during the test period, prior to the date of substantial completion of the entire project. The system must run continuously for 30 consecutive days. During this period, all system functions shall be exercised, and any system interruption and accompanying component, subsystem, or program failure shall be logged for cause of failure, as well as time of occurrence and duration of each failure.

The Contractor shall provide a competently trained technician or programmer on call during all normal working days and hours from the start of the acceptance test until final acceptance of the system.

B. Testing: The systems to be tested on-line will include general operations as well as Remote Diagnostic Software Programs, PLC Configuration and Uploading/Downloading Programs, the Report Generator and Operation as specified herein. Each system function, e.g., status report-backs, logs, and displays shall be exercised several times at a minimum, and in a manner which approximates "normal" system operation. Failure of the system during the above program testing shall be considered as indicating that the programs and operating system do not meet the requirements of the specifications and corrective action shall be required before restarting the acceptance test. Only those components, subsystems, and systems covered in this specification shall be considered for this acceptance test. Problems and failures of other systems shall not be considered as part of this test (except as they display the capabilities of this system to detect failures).

C. Failures: Failures shall be classified as either major or minor. A minor failure would be a small and non-critical component failure, which can be corrected by the City operators.

This occurrence shall be logged but shall not be reason enough for stopping the test and shall not be grounds for non-acceptance. However, should the same or similar component failure occur repeatedly, this may be considered as grounds for nonacceptance. A major failure shall be considered to have occurred when a component, subsystem, or program fault causes a halt in operation of the system and/or when a technician's work is required to make a repair or to re-initiate operation of the system. A major failure shall cause termination of the acceptance test. When the causes of a major failure have been corrected, a new acceptance test with a new 30-day duration shall be started.

D. Technician Report: Each time a technician is required to respond to a system malfunction, he or she must complete a report which shall include details concerning the nature of the complaint or malfunction and the resulting repair action required and taken.

If a malfunction occurs which clears itself or which the operator on duty is able to correct, no report shall be required (logged as specified above). If a technician has performed work but no report is written, then a major failure shall be considered to have occurred.

Each report shall be as specified above). Each report shall be submitted within 24 hours to the Owner.

Project Owner INSTRUMENTATION AND CONTROLS
New River Improvement Project – Calexico 40 90 00 - 18

3.12 TRAINING AND INSTRUCTION
A. General: The Contractor shall provide maintenance and operator training courses by a qualified instructor as described herein. The training courses shall be given on-site during the final stages of the system checkout. All instruction, tools and training material shall be provided by the Contractor.

B. Instructors: The training shall be performed by qualified representatives of the equipment manufacturers and shall be specific to each piece of equipment.

C. Schedule: Training shall be performed during the field functional testing phase of the project. The training sessions shall be scheduled a minimum of 2 weeks in advance of when the courses are to be initiated. The City will review the course outline for suitability and provide comments that shall be incorporated. Functional testing and training will not be scheduled to conflict with each other so City personnel will be able to attend both.

D. Agenda: The training shall include operation and maintenance procedures, trouble shooting with necessary test equipment, and changing set points, and calibration for that specific piece of equipment. An operator’s training course shall be given for up to eight (8) designated personnel of the City.

E. Operator Training: An operator's training course shall be given for up to eight (8) designated personnel of the City. This course shall be designed to teach operations, maintenance, and supervisory personnel how to operate the instrumentation and control systems. Two separate classes shall be offered. Each class shall have a duration of 16 hours offered in four 4-hour sessions. The Contractor will videotape this training and provide the City with two copies of the training on DVD. Operator training shall be completed from Tuesday to Thursday when operations staff are all on duty.

F. Hands-On Instruction: In addition to the maintenance and the operator training courses, the operating and maintenance personnel shall be given hands-on instruction in the functions and operation of the system and instruments 15 days (minimum) prior to startup. This instruction shall be scheduled for two identical sessions of 16 hours each with the City, with 3-4 hours of instruction each day, scheduled at least two weeks in advance. Qualified persons who have been made familiar in advance with the systems shall give instruction.

G. Follow-up Training: 90 days after system acceptance three separate 4 hour sessions shall be offered as follow-up training. This session shall have no formal syllabus and shall be provided to answer questions raised during normal operations. Operator training shall be completed from Tuesday to Thursday when operations staff are all on duty.

END OF SECTION
Project Owner CONTROL SYSTEM DESCRIPTIONS
New River Improvement Project – Calexico 40 90 20 - 1
SECTION 40 90 20

CONTROL SYSTEM DESCRIPTIONS
PART 1 - GENERAL

1.1 Work Included
A. General control sequence for:

1. Pump Back pumping station.

1.2 Related Work
A. Section 01 01 02: Sequence of Operation
B. Section 01 33 00: Submittal Procedures
C. Section 26 29 23: Variable Frequency Motor Controllers D. Section 26 32 13: Engine Generators
E. Section 26 36 23: Automatic Transfer Equipment
F. Section 28 31 00: Intrusion Detection
G. Section 40 90 10: Common Work Results for Instrumentation and Control H. Section 40 71 13: Magnetic Flow Meters
I. Section 40 71 79: Flow Switches
J. Section 40 72 13: Ultrasonic Level Meters
K. Section 40 72 76: Level Switches
L. Section 40 73 00: Pressure Instruments

1.3 System Description
A. Pressure and Level instruments shall include:

TAG DESCRIPTION

ADJUSTMENT

RANGE SETPOINT

SPECIFICATION AND

PLAN REFERENCE
PSH High Discharge Cutout
Pressure Switch
0-200 psi 120 psi . Sheet E207
PI Pressure Indicator 0-200 psi n/a Sheet I203
PT Pressure Transmitter 0-200 psi n/a Sheet I203
LT Level Transmitter 0-13.5 feet n/a Sheet I203
B. Unless otherwise shown, adjustable set point ranges on switches shall be such that indicated set point falls between 30% and 70% of adjustment range.

