Crescent City City Council
April 7, 2025

SURGE TANK PROJECT
CONTRACT 2025-1080
33 11 13 – PIPELINES AND APPURTENANCES
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2. Cement Mortar Coating
a. Exterior coating which requires removal around the complete circumference of the pipe shall be repaired by removing the coating by chipping with a hammer or chisel, squaring the edges to accept repair patch. Wrapping the area with 2 x 4 x 14 GA self-furring wire mesh or an approved stucco netting and guniting the area being patched and hand troweling mortar onto the area being patched. Applying an approved curing compound to the patched area. Avoiding movement and protecting the pipe until the cement mortar achieves its initial set, not less than three hours. b. Exterior coating that does not extend around the entire circumference of the pipe shall be repaired by removing the coating by chipping with a hammer and chisel, squaring the edges to accept repair patch. Applying by brush an approved bonding agent to both the steel area and the edges of the remaining coating. Applying cement mortar to the area being patched and thoroughly compacting it, with finished patch mounding up above and overlapping (at least 1 inch on all sides) the surrounding coating. Applying an approved curing compound to the patched area. If the repair patch is made on pipe in the ditch, it shall be covered with wet burlap, heavy cloth, or similar material, and dirt shall be placed around and over the patched area by hand before proceeding with placing backfill material. c. The cement mortar mix proportions shall be the same as for lining repair. d. If the area to be patched exceeds over half of the pipe circumference, 2 x 4 x 14 GA self-furring wire mesh or an approved stucco netting shall be attached to the pipe prior to the application of the cement mortar.

3. Installation of Repaired Pipe: After the repaired area has achieved initial set, not less than six hours, the pipe section can be installed, providing the patched area of the coating is backfilled with water saturated or wetted soil.

3.6 PVC PIPE INSTALLATION
A. Pipe manufacturer, fitting manufacturer, and material supplier, in addition to the City and the City’s representative, shall have access to the Work during installation. Contractor shall use assistance provided by either manufacturer or supplier where required for proper installation of pipe, fittings, or materials; however, Contractor shall limit role of either manufacturer or supplier to advisory service.

B. All pipe shall be laid true to line and grade and at the locations as shown by the Construction Drawings or as specified. Pipe shall be installed in accordance with AWWA C605 and Manual M23 (latest) (including AWWA C905 pipe and couplings), applicable provisions of manufacturer’s installation guides (latest) and manufacturer's directions. City shall approve manufacturer’s product before its use. Contractor shall furnish City with two manufacturer installation guides for use during construction. Bell ends shall be placed uphill unless otherwise specified.

C. Unless otherwise specified or shown on the Drawings, backfill within the pipe zone shall have a minimum sand equivalent of 50 as determined by ASTM D2419 (latest).

D. After pipe has been set in trench, exterior of spigot and interior of bell shall be thoroughly cleaned. Lubricant recommended by pipe manufacturer and as approved by the City shall be applied to rubber gasket. Lubricant shall be water soluble, nontoxic, shall impart no objectionable taste or odor to the water, shall have no deteriorating effects on the rubber gaskets, and shall not support growth of bacteria. Excess lubricant shall be removed. Pipe ends shall be aligned, and spigot shall be pulled into bell with come-along devices, or

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hoists with chains and slings, unless permitted otherwise. If either the pry bar or the backhoe bucket method is permitted, a timber header shall be placed between the pipe and the pry bar or backhoe bucket before the spigot is pushed into bell.

E. Curved alignment of AWWA C900 pipe shall be accomplished by longitudinal bending of the pipe. Minimum allowable bend radii shall be as specified by the pipe manufacturer.

Unless otherwise allowed by the pipe manufacturer and approved by the City, axial deflection at the pipe joints of AWWA C900 pipe is prohibited. Where closing sections are required, Contractor shall make all necessary measurements to select appropriate pipe lengths and closure couplings for correct installation.

F. Curved alignment of AWWA C905 pipe by use of longitudinal bending is prohibited; however, curved alignment by use of pulled joints will be permitted. Unless otherwise allowed by the pipe manufacturer and approved by the City, maximum joint deflection shall be one (1) degree. For purposes of reducing angular deflections at pipe joints and for closure sections, Contractor may install pipe sections of less than standard length. Where closing sections are required, Contractor shall make all necessary measurements to select appropriate pipe lengths and closure couplings for correct installation.

G. Whenever cutting of pipe is required, it shall be done with a special cutting tool specifically made for cutting and machining PVC pipe. Cut ends and rough edges shall be ground smooth and beveled for push-on joints.

H. Pipe locator wire (No. 14 AWS insulated copper) shall be installed in trench with pipe where shown by the Standard Drawings unless it is specifically deleted by the Construction Drawings or by City. It shall be held in place by looping the pipe at 20-foot intervals maximum, or as specified.

I. As work progresses, a pipe cleaning tool as approved by City shall be drawn through the pipe to remove dirt, rocks, or other foreign material. At the end of each day’s work, all openings in the pipeline shall be plugged with watertight expandable plugs or City approved equal.

J. Unless specified otherwise, polyvinyl chloride pipe shall not be encased with concrete. If protection is necessary, it shall be accomplished by the use of conductor casing(s) as approved by City.

3.7 FIELD HYDROSTATIC TEST AND LEAKAGE TEST
A. Hydrostatic and Leakage Test shall be performed in accordance with Section 33 14 00.

B. Required test pressures shall be applied by pump connected to pipeline sections being tested. The City shall approve pump connections to pipeline before testing begins. As part of the Work, and unless specified otherwise, Contractor shall install, at his expense, top outlets (service taps) required for testing. Contractor shall provide calibrated meters for measurement of leakage, and all pumps, piping, fittings, bulkheads, plugs, valves, gages, power equipment, and manpower necessary for conducting all tests required, all at his expense. Contractor shall furnish the City three copies of all records of all tests performed.