C. Refer to Section 26 29 23 for controls for variable frequency drives.

D. Refer to Section 26 32 13 for controls for standby power generation.

E. Pump station operation mode shall be:

1. In MANUAL operation, operator can use the VFD’s HMI to control the pump in HANDOFF-AUTO modes.

2. In HAND mode, the pump will start immediately , and the pump speed can be set using the HMI keypad.

Project Owner CONTROL SYSTEM DESCRIPTIONS
New River Improvement Project – Calexico 40 90 20 - 2

3. In AUTO mode, the pump will wait for the pump call signal from the pump controller. The speed of the pump will be the analog speed reference signal from the pump controller F. Pump controller sequence of operation shall be :

1. First, the level transmitter, LT400, measures the level in the wet well and sent the level signal to the pump controller.

2. The pump controller will compare the wet well level with the setpoints and command the lead and lag pumps to start and stop as shown below:
a. Level >= LEAD START SP; Start the lead pump.
b. Level <= LEAD STOP SP; Stop the lead pump.
c. Level >= LAG START SP; Start the lag pump.
d. Level <= LAG STOP SP; Stop the lag pump.

The table below show the set points for the lead/lag pump start/stop:

DEFINITIONS VALUE
HIGH LEVEL ALARM SP 7.0 FT
LAG START SP 6.5 FT
LEAD START SP 6.0 FT
LAG STOP SP 4.0 FT
LEAD STOP SP 3.0 FT
LOW LEVEL ALARM SP 2.0 FT
Contractor shall adjust the set points to meet the actual levels at the field.

3. The pumps reference speed will follow the wet well level. If the level is high the pump speed is high and will pump out the water faster. This will decrease the water level. If the level is low, the pump speed is also low to maintain the water level. At some point, there will be an equilibrium condition where the incoming water flow rate to the wet well is the same at the discharge flow rate. The level will stay the same in the wet well.

The table below show the setup parameters for the VFD speed control:

DEFINITIONS RANGES

DEFAULT
VALUE
PUMP

CONTROLLER

PARAMETER NOTES
Minimum Speed 0 – 95% 50% P.20
Wet Well Level at minimum
speed

0.1 – 99.9 FT 3.5 FT P.21
Level at 100% speed 0.1 – 99.9 FT 6.0 FT P.22
Pump Start Speed Boost
Time
0 – 60 Sec 0 Sec P.23 Set at 0 to
disable
Speed of pump under
remote control
0 – 100% 100% P.48
Please reference to the manufacturer operating manual for further information.

G. SCADA shall monitor:

1. Flowrate (analog signal)
Project Owner CONTROL SYSTEM DESCRIPTIONS
New River Improvement Project – Calexico 40 90 20 - 3

2. Discharge pressure (analog signal)

3. Well level (analog signal)

4. VFD (pump) speeds (analog signals)

5. Pump run status (discrete signal)

6. AC power failure (discrete signal)

7. Pump in Hand Mode (discrete signal)

8. Pump system fail (discrete signal)

9. Wet well high alarm (discrete signal)

10. Wet well low alarm (discrete signal)

11. Building and enclosures intrusion alarm (discrete signal)

1.4 Submittals
A. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings Submit ladder diagram
O&M and Programming
Instructions
Submit operation and maintenance instructions.

PLC Programs Submit hard copies and copies on disc

1.5 Unit Prices
A. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

PART 2 - PRODUCTS (not used)
PART 3 - EXECUTION

3.1 Field Quality Control
A. Field testing during of complete control systems shall comply with Section 40 90 10.

END OF SECTION

Project Owner CONTROL SYSTEM DESCRIPTIONS
New River Improvement Project – Calexico 40 90 20 - 4

THIS PAGE INTENTIONALLY BLANK
Project Owner FIBER OPTIC COMMUNICATIONS SYSTEM
New River Improvement Project – Calexico 40 95 80 - 1
SECTION 40 95 80

FIBER OPTIC COMMUNICATIONS SYSTEM
PART 1 - GENERAL

1.01 THE REQUIREMENT
A. The Contractor shall provide and install fiber optic cable and fiber optic components complete and operable, in accordance with the Contract Documents.

B. The requirements of Section 40 90 00, Instrumentation and Control apply to this section.

C. Due to the complexities associated with fiber optic cable, it is the intent of these Specifications that the Instrumentation Supplier be responsible to the Contractor for the installation of the fiber optic cable. The Instrumentation Supplier shall submit on the experience of the instrumentation supplier to demonstrate that the Instrumentation Supplier meets the following minimum criteria:

1. Submit documentation of proof to show that the persons responsible for the installation of the fiber optic cable have been formally trained in the installation of fiber optic cable and have a minimum of 3 years of experience in the installation of fiber optic cables.

2. In addition, list the following information of the experience of the fiber optic installation technicians:
a. Name of plant, owner of plant, contact name and telephone number of at least three projects where fiber optic cable was installed. b. Type of equipment installed, manufacturer and model numbers. c. Date of completion or acceptance.

1.02 CONTRACTOR SUBMITTALS
A. General: Shop Drawings shall be submitted in conformance with the requirements of Section 40 90 00, Instrumentation and Control.

PART 2 - PRODUCTS

2.01 FIBER OPTIC CABLE
A. Industrial grade, water resistant optic fiber, coated with a suitable material to preserve the intrinsic strength of the glass, suitable for outdoor installation in conduits which are encased or in cable trays.

Project Owner FIBER OPTIC COMMUNICATIONS SYSTEM
New River Improvement Project – Calexico 40 95 80 - 2
B. Cable of all dielectric construction.

C. Riser-rated, UL OFNR.

D. Multi-mode, graded index, solid glass waveguides with the following characteristics:

1. Fibers: As shown on the Drawings.

2. Nominal Core Diameter: 62.5 microns.

3. Minimum Ellipicity: 2.0 percent.

4. Outside Clad Diameter: 125.0 microns.

5. Maximum Numerical Aperture (NA): 0.275.

6. Maximum Attenuation (1,300 nm): 1.2 dB/Km.

E. Each fiber continuous with no factory splices.

F. Loose tube.

G. Fiber Distributed Data Interface (FDDI) compatible and meets the requirements of ANSI X3T9.5 for FDDI cable.

H. Construction:

1. Loose Tube Cable: Dielectric strength members shall have no preferential bend and require no bonding or grounding. Cable shall have a medium density PE jacket.

2. Tight Buffer Cable: Cable shall be multi-fiber utilizing 900 mm tight-buffered fibers surrounded by dielectric strength members with a flame-retardant outer jacket.

I. Maximum Short-Term Tensile Load: 1,350 pounds.

J. Maximum Long-Term Tensile Load: 400 pounds.

K. Type: Corning Cable Systems, Type 012KSF-T4130D20
L. The fiber fan out kits used for terminations shall be Corning Cable Systems FANBT25-12.

2.02 FIBER OPTIC PATCH PANELS
A. General: Patch panels shall be provided by the Contractor and in accordance to Drawings
B. Each patch panel shall accommodate all optical fibers in the cable, and shall have hinged lockable doors.

C. Fiber connectors shall be SC/UniCam type, Corning Cable Systems Part Number 95-000-41, in all locations.

Project Owner FIBER OPTIC COMMUNICATIONS SYSTEM
New River Improvement Project – Calexico 40 95 80 - 3
D. All fibers shall be connected and labeled.

E. Provide patch cords to connect the fibers from the fiber patch panels to the switches and to interconnect fibers within the patch panels. Patch cords shall be Type Corning Cable Systems 575702K5141XXXF (xxx=length in feet as required).

F. Type: Environmental Distribution Center (EDC) EDC-06P-NH NEMA 4X enclosure with Corning Cable Systems CCH-CP12-91 closet connector housing panels, with SC adapters.

2.03 INNERDUCT:

A. Function: Installs into conduit system to provide smooth, low-friction path through conduit, with only one cable per path to facilitate changing individual cables.

B. Features:

1. Size and Count:
a. 4-inch Conduit: Three, 32 mm.
b. 2-inch Conduit: One, 32mm.

2. Type: Annular, corrugated innerduct or ribbed.

3. Material: HDPE.

4. Color Code: Orange, blue, green, brown, white, or grey.

5. Strength: Minimum 600-pound tensile strength, with no more than 5 percent ovalization at 600-pound tension.

6. Lubrication: Prelubricated.

C. Manufacturers:

1. Endocor.

2. Dura-Line.

2.04 MEDIA CONVERTER
A. Copper to Fiber Optic Converter:

1. General:
a. Function: Connect Concentrator to Copper/F.O. Converter and connect to EDC (Path panel) plant fiber optic network.

2. Service:
a. Temperature: 32 to 104 degrees F.
b. Humidity: 80 percent, noncondensing.

4. Feature
a. Mounting: In panel and Wall or rack.

5. Power: 24VDC.

6. Manufacturers and Products:
a. Moore Industries
Project Owner FIBER OPTIC COMMUNICATIONS SYSTEM
New River Improvement Project – Calexico 40 95 80 - 4
PART 3 - EXECUTION

3.01 EQUIPMENT, MATERIALS AND WORKMANSHIP
A. General: It is the intent of these Contract Documents to secure high quality in all equipment and materials, and to require first class workmanship, in order to assure long, trouble-free operation and minimum maintenance of the installed components.

B. Equipment and materials shall be the products of reputable, experienced manufacturers with a verifiable history of manufacturing similar equipment.

Similar items in the Project shall be the products of the same manufacturer. All equipment shall be of industrial grade and standard construction, shall be of sturdy design and manufacture, and shall be capable of long, reliable, troublefree service.

C. All work, including installation, calibration, testing, adjustment, startup and maintenance, shall be done by qualified experienced personnel who are technically skilled in their trade, are thoroughly instructed, and are competently supervised. The resulting completed installation shall reflect professional quality work, employing the highest industrial standards and methods.

D. The fiber optic cable shall be installed without field splices. Cable shall be run continuously between connection centers. All conduit runs shall be installed as not to exceed the minimum bending radius of the fiber optic cable as defined by the cable manufacturer.

E. Innerduct:

1. Installed in accordance with manufacturer’s recommendations.

2. In all fiber optic conduits.

3. Install no more than one innerduct of each color in single conduit.

4. Terminate innerducts in conduit with fabricated termination kits.

5. Identify innerducts at both ends by methods such as color-coding or waterproof tags wired through innerduct wall.

6. Sealing:
a. Cabled Innerducts: Seal cables into innerducts to stop ingress of water and grit with fabricated expansion seals that have separate seals for each cable.
b. Innerduct to Conduit: Seal gaps between innerducts and conduit with sealing compound such as 3M Ductseal.
c. Empty Innerducts:
1) After installation, provide a pull cord for each innerduct and Project Owner FIBER OPTIC COMMUNICATIONS SYSTEM
New River Improvement Project – Calexico 40 95 80 - 5
attach the ends of the pull cord to fabricated expansion plugs and tuck excess cord into the innerduct.
2) Seal innerducts with fabricated expansion plugs to stop ingress of water and grit. Remove plugs as required to install cables.

3.02 TESTING OF FIBER OPTIC CABLE INSTALLATION
A. Acceptance Testing: The Contractor shall perform post-installation fiber optic cable acceptance tests of all cable installed under this Contract. The Engineer shall be notified a minimum of 5 days in advance so they may have the opportunity to witness the tests. The tests shall measure a total attenuation or loss for each fiber on each cable reel. Document results of physical inspections to identify any cable and reel damage conditions, less or more than the specified fibers in the cable, and any deviations from the manufacturer’s specifications.