C. Unless specified otherwise, Contractor shall test against test plates for pipelines 12 inches and smaller. Contractor shall not remove said test plates until pipelines have been tested, disinfected, and accepted by the City.

D. Contractor, at his expense, shall locate and repair leaks or other defects which may develop or become apparent during test. Contractor shall excavate, including removal of backfill already placed, and make all repairs necessary for required water tightness, and then replace all excavated material, after which Contractor shall retest repaired pipeline

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section. Pipeline sections shall be repeatedly repaired and tested until they meet requirements set forth herein.

E. Pipe manufacturer and fitting manufacturer shall have free access to the Work during testing. Any improper act on the part of Contractor which the pipe and fitting manufacturer may observe shall be reported to the City. Pipe and fitting manufacturer shall be free to observe and verify all tests.

F. After completed pipeline and appurtenances or test sections have successfully met test requirements to the satisfaction of the City, the entire pipeline or each test section shall be filled or shall remain filled with water until completion of the Work, unless otherwise ordered by the City.

3.8 MISCELLANEOUS REQUIREMENTS
A. Connections to Existing Water Mains: The Contractor shall make all connections to existing water mains in the presence of City’s Inspector. Contractor shall provide all labor, equipment, and materials necessary to perform connection work including, but not limited to, isolation gate valve, fittings, and adapters.

B. Hydrostatic testing against isolation valves will not be allowed. Adjacent to the isolation valve, Contractor shall install a test plate for the aforementioned test and, after satisfactory test, remove said test plate and replace it with a 1/8 inch thick minimum ring gasket. The use of any other test appurtenances shall be as approved by the City.

C. Field Painting: Contractor shall field paint all aboveground, bare, or exposed piping and appurtenances in accordance with the applicable specifications and drawings.

D. Plastic detectable warning tape shall be installed above the piping a maximum of 3 feet below grade.

END OF SECTION

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CONTRACT 2025-1080
33 12 16 – MANUAL VALVES
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SECTION 33 12 16

MANUAL VALVES
PART 1 - GENERAL

1.1 DESCRIPTION
This Section includes materials, testing, and installation of manually operated valves and check valves.

1.2 SUBMITTALS
Furnish submittals in accordance with the requirements of technical specifications and plans. The following submittals are required:

1. Manufacturer’s catalog data and detail construction sheets showing all valve parts and describing material of construction by material and specification (such as AISI, ASTM, SAE, or CDA)

2. Valve dimensions including laying lengths. Show dimensions and orientation of valve operators, as installed on the valves.

3. Valve linings and coatings
PART 2 – MATERIALS

2.1 GENERAL
Provide valves complete with operating handwheels, levers, chainwheels, extension stems, floor stands, worm gear operators, operating nuts, chains, and wrenches required for operation. Valves shall have the name of the manufacturer and the size of the valve cast or molded onto the valve body or bonnet or shown on a permanently attached plate.

1. All parts in contact with potable water shall be fabricated from approved no lead/ultra-low lead material containing residual lead levels that shall not exceed a maximum of 0.25% weighted average lead content as per California Health and Safety Code Section 116875. Moreover, said parts in contact with drinking water supply shall be certified as suitable for contact with potable water in compliance with ANSI/NSF Standard 61, Drinking Water System Components – Health Effects. Parts not in contact with potable water shall comply with the requirements of ASTM B62 and ASTM B584 Copper Alloy Number C83600 or C84400, respectively.

2.2 VALVE OPERATORS
A. Operators for Exposed Valves Smaller Than 6 Inches: Provide lever or wrench operators having adjustable, open stop memory positions for exposed valves smaller than 6 inches.

B. Operators for Buried and Submerged Valves

1. Provide direct acting 2-inch square AWWA operating nuts for all buried and submerged valves less than 6 inches, and for buried and submerged gate valves less than 24 inches.

2. Provide watertight shaft seals and watertight valve and actuator cover gaskets. Provide totally enclosed operators designed for buried or submerged service.

C. Operators for Valves 6 Inches and Larger

1. Provide gear operators on butterfly, plug, and ball valves 6 inches and larger. Gear operators for valves 8 inches through 20 inches shall be of the worm and gear, or of the traveling nut type. Gear operators for valves 24 inches and larger shall be of the worm and gear type.

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2. Enclose gear operators, suitable for running in oil, with seals provided on shafts to prevent entry of dirt and water into the operator. Gear operators for valves located above ground or in vaults and structures shall have handwheels. Minimum handwheel diameter shall be 12 inches.

3. Gear operators shall be of the totally enclosed design, proportioned to permit operation of the valve under full operating head with a maximum pull of 80 pounds on the handwheel or crank.

Operators shall be provided with open and closed position stop limiting devices. Operators shall be of the self-locking type to prevent the disc or plug from creeping. Design operator components to withstand a pull of 200 pounds for handwheel or chainwheel operators between the input and stop limiting devices without damage, and an input torque of 300-footpounds for operating nuts when operating against the stops.

4. Self-locking worm gears shall be a one-piece design of gear bronze material (ASTM B 427), accurately machine cut. The worm shall be hardened alloy steel (ASTM A 322, Grade G 41500; or ASTM A 148, Grade 105-85), with thread ground and polished. The reduction gearing shall run in a proper lubricant. Operators shall be Limitorque Model T Series, EIM Model MG or approved equal.

5. Gear operators shall be able to rotate the valve element (disc, plug or ball) from the fully closed position to fully open in a number of turns of the operator not exceeding two times the valve diameter in inches (i.e., for a 12-inch valve, the number of turns of the operator shall not exceed 24).

D. Operating Torque Requirement for Buried Valves: Design operators on buried valves to produce the required torque on the operating nut with a maximum input of 150- foot pounds.

E. Opening Direction: Valve operators, handwheels, or levers shall open by turning counterclockwise.

F. Position Indicators: Provide valve position indicators for all above ground valves.

2.3 VALVE BOXES FOR BURIED VALVES
A. General: Valve boxes shall be 8-inch Class 100 asbestos cement pipe, 8-inch Schedule 40 PVC pipe, or 8-inch SDR sewer pipe.