B. A recording optical time domain refractometer (OTDR) shall be utilized to test for end-to-end continuity and attenuation of each optical fiber. The OTDR shall be equipped with an 850 nm light source for the multi-mode fiber (MMF). The OTDR shall have an X-Y plotter to provide a hard copy record of each test measurement. The OTDR shall be equipped with sufficient internal masking to allow the entire cable section to be tested. This may be achieved by using an optical fiber pigtail of sufficient length to display the required cable section.

C. The OTDR shall be calibrated for the correct index of refraction to provide proper length measurement for the known length of reference fiber.

D. A transmission test shall be performed with the use of an 850 nm stabilized light source and 850 nm power meter. This test shall be conducted in both directions on each fiber of each cable.

3.03 INSTALLATION SERVICES
A. General: The Contractor shall install, test, and provide complete test reports for all network hardware and software furnished under these Specifications.

B. Installation Coordination: The Contractor shall coordinate all installation and testing with the District. No Site work shall be done without a minimum of 3 working days’ notice.

C. Sequence of Work: The Contractor shall coordinate the sequence of work with the District. Existing conduit schedules will be made available to the Contractor upon request.

END OF SECTION
Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 1
SECTION 41 24 00

AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE
PART 1 - GENERAL

1.1 Scope of Work
A. This section specifies a Traveling Gripper Rake for collection and removal of coarse solids from Raw Water Intake Bar Screens. The rake shall be a single piece of equipment capable of automatically (or manually under pushbutton or wireless control) raking multiple screens, and transporting debris to a designated dumpsite as shown on the drawings. Multiple pieces of equipment such as a trash rakes combined with conveyors and/or re-handling equipment shall not be allowed. One manufacturer shall design and furnish the bar screen guides and traveling gripper rake support structure for unit responsibility including all structural supports, controls, and anchor bolts as specified herein and shown on the drawings.

B. The type of equipment specified herein allows each bar screen to be front cleaned one trolley-mounted rake head assembly, operating on an overhead support structure and enclosed monorail system, with teeth designed to penetrate the bar screens while descending and remove collected debris from the bar screen while ascending. Designs employing multiple rakes, designs employing rakes which penetrate the bars at the invert and rake while ascending and designs employing chains, sprockets, bearings, shafts or other moving parts fixed to bar screens are explicitly excluded under this specification.

Designs employing open monorail construction, pivoting teeth by changing cable lengths or by static weight, raking by telescoping arms or “backhoe” type rakes shall not be allowed.

C. Equipment List (General)

ITEM QTY DESCRIPTION NOTES
1 2 Bar Screens and Support Structure T304/T316 Stainless Steel per Drawings, Coordinate with Division 05
2 1 Trolley Unit Complete Heavy-Duty T316 Stainless Steel Weatherproof Enclosure
3 1 Gripper Rake T316 Stainless Steel
4 See Notes Structural Support Columns, Trusses and
Beams
Hot Dipped Galvanized Steel per
Drawings, Coordinate with Division 05 and
Division 09.
5 90-feet Monorail Curved and Straight Sections Hot Dipped Galvanized Steel 6 2 Maintenance Platforms with Ladders
Complete
Hot Dipped Galvanized Steel per
Drawings, Coordinate with Division 05 and
Division 09.
7 1 Main Control Panels Non-Hazardous Area Outdoor Area, NEMA 4X Stainless Steel with PLC in Separate
NEMA 4X Stainless Steel Panel attached
to the trolley
8 1 Wireless Remote NEMA 3R Stainless Steel
9 1 Local Control Station with H-O-A and HMI
at Deck Level
NEMA 4X Stainless Steel
Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 2
10 2 Upstream and Downstream Level
Sensors for Differential Level
Measurement Across Bar Screen
Submersible level Controller (Pressure
Type, See drawings and Coordinate with
Section 40 72 13
11 1 Power Rail Enclosed Conductor System Internal Style Mounted within Monorail 12 Lot Anchor Bolts See Drawings and Coordinate with Division 05 for Materials and Requirements

1.2 Related Work
A. Section 01 33 00: Submittal Procedures
B. Section 01 40 00: Quality Requirements
C. Section 01 66 00: Product Storage and Handling Requirements D. Section 01 73 33: Mechanical Identification
E. Section 05 05 23: Metal Fastenings and Welds
F. Section 05 12 00: Structural Steel Framing
G. Section 05 40 00: Cold-Formed Metal Framing
H. Section 05 50 00: Metal Fabrications
I. Section 05 51 00: Stairs and Ladders
J. Section 05 53 00: Gratings and Floor Plates
K. Section 09 92 00: Galvanizing
L. Section 26 05 10: Common Work Results for Electrical M. Section 40 72 13 Ultrasonic and Submersible Level Meters

1.3 System Description
A. Performance Requirements

1. General: Equipment furnished under this section shall be suitable for automatic (or manual) operation for a fresh water intake from the New River and shall be a single piece of equipment designed and arranged to remove trash, plastic bags, branches, tires and other debris from bar screens for transport and discharge into the discharge area.

2. Functional: The Bar Screen Cleaner shall primarily consist of an overhead type track supported by a truss structure as shown on the drawings, a traversing trolley and a gripper unit. The trolley shall travel along an overhead track until the desired Bar Screen has been reached. The gripper rake shall then be lowered to engage the bar screen guides at deck level and penetrate each bar screen for debris removal to just above invert elevation. The gripper shall then be closed, raised and debris transported to the dumping site.

3. The overhead track shall be fabricated from structural shapes and folded plate or two (2) channel sections continuously welded to an intermediate top plate to protect the traversing motor/wheels from inclement weather. Designs utilizing open type monorails shall not be allowed. This provides the track for the traversing drive and support wheels fitted to the top of the trolley. The monorail will be supported across the main span with a truss structure as shown on the drawings.

4. The trolley unit shall contain the traversing gear motors, shaft and hydraulic power pack, and NEMA 4X control panels attached to the trolley. The trolley shall be traversed by two (2) gear motors mounted on top of the trolley and shall include rubber-rimmed wheels, fitted directly to the gearbox output shaft designed to run inside the track. The hoisting Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 3
gear shall consist of two spirally grooved rope drums mounted on a common shaft within the trolley to raise and lower the gripper. The hoist shaft shall be driven by a 5.0 HP geared motor unit. The hydraulic power pack shall provide for the operation of the hydraulic cylinders which open/close the gripper. Designs which utilize mechanical closing rakes shall not be allowed. Fluid power shall be transferred to cylinders through high strength hoses which are to be wound on spring tensioned drums operating in sequence with hoisting drums. The hoses shall be located downstream of the hoisting cables for protection. The hydraulic fluid shall be biodegradable for environmental concerns. Electrical power to the trolley unit shall be supplied by a power rail which contains power leads for the NEMA 4X control panels attached to the trolley.

5. The gripper rake shall be supported by the hoisting shaft via wire ropes and shall consist of a series of special teeth designed to engage with each bar screen and shall be opened/closed by hydraulic cylinders. The gripper head shall be prevented from excessive lateral swaying when traversing motion stops by specially designed swing restrictors.

B. Operating Conditions

1. Site Data
Site Location New River, Calexico, CA
Liquid Being Screened
Urban drainage water consisting of dry and wet weather
runoff, treated wastewater effluent, and other nuisance drainage.

Number of Screens Serviced Two (2) @ 19’-0” wide x 12’-0” tall (each) Top of Screen Level Plan Elev. 71.0
High Water Level Plan Elev. 70.0 (max @ 100 yr river flow) Normal Level Range Plan Elev. 61.0 to 62.5
Low Water Level Plan Elev. 60.5 (low river flow)
Channel Invert Plan Elev. 59.0
Invert Level Plan Elev. 59.0
Channel Width Two (2) at 19’-0” width
Channel Depth 12’-0”
Screen Inclination 75 deg. from horizontal

2. Technical Data – Trolley Mounted Racking System
Number of Cleaners One (1) BT 1000 Bosker Unit
Gripper Width 6’-6”
Maximum Debris Load 1,100 Lbs.

Maximum Volume Load
Weight of Trolley 2,200 Lbs.

Weight of Gripper Max. 1,200 Lbs.

Length of Straight Track 84’-0”
Curve Track Radius 9’-0” Radius (90 degree turn)
Raking Speed (up/down) 60 Fpm/
Traversing Speed (left/right) 100 Fpm
Gripper open/close time 6 Sec
Hoist Motor Size 5.5 Hp
Traversing Motor Size (Two Each) 0.5 Hp x 2
Hydraulic Motor Size 2.0 Hp
Motor Speeds 1800 Rpm/1500 Rpm
Motor Enclosure TEFC/IP55
Motor Insulation Class H
Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 4
Motor Supply 460V/3Ph/60Hz
Hydraulic Operating Pressure 1300 PSI

1.4 Quality Assurance
A. Manufacturer’s Experience
Only manufacturer’s having supplied equipment for at least five (5) installations of the same design as specified herein shall be considered qualified. The manufacturer shall also have been in operation for a minimum of ten (10) years within the U.S. to be qualified as a supplier. In order to qualify, the referenced installations shall be on fresh water intake applications. Manufacturers proposing alternate designs, prototypes, different raking sequences, deck mounted rakes or any other design other than specifically required herein shall not be allowed.

B. Factory Test
Each bar screen cleaning system and controls shall be electrically tested and adjusted prior to shipping. The screen cleaning system manufacturer shall submit a copy of the testing report to the Engineer for review and acceptance prior to shipping the equipment.

1.5 References
A. This section contains references to the following documents, which are part of this section as specified and modified. In case of conflict between the requirements of this section and those of listed documents, the requirement of this section shall prevail:

ASTM A-36 – Carbon Steel Plate and Shapes
ASTM A-123 – Zinc (Hot Dip Galv.) Coatings on iron and steel products AWS D1.1 – Structural Welding Code-Steel
AWS D1.6 – Structural Welding Code-Stainless Steel
NEMA – National Electrical Manufacturers Association
UBC/CBC – Uniform Building Code / California Building Code AISC – American Institute of Steel Construction
ANSI – American National Standards Institute

1.6 Submittals
A. A copy of this specification section, and all referenced and applicable sections, with addendum updates included, shall be provided with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (√) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated and therefore requested by the Contractor, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph. The remaining portions of the paragraph not underlined shall signify compliance on the part of the Contractor with the specifications.

The submittal shall be accompanied by a detailed, written justification for each numbered deviation.

B. Furnish the following submittals.

SUBMITTAL DESCRIPTION
Shop Drawings A copy of the contract document control diagrams and process and instrumentation diagrams relating to the submitted equipment, with addendum updates that apply to the equipment in this section, marked to show specific changes necessary for the equipment proposed in the submittal. If no changes are required, the drawing or drawings shall be marked “no changes Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 5

SUBMITTAL DESCRIPTION
required”.

Experience statement specified in paragraph 1.4 A with list of water treatment installations for the past 120 months.

Complete dimensional layout drawings of the steel supporting structure, enclosed monorail, and maintenance platforms.

Complete dimensional assembly and installation drawings for the bar screens and bar screen structural support system.

Electrical elementary diagrams, internal connection diagrams and external interconnection diagrams.

Local control panel layout drawings indicating the front door and rear panel equipment arrangement and dimensions
Product Data Submit per Product Data requirements.

Catalog data for all mechanical and electrical components, motors, hydraulic pumps, materials of construction, coatings, etc.

Gear reduction unit catalog data.

Structural steel support structure, monorail, integral power rail, bar screen and related components.

Manufacturer statement of design including bar screen cleaner gripper speed and cycle time.

Installation Instructions Submit per Installation Instruction requirements.

O & M Instructions Submit per Operation and Maintenance Instruction requirements. Include typical blank log sheets for Owner 6-month scheduled testing.

Include theory of operation of actuator and intermediate gearing.

Include complete parts list and part changeout instructions.