B. Valve Box Caps: Valve box caps shall be cast iron, and shall be designed to rest without a frame on a cast-in-place concrete ring surrounding the valve extension pipe. Taper the cap skirt for a close fit inside the upper sleeve portion of the valve box. Minimum weight of nominal 10-inch cap shall be 40 pounds. Caps for potable water valve boxes shall be circular with the word WATER cast on the cap. Caps for reclaimed water valve boxes shall be triangular with the word “IRRIG” cast on the cap. Coat caps per manufacturer’s recommendation. Color for potable waterlines shall be OSHA-ANSI safety yellow. Color for reclaimed waterlines shall be purple (Pantone 512).

C. Manufacturers: Valve boxes for potable water lines shall be Brooks 3RT, Eisel Enterprises, Inc. H & C No. 10, or approved equal. Valve boxes for reclaimed water lines shall be Brooks 4TT, Eisel Enterprises, Inc. H & C 4TT, or approved equal.

2.4 EXTENSION STEMS FOR BURIED VALVE OPERATORS
Where the depth of the valve is such that its operating nut is more than 3 feet below grade, provide operating extension stems to bring the operating nut to a point between 24 to 36 inches below the surface of the ground and/or box cover. Extension stems shall be steel and shall be complete with 2- inch-square operating nut. Provide stem with a 1/8-inch center guide to keep stem centered. Do not use pinned couplings.

2.5 BOLTS, NUTS, AND GASKETS FOR FLANGED VALVES
Describe bolts and nuts for flanged valves in the detailed individual piping specifications.

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2.6 PAINTING AND COATING
A. Above Ground Valves or Valves in Vaults: Coat metal valves (except bronze and stainless steel valves) located above ground or in vaults and structures in accordance with manufacturer’s recommendations. Apply the specified prime coat at the place of manufacture. Apply intermediate and finish coats in field. Finish coat shall match the color of the adjacent piping. Handwheels shall receive the same coating as the valves.

B. Buried Valves: Coat buried metal valves and extension stems at the factory per the manufacturer’s recommendation.

C. Interior Coating: Coat metal valves 4 inches and larger on the interior metal parts, excluding seating areas and bronze and stainless steel pieces, per the manufacturer’s recommendation.

Coating shall be applied at the factory by the valve manufacturer.

2.7 VALVES
A. Above Ground Gate Valves 3 Inches and Smaller: Above ground gate valves, 1/4-inch through 3 inches, for water service shall be non-rising stem, screwed bonnet, solid wedge disc type designed for a minimum working pressure of 220 psi. Valves shall have threaded ends. Materials of construction shall be as follows:

Component Material Specification
Body, Bonnet, Disc Bronze ASTM B62
Stem Bronze or ASTM B62, B99
Copper Silicon (Alloy 651), B584
(Alloy C87600),
B371 (Alloy 694)
Stem material shall have a minimum tensile strength of 60,000 psi and a minimum yield strength of 30,000 psi. Handwheels shall be brass. Packing shall be Teflon asbestos. Valves shall be Crane 438, Stockham 103, or approved equal.

B. Buried Gate Valves Smaller Than 3 Inches: Buried gate valves for air or water service shall be non-rising stem type, double disc, parallel seat, and shall be designed for a minimum working pressure of 200 psi. Valves shall have flanged, PVC, or threaded ends as required for the type of pipe used. Materials of construction shall be as follows:

Component Material Specification
Body, Bonnet, Cast Iron ASTM A126,
Operating Nut, Class B
stuffing box
Bonnet Bolts Steel, Cadmium ASTM A307,
Stuffing Box Plated Grade B; B766
Bolts Class 25, Type II
Discs, Disc Nut, Bronze ASTM B62
Disc Ring, Seat Nut
O-ring Synthetic Rubber ASTM D2000

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Stem Copper Silicon or ASTM B584,
Manganese Bronze Alloys C86200,
C86300, C86400,
C87500, or C87600
Valves shall be Stockham G-736, G-739, or G-745; Kennedy Figure 597X or 561X; Mueller Series A2380; or approved equal.

C. Gate Valves 3 Inches and Larger: Valves shall conform to AWWA C500 and the following. Valves shall be non-rising stem, parallel faced, bottom wedging double-discs, with O-ring seals. The minimum designated water working pressure shall be 200 psi for valves 3 inches through 12 inches and 150 psi for larger valves. Bronze for internal working parts, including stems, shall not contain more than 2% aluminum nor more than 7% zinc. Bronze shall be ASTM B 62 (85-5-5-5) bronze, except that stem bronze shall have a minimum tensile strength of 60,000 psi, a minimum yield strength of 30,000 psi, and a minimum of 10% elongation in 2 inches. Materials of construction shall be as follows:

Component Material Specification
Body, Bonnet, Cast Iron ASTM A126,
Operating Nut Class B
Stuffing Box
Bonnet Bolts Stainless Steel ASTM A276,
Stuffing Box Type 316
Bolts
Disc, Disc Pin, Bronze ASTM B21,
Seat Ring ASTM B62
Stem Bronze ASTM B138
O-ring Synthetic Rubber ASTM D2000
Valves shall be Clow AWWA gate valves, Kennedy AWWA gate valves, Mueller Series A2380, or approved equal.

D. Butterfly Valves 4 Inches and Larger, Class 150B: Butterfly valves shall be short body, flanged type, conforming to AWWA C504, Class 150B. Do not use wafer style valves. Unless otherwise noted, minimum working differential pressure across the valve disc shall be 150 psi. Valve ends shall be as shown on the drawings; flanged ends shall be Class 125, ANSI B16.1. Valve shafts shall be Type 304 or 316 stainless steel, or carbon steel with Type 316 stainless steel journals and static seals. Valve shafts shall be stub shaft or one-piece units extending completely through the valve disc. Test valve bodies at a pressure equal to twice the design working pressure.