Include recommended list of spare parts
Include list of special tools for installation, maintenance and adjustments.

Include lubrication guide with list of recommended lubricants and lubrication frequency.

Include specifications and ordering information for replacement motors.

Submit expanded parts drawings of mechanical and electrical parts.

Certificate of Compliance Submit certificate of compliance with ANSI Z21 per Certificate of Compliance requirements.

Manufacturer’s Statement of
Responsibility
Submit per Manufacturer’s Statement of Responsibility requirements.

Test Record Transcripts Submit for factory tests per Test Record Transcript requirements.

Factory Training Certification Submit evidence installation technicians have been factory trained on specific models installed prior to technicians performing work on valves and actuators.

Warranty Furnish 3-year parts and labor warranty from date of final acceptance.

Warranty shall include service contract for duration of warranty period.

C. Refer to Section 01 33 00 for definition of requirements for Shop Drawings, Product Data, Installation Instructions, O&M Instructions, Certificates of Compliance, and Test Record Transcripts.

1.7 Delivery, Storage, and Handling
A. Refer to Section 01 65 00 and 01 66 00 for delivery, storage, and handling requirements.

B. Strictly follow Manufacturer’s instructions and warranty requirements for delivery, storage, and handling of seismic valve controllers.

1.8 Unit Prices
C. Payment for Work in this section shall be included as part of lump-sum or unit-price bid amount for which such Work is appurtenant.

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PART 2 - PRODUCTS

2.1 Acceptable Manufacturers
A. Acceptable manufacturers shall include the “Bosker® Raking Machine, BT 1000 Unit” as manufactured by OVIVO US, LLC. No alternate designs are allowed.

2.2 Materials of Construction
A. Trolley-Mounted Racking System
Gripper Stainless Steel, Gr. 316
Hoist Cables Stainless Steel, Gr. 316
Trolley/Hoist Parts Mild Carbon Steel
Trolley Enclosure Stainless Steel, Gr. 316
Track Mild Carbon Steel (HDG)
Columns Mild Carbon Steel (HDG)
Maintenance Platforms, Handrail, Grating, and Ladders Mild Carbon Steel (HDG) Track/Columns Fasteners Zinc Plated/Stainless Steel, Gr. 316 Foundation Fasteners Stainless Steel, Gr. 316
B. Bar Screen Guides
Gripper Guides Extending to Deck Level Stainless Steel, Gr. 304 Bar/Beam Fasteners Stainless Steel, Gr. 316
C. Accessories

1. Provide the first filling of lubricants
D. Protection

1. Track, support structure monorail and column structural parts shall be hot dip galvanized in accordance with ASTM A-123 including the track and columns. The truss for support of the monorail shall be constructed of 304 stainless steel.

2. Items procured by equipment manufacturer such as motors, gearboxes, etc., shall be supplied in the manufacturers’ standard finish, suitable for the application.

2.3 Equipment
A. General

1. The only obstructions in the channel flow stream during cleaning shall be the bar rack, its supports, cable and gripper assembly, and the gripper guides attached to the existing bar screens.

B. Welding

1. Welding on items designated for galvanizing shall be per recommended standards for galvanized structural fabrication.

C. Bar Screens

1. The existing bar screens will be fitted with 316 stainless steel guides to prevent the gripper from being pushed away from the bar screens during periods of high flow.

D. Gripper

1. The gripper shall be manufactured from heavy plate and shapes with teeth spaced to match the openings in the bar screens. The gripper shall operate by being traversed over the required bar screen during a cleaning cycle. The gripper shall be in the open position when being lowered.

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2. The rear (downstream) teeth shall normally engage with the bar screen at the normal water elevation. Teeth shall automatically engage and self-center between the bars during the descent.

3. The gripper shall continue to be lowered until it reaches the invert elevation (or an immobile object).

4. The gripper shall be closed under hydraulic power by controls above deck level when the invert has been reached (or at any time under manual control). The hydraulic cylinders shall be suitable for submerged service.

5. When closing, the upstream teeth of the gripper shall be rotated towards the rear teeth and close in conjunction with the rear teeth to remove and lift objects or debris build up wider than the bar screen opening and within the lifting capacity of hoist.

E. Trolley

1. The trolley shall contain all the necessary traversing and hoisting equipment. This shall include the traverse motor-reducer, traversing drive and follower wheels, hydraulic power unit and hoist drums, hoist cables, hydraulic hose with spring tensioned hose reel, slack cable tension roller and limit switches, hoist raising and lowering limit switches, over-travel limit switches and proximity sensor for automatic operation.

2. The trolley shall be enclosed on all four (4) sides by a T316 stainless steel enclosure.

The two (2) sides parallel to the track shall include doors to allow access for maintenance of the internal components from the maintenance platform.

3. The traverse motor reducers shall be adequately sized to allow for continuous operation including loads from the trolley and gripper fully loaded with a minimum service factor of

1.15. 4. The hoist motor reducer shall be adequately sized to allow for continuous operation including loads from the gripper fully loaded with a minimum service factor of 1.15. The hoist drive unit shall be mounted directly onto the hoist drum shaft. The hoist drums shall be sized to properly wind the wire ropes during raising or lowering operations. The hoist drums shall be machined from heavy tubing and shall include welded ends with hubs keyed to the hoist shaft. The trolley unit shall include two (2) hoist drums. The opposite end of the hoist shaft shall include a chain drive and nylon pinion to properly operate the hydraulic hose reel in unison with the hoist drums. The hydraulic hose reel shall be spring tensioned to prevent the hoses from allowing slack. The hoist shaft shall also include two (2) slack rope rollers which shall maintain a constant tension on the hoist cables and stop the lowering operation of the hoist upon sensing a “slack” hoisting wire rope.