Materials of construction shall be as follows:

Component Material Specification
Body Cast Iron or ASTM A48,
Ductile Iron Class 40; ASTM
A126, Class B; or
ASTM A536, Grade 65-45-12
Exposed Body Stainless Steel ASTM A276,
Capscrews, and Type 316

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Bolts and Nuts
Discs Cast Iron ASTM 126, Class B
Stainless Steel 316
The rubber seat shall be an integral part of the valve body. Rubber seats fastened to the disc by any means are not allowed. Valves shall be Pratt Monoflange MKII or approved equal.

E. Ball Valves 2 Inches and Smaller: Ball valves, 2 inches and smaller, for water service shall be stainless steel, and shall be rated at a pressure of 300 psi WOG at a temperature of 150°F.

Valves shall have plastic coated lever operators. Valves shall have full bore ports, screwed ends, and non-blowout stems. Materials of construction shall be as follows:

Component Material Specification
Body, Ball, Stainless Type 316, ASTM
Stem Steel A276
Seat, Seals Teflon
Valves shall be Stockham Figure S-127, or approved equal.

F. Ball Valves 2-1/2 Inches to 6 Inches: Ball valves 2-1/2 inches to 6 inches shall be rated for a minimum working pressure of 150 psi. Valves shall have flanged ends. Materials of construction shall be as follows:

Component Material Specification
Body, Ball Ductile Iron ASTM A395,
ASTM A445
Stem Carbon Steel ASTM A216,
Grade WCB
Seat, seals Teflon
Valves shall be Jamesbury Style 150F, Powell Figure 4222T, or approved equal.

G. Lubricated Plug Valves 4 Inches and Smaller: Lubricated plug valves of sizes 4 inches and smaller shall have carbon steel bodies and plugs and shall be short pattern with bolted glands and resilient packing. Plug coating shall be Teflon, permanently bonded to the plug. Unless noted otherwise on the drawings, valve ends shall be flanged, with face-to-face dimensions conforming to ANSI B16.1, Class 125. Valves shall have a pressure rating of 200 psi WOG. Lubricate valves with manufacturer’s recommended lubricant for cold water service. Valves shall be Nordstrom Figure 1925 or approved equal.

H. Lubricated Plug Valves 6 Inches Through 20 Inches Class 125: Lubricated plug valves of sizes 4 inches through 20 inches shall have cast iron (ASTM A126, Class B) bodies and plugs. Valves shall be of the regular pattern with bolted glands and resilient packing. Plug coating shall be Teflon, permanently bonded to the plug. Unless noted otherwise on the drawings, valve ends shall be flanged, with face-to-face dimensions conforming to ANSI B16.1, Class 125. Valve shall have a pressure rating of 200-psi WOG. Valves shall be enclosed worm gear operated and watertight for submerged service. Lubricate valves with the manufacturer’s recommended lubricant for cold-water service. Valves shall be Rockwell Figure 169, Powell, or approved equal.

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I. Eccentric Plug Valves, 4 Inches Through 12 Inches: Eccentric plug valves, 4 inches through 12 inches, shall be of the non-lubricated type. Minimum pressure rating shall be 175 psi. Unless noted otherwise on the drawings, ends shall be flanged, Class 125 per ANSI B16.1. Materials of construction shall be as follows:

Component Material Specification
Body Cast Iron ASTM A126, Class B
Plug Cast Iron ASTM A126, Class B
Ductile Iron ASTM A536, Grade 65-45-12
Ni-Resist
ASTM A436
Plugs shall have neoprene facing to provide drip-tight shutoff. Valve body seats shall have a raised welded-in overlay of not less than 90 percent nickel. Packing shall be replaceable with valve body under full pressure and with valve in the fully open position. Plug shall be of the onepiece design. Valves shall be DeZurik Series 100, Figure 118, or approved equal.

J. Resilient Seated Gate Valves, 3 Inches Through 12 Inches: Resilient seated gate valves shall conform to AWWA 509 and the following requirements. Valves shall be designed for a minimum working pressure of 200 psi and shall be bubble-tight at that pressure. Valves shall have nonrising stems. Stem nuts shall be independent of the gate and shall be made of solid bronze. All internal working parts, including the stem, shall be all bronze containing not more than 2 percent aluminum or more than 7 percent zinc. Bronze shall be ASTM B62 (85-5-5-5) bronze, except that stem bronze shall have a minimum tensile strength of 60,000 psi, a minimum yield strength of 30,000 psi, and a minimum of 10 percent elongation in 2 inches. Materials of construction shall be as follows:

Component Material Specification
Body Operating Nut, Cast Iron ASTM A126, Class B
Bonnet, Seal Plate
Gate Cast Iron ASTM A126, Class B
Ductile Iron ASTM A536, Grade 65-45-12
Bonnet and Seal Stainless ASTM A276, Type 316
Plate Nuts and Bolts Steel
O-Rings Synthetic ASTM D2000
Rubber
Provide low friction, torque reduction thrust bearings both above and below the stem collar.

Stuffing boxes shall be O-ring seal type with two rings located in stem above thrust collar. Each valve shall have a smooth unobstructed waterway free from any sediment pockets. Encapsulate gates in Buna-S rubber or nitrile elastomer. Valves shall be Clow RW, Mueller A2360, American AVK, American Flow Control AFC500, and M&H Style 4067, or approved equal.

K. Check Valves 4 Inches and Larger:

1. Swing Check Valves: Swing check valves shall conform to AWWA C508, and shall be iron body, bronze mounted with the following materials of construction:

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Component Material Specification
Disc or Clapper, Bronze or ASTM B62, B16, or B584
Seat Ring, Valve Brass (alloys C84400 or
Body Seat Ring C87600)
Body and Cap Cast Iron ASTM A126, Class B
Disc and Hinge Cast Iron or ASTM A126, Class B
or Arm Bronze ASTM B62
Hinge Pin Stainless ASTM A276, Type 303,
Steel 304 or 410
Cover Bolts and Stainless ASTM A193, Grade B8M;
Nuts Steel ASTM A194, Grade 8M
Ends shall be flanged, Class 125, ANSI B16.1. Design valves for a minimum working pressure of 150 psi. Equip valve with outside lever and spring. Valves shall be Clow f-5340, M&H Style 259, or approved equal.