5. The hydraulic pump unit shall provide fluid to open and close the hydraulic cylinders mounted on the gripper. The unit shall be capable of continuous operation and shall be sized to develop 1300 psig. The unit shall include all the necessary components for adequate operation including but not limited to the motor, pump, coupling, oil return filter, oil reservoir, hydraulic hoses and fittings. The unit shall trip “OFF” and signal “Hydraulic Failure” if the required fluid level is not maintained. The hydraulic unit shall be filled with biodegradable fluid with additives at the required viscosity based on service conditions.

The hydraulic fluid reservoir shall be fitted with a thermostatically operated heater to maintain a minimum temperature of the hydraulic fluid during cold weather conditions.

F. Monorail

1. The monorail shall be manufactured from structural shapes and folded plate or two (2) carbon steel channels with an intermediate plate welded between the facing flanges to protect the traverse drive motor/wheels and other trolley components from inclement weather. Designs utilizing an open “I” beam or wide flange monorail shall not be allowed.

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2. The monorail structure shall be of sufficient size and strength to withstand the forces from the trolley, fully loaded gripper, required support span, seismic forces, and wind speeds as specified in the site data and in accordance with AISC practices.

3. The monorail shall include caps at each end to prevent over travel and access plates to allow for access/removal of the trolley and gripper. The monorail shall be constructed of galvanized carbon steel.

G. Monorail Support Truss

1. Coordinate materials of construction with structural support components. See Drawings and refer to items specified under Division 05.

H. Maintenance Platform

1. The maintenance platform shall be constructed of galvanized carbon steel with ladders as shown on the Drawings. Grating shall be galvanized carbon steel.

2. Aluminum or galvanized carbon steel hand rails shall be supplied to enclose the area around the maintenance platform.

3. The maintenance platform will provide access to both sides of the Bosker trolley for maintenance purposes.

I. Columns

1. The truss support columns shall be manufactured from galvanized carbon steel tubing and plate as shown on the Drawings. The columns shall be adequately sized to support the truss and monorail at the spacing indicated on the drawings.

2. The columns shall be “H” shaped or “L” shaped with heavy flanged feet for fixing to the deck and discharge area as shown on the Drawings. The feet shall be grouted in place by the contractor and shall be anchored via properly sized approved seismic anchor bolts as shown on the Drawings.

J. Power Rail

1. Electrical power shall be supplied to the trolley unit via a power rail located within the enclosed monorail. Power rail shall be suitable outdoor use and atmospheric weather conditions.

2.4 Electrical Controls
A. General

1. Main and local electrical control panels shall be designed by the manufacturer and shall be provided in NEMA 4X stainless steel enclosures.

2. Remotes shall be designed by the manufacturer and shall be provided in NEMA 3R stainless steel enclosures.

B. Control Panels, Local Control Station, and Wireless Remote The controls shall include the necessary components to allow for proper operation of the equipment and shall consist of the following components.

1. One (1) NEMA 4X 316 stainless steel control panel, internally prewired, to house the necessary contactors, terminal blocks, control power transformer, fuses, relays, indicator lamps and pushbuttons including an Allen Bradley PLC. The panels shall be attached to the rear of the trolley. The Allen Bradley PLC shall be housed in a separate NEMA 4X 316 stainless steel enclosure separate from the 480-volt distribution components.

2. One (1) wireless remote to house the pushbuttons for opening and closing the gripper, raising and lowering the gripper and traversing left and right under manual control. The wireless remote shall allow operation of the equipment in the manual mode and in case of a PLC failure.

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3. One (1) NEMA 4X local control station shall be mounted at deck level and shall include an HMI for operation of the equipment as well an H-O-A switch. Access to the PLC shall be available from this enclosure from an Ethernet over radio connection. E-Stops shall also be included in this local panel.

4. Access into the control panels shall be through a door complete with a mechanically interlocked isolating switch which renders the internal circuits safe, unless they are behind indented insulated shrouds or of “safe” low voltage levels.

5. The control panels shall be fitted with a thermostatically controlled anti-condensation heater separately fused.

6. The panels shall include any additional controls, indications or alarms considered necessary for safe operation and protection of the equipment.

7. “Emergency Stop” pushbutton(s) mounted in NEMA 4X enclosures of the twist to reset pattern shall be provided on the screen rake assembly support columns at required safe spacing. These E-Stops shall be tied in to the local NEMA 4X local control station.

C. Differential Level Sensors

1. The Bar Screen Cleaner Manufacturer shall supply submersible level transducers for the bar screens. One (1) transducer shall be mounted upstream of the bar screens and one (1) transducer shall be mounted downstream of the bar screens (two total). The submersible transducers shall be as specified in Section 40 72 13.

2. An excess differential head signal across the screens shall initiate a cleaning cycle.

D. General Operational Description

1. The gripper cleans the screen section by section, returning to the dump area to discharge its load after each cleaned section.

2. The system may be operated automatically or manually. Automatic Operation may be started by one of the following:
a. By depressing the start pushbutton on the local control panel b. By the time clock in the main control panel
c. By the differential level controls

3. When the start command is given, the trolley shall traverse towards the first raking position. As the trolley approaches the raking position, a proximity switch senses the first pick-up plate and the traverse motor stops.

4. After a preset delay the hoist motor is switched on and the gripper is lowered down the screen.

5. The correct depth is sensed by the rotating arm in the trolley actuating the proximity switch and the hoist motor stops. If the proximity switch fails to stop the hoist motor, the mechanical limit switch is actuated and a fault is indicated. If the gripper encounters an obstruction before it reaches the bottom of the screen, the slack rope device actuates a proximity switch which then operates in the same way as the lower limit switch. Again, if the switch fails, a mechanical back up switch is actuated, and a fault is indicated.

6. When the hoist motor stops, either under control from the lower limit or slack rope proximity switches, the hydraulic valve to the gripper cylinders moves to close, the hydraulic motor starts, and the gripper is closed.

7. When the cylinders are fully closed, the increase in hydraulic pressure actuates a bypass, the hydraulic motor stops and the hoist motor starts. If the correct fluid level is not maintained, a fail lamp shows on the control panel. A failure is also indicated if the cycle time is exceeded.

Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 10

8. As the gripper enters the swing restrictor plates on the trolley, the upper hoist proximity switch is actuated, the hoist motor is stopped, and the traverse motor starts toward the dump area. If the proximity switch fails a mechanical back up switch is actuated, and a fault is indicated. As the gripper approaches the selected dump area, the proximity switch on the trolley detects the sensing plate and the traverse motor stops. The hydraulic control valve moves to the open position, the hydraulic motor starts, and the gripper opens.

9. When the cylinder(s) reaches the full open position, the hydraulic pump stops and resets the traverse.

10. The cycle is repeated and trolley proceeds to the next programmed raking position.

When all programmed positions have been raked, the trolley will traverse and then stop at the “Park” position.

E. System Operation - Automatic

1. The automatic controls of the bar screen cleaner shall be as follows:
a. Programmable for set frequencies of operation overriding the differential level controls.
b. An adjustable time delay from the “start” signal during which time [both visual and audible alarms shall operate.

F. System Operation - Manual

1. Manual Operation shall be performed by depressing the appropriate momentary contact pushbutton on the remote.

2. The operator moves the trolley and gripper out along the track until it is properly positioned above the selected area or bar screen to be serviced.

3. The operator then verifies the gripper teeth are open and then proceeds to lower the gripper. As the gripper descends, the rear teeth shall engage with the screen bars near the top of the Bar Screen. As the gripper continues to descend, accumulations of debris shall be collected into the “jaws” of the gripper until the invert elevation is reached where lowering shall automatically cease. The operator may now close the gripper and raise it along with accumulated screenings to a point above deck level where raising shall automatically cease.

4. With the gripper at fullest height, the operator may now traverse the trolley to the predetermined dumpsite. When the operator verifies that the gripper is properly positioned over the dump area, the operator may open the gripper to dump the contents.

5. The operator will then traverse the gripper to the next cleaning position and repeat the previous steps. When all the positions have been cleaned, the gripper may be returned to the predetermined “Park” position until the next cleaning cycle is required.

6. The system shall incorporate several safety functions as follows:
a. If a large quantity of debris or other obstruction prevents the gripper from descending to the invert elevation, a “Slack Rope” limit switch shall cease the lowering motion.

The gripper may then be closed, raised and the debris taken to the dump area. b. Limit switches shall be fitted to each end of the track to prevent inadvertent overtravel. c. If hydraulic fluid level is not maintained, a “Hydraulic Failure” will be indicated at the main panel.

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2.5 Equipment Guards
A. The trolley enclosure shall include access doors which shall only be opened with the machine disabled to allow maintenance. The trolley and gripper shall operate on an overhead monorail and cannot be guarded during operating from below therefore extreme caution shall be utilized during operation.

B. The equipment will be located within a secured fenced area to prevent unauthorized access. Authorized personnel will need to be aware surroundings during automated operation of the trolley system. Contractor shall post caution signs within the site to warn personnel of the automated equipment operation.

2.6 Finishes
A. Stainless Steel components shall be provided with an ASTM A-240 or A-276 finish.

B. Galvanized components shall be provided with an ASTM A-123 or ASTM A-153 finish, whichever is applicable.

2.7 Spare Parts
A. Provide the following spare parts in the quantities noted:

1. Oil Filter: 2 Each

2. Hydraulic Hoses to Gripper: 1 Set

3. Hydraulic Hoses to Cylinder: 1 Set
B. The spare parts shall be tagged and stored by the contractor in accordance with the project requirements
PART 3 - EXECUTION

3.1 Installation
A. The bar screen manufacturer shall provide factory-trained personnel to supervise installation, adjustment, field testing and initial operation of all components.

B. The bar screen guides shall be aligned connected and installed at the locations shown and in accordance with the manufacturer’s recommendations.

3.2 Operator Training
A. The bar screen supplier shall provide two (2) 4-hour instruction sessions conforming to the requirements of the training specifications. The training sessions shall include preventive maintenance requirements, overhaul and troubleshooting instructions and normal operating practices.

3.3 Field Quality Control
A. The following operational tests shall be performed in the sequence specified. Tests shall be conducted with the raking machine supplier’s Field Representative present.

1. Test 1: The contractor shall test the traversing length of each trolley by hand operation to verify that the trolley shall reach the farthest bar screen at the side opposite the trolley parking position. The trolley shall then be traversed to the respective parking position where traversing further in that direction shall be prevented. This test shall be conducted until three (3) successful consecutive tests are achieved.

2. Test 2: The contractor shall park the trolley at the respective dumpsite and lower the trolley to the ground elevation to verify that the lowering operating shall cease upon the trolley resting on the ground and providing a slack rope situation. The gripper shall then be raised to its fullest height to verify the hoist shall stop upward motion upon rising to Project Owner AUTOMATIC TROLLEY-MOUNTED TRASH SCREEN RAKE New River Improvement Project – Calexico 41 24 00 - 12
the proper height. This test shall be conducted until five (5) successful consecutive tests are achieved.

3. Test 3: The contractor shall test the opening and closing capabilities of the gripper and verify it shall fully open and close as required. This test shall be conducted until five (5) consecutive test have been achieved.

4. Test 4: The contractor shall test the automatic modes of each system separately as follows: the system shall be switched to “automatic” and the 24-hour timer prevented from engaging. Each set (separately) of upstream transducers shall have objects placed below the sensor to provide a false differential. The test shall verify that the trolley properly parks over each bar screen, the gripper lowers, closes and raises, the trolley returns to the dumpsite, the gripper opens, then returns to the next bar screen until all or the respective bar screens have been cycled through. Each transducer set shall be tested separately at least one (1) time.

5. Test 5: The contractor shall engage the time clock to prove that the system shall cycle through the entire set of bar screens. Time clock shall be tested at least once or until one successful test is achieved.

END OF SECTION

Calexico City CouncilAugust 10, 2022

Calexico City Council
August 10, 2022