2. Silent Check Valves, Class 150: Design silent check valves to be installed between the flanges of the adjoining pipe. Equip valves with a spring mechanism to provide for non-slam closure of the valve without backflow, in any position, and shall not be dependent on gravity or backflow for closure. Materials of construction shall be as follows.

Component Material Specification
Body Cast Iron or ASTM A 126,
Ductile Iron Class B; or ASTM A 536,
Grade 65-45-12
Plug and Seat Bronze ASTM B 584,
Spring, Pin, Stainless Steel AISI Type 316
Stops
Sealing Element Buna-N
Valves shall be APCO Series 600, or approved equal.

L. Solenoid Valves 1-1/2 Inches and Smaller: Solenoid valves of sizes 1/4-inch through 1½ inches for water and air service shall have forged brass (Alloy C23000) or bronze (ASTM B 62) bodies with Teflon main seats. Internal plunger, core tube, plunger spring, and cage assembly shall be stainless steel (Types 302, 304, or 305). Solenoid enclosures shall be NEMA Type IV. Valve actuators shall be 120-volt AC. Seals shall be Teflon. Valves shall have a maximum operating pressure and a maximum differential pressure of 250 psi. Energize solenoid valves to open or close, as required. Valves shall be ASCO “Red Hat”, or approved equal.

M. Tapping Valves: Tapping valves shall conform with the requirements for gate valves 3 inches and larger. Valve ends shall be flanged, and the flange at one end shall have slotted boltholes to fit standard tapping machines. Seat rings shall be oversized to permit the use of full-size cutters.

Tapping valves shall be Mueller, Kennedy, or approved equal.

N. Tapping Sleeves: Tapping sleeves shall be cast iron or steel. Cast iron tapping sleeves shall be mechanical joint. Steel tapping sleeves shall be epoxy-coated in accordance with the manufacturer’s recommendation. Gaskets shall be Buna-N rubber with a wide cross section.

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Bolts, nuts, and washers shall be type 316 stainless steel. Tapping sleeves shall be Clow, Kennedy, Koppl CN-120 (with 1/4-inch wall thickness), Koppl AS-150, Mueller, Smith Blair CC622, or approved equal.

O. Detector Check Valves: Detector check valves shall have flanged ends conforming to ANSI B16.1, Class 125. Pressure test valves to twice design working pressure. Valve casing shall be hot-dipped galvanized and body shall be tapped to accept by-pass meter piping. Materials of construction shall be as follows:

Component Material Specification
Body, Bonnet Cast Iron ASTM B126 Class B
Bonnet Bolts Stainless Steel ASTM A276 Type 304
Hinge Pin Stainless Steel ASTM A276
(Shaft) Type 304 or 316
Clapper Bronze ASTM B62
Clapper Seat Bronze ASTM B62
Ring (Tinned)
Clapper Seal Rubber
Weight Lead
The mainline valve shall automatically open, permitting unrestricted flow, when the pressure loss through the by-pass meter is approximately 1.5 psi. Valves shall be Hersey EDC II, Grinnel, Mueller A-2133-6, or approved equal.

P. Corporation Stops: Corporation stops shall be manufactured of bronze conforming to ASTM B62.

The inlet fitting shall be a male iron pipe thread when used with a saddle and the outlet connection shall be a flare type unless otherwise specified.

PART 3 - EXECUTION

3.1 JOINTS
A. Flanged Joints: Bolt holes of flanged valves shall straddle the horizontal and vertical centerlines of the pipe run to which the valves are attached. Clean flanges by wire brushing before installing flanged valves. Clean flange bolts and nuts by wire brushing, lubricate threads with oil and graphite, and tighten nuts uniformly and progressively. If flanges leak under pressure testing, loosen or remove nuts and bolts, reseat or replace the gasket; reinstall or re-tighten the bolts and nuts; and re-test the joint. Joints shall be watertight.

B. Threaded Joints: Clean threaded joints by wire brushing or swabbing. Apply Teflon joint compound or Teflon tape to pipe threads before installing threaded valves. Joints shall be watertight.

3.2 VALVE INSTALLATION
A. Valves in Horizontal Piping: Unless otherwise indicated on the drawings, install valves in horizontal runs of pipe having centerline elevations 4'-6", or less, above the floor, with their

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operating stems vertical. Install valves in horizontal runs of pipe having centerline elevations between 4'-6" and 6'-9" above the floor with their operating stems horizontal.

B. Valves in Vertical Piping: Install valves on vertical runs of pipe that are next to walls with their stems horizontal, away from the wall. Install valves on vertical runs of pipe that are not located next to walls with their stems horizontal, oriented to facilitate valve operation.

C. Buried Valves: Wrap buried valves with two layers of 8-mil polyethylene wrap per AWWA C105.

D. Valve Supports: Concrete supports are not required for valves bolted to flanged pipe or fittings.

3.3 VALVE BOXES
Firmly support valve boxes and keep them centered and plumb the valve over the operating nut of the valve. Do not use beveled sections of pipe at the top of the valve extension pipe. The top cut shall be square, and machine made. In new tracts, and where pavement has not been placed, the valve extension risers for “key valves” shall extend well above the ground level to permit ease of location in case of emergency shutoffs. The final valve box elevation shall be flush with the finished pavement surface or at the elevation noted on the plans.

3.4 TAPPING SLEEVES
Install tapping sleeves in accordance with the manufacturer’s instructions. Thoroughly clean the pipe barrel with a wire brush to provide a smooth, hard surface for the sleeve. Support the sleeve independently of the pipe during the tapping operation. The sleeve shall be pressure-tested in the presence of the City prior to tapping. Provide thrust blocks at the tapping sleeve.

3.5 VALVE LEAKAGE TESTING
Test valves for leakage at the same time that the connecting pipelines are tested.

END OF SECTION

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33 13 00 – CHLORINATION OF WATER MAINS FOR DISINFECTION 1 of 4
SECTION 33 13 00

CHLORINATION OF WATER MAINS FOR DISINFECTION
PART 1 - GENERAL

1.01 DESCRIPTION
This section includes materials and procedures for disinfection of water mains by the continuous feed method and by the slug method and disinfection of structures. Disinfect piping in accordance with AWWA C651 and disinfect structures in accordance with AWWA C652 and C653, except as modified below.

1.02 RELATED WORK DESCRIBED ELSEWHERE
Pressure Testing of Piping: 40 05 15.

1.03 JOB CONDITIONS
A. Discharge of chlorinated water into watercourses or surface waters is regulated by the National Pollutant Discharge Elimination System (NPDES). Disposal of the chlorinated disinfection water and the flushing water is the Contractor's responsibility. Dechlorinate the disinfection water such that the chlorine residual complies with California Regional Water Quality Control Board Order No. R5-2008-0081, NPDES No. CAG995001.

B. Schedule the rate of flow and locations of discharges in advance to permit review and coordination with Owner and cognizant regulatory authorities:

C. Use potable water for chlorination.

D. Submit request for use of water from waterlines of Owner 48 hours in advance.

PART 2 - MATERIALS

2.01 LIQUID CHLORINE
Inject with a solution feed chlorinator and a water booster pump. Follow the instructions of the chlorinator manufacturer.

2.02 CALCIUM HYPOCHLORITE (DRY)
Dissolve in water to a known concentration in a drum and pump into the pipeline at a metered rate.

2.03 SODIUM HYPOCHLORITE (SOLUTION)
Further dilute in water to desired concentration and pump into the pipeline at a metered rate.

2.04 CHLORINE RESIDUAL TEST KIT
For measuring chlorine concentration, supply and use a medium range, drop count, DPD drop dilution method kit per AWWA C651, Appendix A.1. Maintain kits in good working order available for immediate test of residuals at point of sampling.

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2.05 DECHLORINATION MATERIALS
If dechlorination is required and the Contractor elects to use a means of chemical dechlorination, use one of the chemicals described in AWWA C655.

PART 3 - EXECUTION

3.01 CONTINUOUS FEED METHOD FOR PIPELINES
Introduce potable water into the pipeline at a constant measured rate. Feed the chlorine solution into the same water at a measured rate. Proportion the two rates so that the chlorine concentration in the pipeline is maintained at a minimum concentration of 25 mg/L. Check the concentration at points downstream during the filling to ascertain that sufficient chlorine is being added.

3.02 SLUG METHOD FOR PIPELINES
Introduce the water in the pipeline at a constant measured rate. At the start of the test section, feed the chlorine solution into the pipeline at a measured rate so that the chlorine concentration created in the pipeline is 100 mg/L. Feed the chlorine for a sufficient period to develop a solid column or "slug" of chlorinated water that will, as it passes along the line, expose all interior surfaces to a concentration of at least 100 mg/L for at least three hours.

3.03 DISINFECTION OF VALVES, BLIND FLANGES, AND APPURTENANCES During the period that the chlorine solution or slug is in the section of pipeline, open and close valves to obtain a chlorine residual at hydrants and other pipeline appurtenances. Swab exposed faces of valves and blind flanges prior to bolting flanges in place with a 1% sodium hypochlorite solution.

3.04 DISINFECTION OF CONNECTIONS TO EXISTING PIPELINES
Disinfect isolation valves, pipe, and appurtenances per AWWA C651, Section 4.7. Flush with potable water until discolored water, mud, and debris are eliminated. Swab interior of pipe and fittings with a 1% sodium hypochlorite solution. After disinfection, flush with potable water again until water is free of chlorine odor.

3.05 CONFIRMATION OF RESIDUAL IN PIPING
A. After the chlorine solution applied by the continuous feed method has been retained in the pipeline for 24 hours, confirm that a chlorine residual of 10 mg/L minimum exists along the pipeline by sampling at air valves and other points of access.

B. With the slug method, confirm by sampling as the slug passes each access point and as it leaves the pipeline that the chlorine concentration in the slug is at least 50 mg/L.

3.06 PIPELINE FLUSHING
After confirming the chlorine residual, flush the excess chlorine solution from the pipeline until the chlorine concentration in the water leaving the pipe is no higher than that generally prevailing in the distribution system.

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3.07 SAMPLING AND BACTERIOLOGIC TESTING
A. There shall be no water in trenches up to the connection for sampling. The sampling piping shall be clean, disinfected, and flushed prior to sampling.

B. Collect two sets of samples per AWWA C651, Section 5.1, deliver to a certified laboratory within six hours of obtaining the samples, and obtain a bacteriologic quality test to demonstrate the absence of coliform organisms in each separate section of the pipeline and in each structure after chlorination and refilling. Collect at least one set of samples from every new water main plus one set from the end of the pipeline and at least one set from each branch. At each connection to an existing pipeline, take two additional samples. Use pipeline blowoffs and dedicated sampling ports for obtaining samples.

3.08 PIPING TEST FACILITY REMOVAL
After satisfactory disinfection, disinfect and replace air valves, restore the pipe coating, and complete the pipeline where temporary disinfection or test facilities were installed.

3.09 PIPING TO BE DISINFECTED
A. Disinfect all piping except:

1. Sewers, reclaimed water, and drainage piping.

2. Storm drain piping.

3. Reinforced concrete and vitrified clay pipe.

B. Disinfect (internally) any piping inside the following structures:

1. Surge tank.

3.10 DISINFECTION OF STRUCTURES
A. Disinfect per AWWA C652, Method 1, 2, or 3 and AWWA C653.

B. Disinfect the interior of the following structures:

1. Surge tank.

C. The Owner will provide potable water at no cost to the Contractor for the first disinfection effort.

If bacteriological testing shows that the first disinfection effort was not successful, the Contractor will be charged the cost of additional water at the Owner's current rates.

3.11 REPETITION OF PROCEDURE
If the initial chlorination fails to produce required residuals and bacteriologic tests, repeat the chlorination and retesting until satisfactory results are obtained.

3.12 DECHLORINATION
Dechlorinate per AWWA C655. Perform testing of residual chlorine before discharge of water into the environment.

3.13 DISPOSAL OF WATER

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Chlorinated water will be trucked to a local quarry site and sprayed on the land. Contractor to provide information to City staff on proposed disposal site location with requirements/conditions.

END OF SECTION

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33 14 00 – WATER MAINS
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SECTION 33 14 00

WATER MAINS
PART 1 – GENERAL
A. The work to be done under this section shall include the labor, tools, equipment, and necessary incidentals to install water mains, fittings, valves, fire hydrants, precast utility boxes, thrust blocks and related incidentals complete and in place.

B. Contractor shall furnish all necessary materials not otherwise provided by the Owner in order to install a complete and functioning system. Materials furnished by the Contractor shall conform to the requirements of Part 2 Products herein.

PART 2 – PRODUCTS
A. Pipe shall be poly vinyl chloride (PVC) pipe conforming to AWWA C900-16 or Ductile Iron pipe (DIP) conforming to AWWA C151-17 of the size and type as shown on the Plans.

B. Fittings shall be Ductile Iron conforming to AWWA C110-12 unless noted otherwise on the Plans or by direction of the Owner.

C. Gate valves shall be Resilient-Seated gate valves as manufactured by Kennedy Valve Company or Mueller Company conforming to AWWA C509- 01, or equal.

D. Double check valves (backflow prevention devices) shall be lead-free bronze for as manufactured by Apollo or Watts, conforming to AWWA C510-17, or equal.

E. Combination air valve (CAV) shall be single-body valve as manufactured by Val-matic or Apco, conforming to AWWA C512-15, or equal.

F. Blow-off valve (BOV) shall be 2" threaded brass with adjustable pressure setting as manufactured by Ford or equal.

G. Fire Hydrants shall be Clow Valve Company Model 860 wet barrel hydrant conforming to AWWA C503-14, with one 4½ inch NST outlet and two 2½ inch NST outlets.

H. Concrete for thrust blocks shall conform to Specification 03 30 00.

I. Concrete for precast boxes housing water valves, appurtenances, or accessories shall conform to Specification 03 48 00. The Contractor shall propose sizes for precast boxes following the submittal procedures in Specification 01 33 00.

F. Restraint joint connectors shall be “Megalug” by EBBA Iron or “Gripring” by Romac Industries or approved equal.

PART 3 – EXECUTION
A. The Contractor shall provide all labor, materials, tools, equipment, and

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necessary incidentals, to install water mains, fittings, valves, fire hydrants, thrust blocks and related incidentals as indicated on the Plans, described herein or as otherwise required for a complete job.

B. Underground pipe installation shall be in accordance with AWWA C605-13 for PVC pipe and AWWA C600-17 for Ductile Iron pipe. The installed pipe shall be pressure tested to 100 psi and in accordance with AWWA C605-13 as regards procedure and allowable water loss. The testing shall treat Ductile Iron pipe as if it were PVC pipe.

C. The installed pipe shall be disinfected in accordance with AWWA C651.

D. All points where change of direction of water flow may occur and end of lines shall be properly retrained with thrust blocks and restraint connectors.

E. All connections to fittings tees, valves, bends, end of line plugs/caps, shall use restraint connectors (Megalug, Gripring or equal).

END OF SECTION

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CONTRACT 2025-1080
40 05 00 – GENERAL PIPING REQUIREMENTS
1 of 5
SECTION 40 05 00

GENERAL PIPING REQUIREMENTS
PART 1 - GENERAL

1.01 DESCRIPTION
This section describes the application of the piping materials shown in the drawings and the general requirements for selecting piping materials; selecting the associated bolts, nuts, and gaskets for flanges for the various piping services in the project; and miscellaneous piping items.

1.02 SUBMITTALS
A. Submit shop drawings in accordance with the General Provisions and Section 01 33 00.

B. Submit affidavit of compliance with referenced standards (e.g., AWWA, ANSI, ASTM, etc.).

C. Submit certified copies of mill test reports for bolts and nuts, including coatings if specified.

Provide recertification by an independent domestic testing laboratory for materials originating outside of the United States.

D. Submit manufacturer's data sheet for gaskets supplied showing dimensions and bolting recommendations.

1.03 DEFINITIONS OF BURIED AND EXPOSED PIPING
A. Buried piping is piping buried in the soil, commencing at the wall or beneath the slab of a structure. Where a coating is specified, provide the coating up to the structure wall. Unless detailed otherwise, coating shall penetrate wall no less than 1 inch. Piping encased in concrete is considered to be buried. Do not coat encased pipe.

B. Exposed piping is piping in any of the following conditions or locations:

1. Above ground.

2. Inside buildings, vaults, or other structures.

3. In underground concrete trenches or galleries.

1.04 PIPING SERVICE
Piping service is determined by the fluid conveyed, regardless of the pipe designation. For example, pipes designated "Air Low Pressure," "Air High Pressure," and "Air" are all considered to be in air service.

1.05 DEFAULT PIPING MATERIALS
If no material is shown in the drawings, use the following piping materials:

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Service
Size Range
(inches) Material
Specification
Section
Buried
Water
4 and larger Ductile iron or
Steel Pipe
40 20 40 or 40 20 57
Exposed
Water
3 and smaller Steel or stainless
steel
40 20 57 or 40 20 76
4 and larger Ductile iron or
steel pipe
40 20 40 or 40 20 57
PART 2 - MATERIALS

2.01 MATERIALS SELECTION AND ALTERNATIVE MATERIALS
A. The Piping Schedule in the drawings lists the material and specification for each piping service in the project. In locations where the piping material referenced on the Piping Schedule is not appropriate, the piping material is indicated in the drawings. Materials called out in the drawings shall govern over materials stated in the Piping Schedule.

B. The Piping Schedule in the drawings may show alternative piping materials for certain services.

In such cases, the same pipe material shall be used for all pipe sizes in all locations for the given piping service. Do not intermix piping materials.

2.02 THREAD FORMING FOR STAINLESS STEEL BOLTS
Form threads by means of rolling, not cutting or grinding.

2.03 BOLTS AND NUTS FOR FLANGES FOR STEEL AND DUCTILE-IRON PIPING A. Bolts and nuts for Class 125 or 150 flanges (including AWWA C207, Class D) located indoors, outdoors above ground, and in vaults and in dry structures shall be carbon steel, ASTM A307, Grade B, hot-dipped galvanized per ASTM F2329.

B. Bolts and nuts for buried or submerged Class 125 or 150 flanges and Class 125 or 150 flanges located outdoors above ground or in vaults and structures shall be Type 316 stainless steel conforming to ASTM A193, Grade B8M for bolts and ASTM A194, Grade 8M for nuts or Type 304 stainless steel conforming to ASTM A193 (Grade B8) for bolts and ASTM A194 (Grade 8) for nuts.

C. Hex head machine bolts for use with lugged valves shall comply with ASTM A193, Grade B7.

D. Fit shall be Classes 2A and 2B per ASME B1.1 when connecting to cast-iron valves having body bolt holes.

E. Bolts used in flange insulation kits shall conform to ASTM A193 (Grade B7). Nuts shall conform to ASTM A194 (Grade 2H).

F. Provide washers for each nut. Washers shall be of the same material as the nuts.

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2.04 BOLTS AND NUTS FOR FLANGES FOR CARBON STEEL STAINLESS STEEL PIPING IN

CHEMICAL SERVICE (INCLUDING BOLTS WITHIN CHEMICAL ENCLOSURE) A. Bolts and nuts for flanges shall be Type 316 stainless steel conforming to ASTM A193, Grade B8M for bolts and ASTM A194, Grade 8M for nuts.

B. Bolts for piping in sodium hypochlorite service shall be titanium, per ASTM F467, Grade Ti1, Ti2, or Ti7. Nuts shall conform to ASTM F467, same material as the bolts.

C. Hex head machine bolts for use with lugged valves shall comply with ASTM A193, Grade B8M, Class 2.

D. Provide washer for each nut. Washers shall be of the same material as the nuts.

2.05 LUBRICANT FOR STAINLESS STEEL BOLTS AND NUTS
Lubricant shall be chloride free and shall be RAMCO TG-50, Anti-Seize by RAMCO, Specialty Lubricants Corporation Husky Lube O'Seal, or equal.

2.06 GASKETS FOR FLANGES FOR STEEL PIPING IN WATER SERVICE A. Gaskets shall be NSF 61 certified for potable water service.

B. Gaskets for flat face and raised face flanges shall be 1/8-inch thick and shall be one of the following nonasbestos materials:

1. Aramid fiber-inserted rubber. Gaskets shall be suitable for a pressure of 200 psi at a temperature of 180°F. Products: Garlock Multi-Swell 3760-U or equal.

2. PTFE with inert filler, 1/8 inch thick, bound with nitrile. Gaskets shall be suitable for a pressure of 500 psi at a temperature of 400°F. Products: Garlock Gylon Style 3505 or equal.

2.07 GASKETS FOR FLANGES FOR DUCTILE-IRON PIPING AND FITTINGS IN WATER

SERVICE
A. Gaskets shall be NSF 61 certified for potable water service.

B. Gaskets shall be full face, 1/8-inch thick, aramid fiber-inserted rubber. Gaskets shall be suitable for a water pressure of 200 psi at a temperature of 180°F. Gaskets shall have "nominal" pipe size inside diameters not the inside diameters per ASME B16.21. Products: Garlock Multi-Swell 3760-U or equal.

2.08 GASKETS FOR FLANGES FOR STAINLESS STEEL PIPING
A. Gaskets shall be NSF 61 certified for potable water service.

B. Gaskets shall be full face, 1/8-inch thick. Gaskets shall be one of the following nonasbestos materials:

1. Aramid fiber-inserted rubber. Gaskets shall be suitable for a pressure of 200 psi at a temperature of 180°F. Products: Garlock Multi-Swell 3760-U or equal.

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2. PTFE with inert filler, 1/8 inch thick, bound with nitrile. Gaskets shall be suitable for a pressure of 500 psi at a temperature of 400°F. Products: Garlock Gylon Style 3505 or equal.

2.09 MOLDABLE FILLER TAPE FOR PIPE SURFACE TRANSITION AREAS A. Filler tape shall be a 100% solids mastic-like butyl-rubber filler designed to fill and smooth the transition areas between adjacent coating surfaces such as step-down weld areas, surface irregularities beneath heat-shrink sleeves, pipefittings, and exothermic welds for cathodic protection bonding wire connections. Characteristics:

1. Thickness per ASTM D1000: 1/8 inch minimum.

2. Peel adhesion to primed pipe: 300 ounces per inch minimum.

3. Elongation: 600% minimum.

B. Products: Tapecoat “Moldable Sealant,” Polyken No. 939 Filler Tape, or equal.

PART 3 - EXECUTION

3.01 INSTALLING PIPE SPOOLS IN CONCRETE
Install pipes in walls and slabs before placing concrete.

3.02 RAISED FACE AND FLAT FACE FLANGES
Where a raised face flange connects to a flat-faced flange, remove the raised face of the flange.

3.03 INSTALLING ABOVEGROUND OR EXPOSED PIPING
A. Provide pipe hangers and supports as detailed in the drawings.

B. Install pipe without springing, forcing, or stressing the pipe or any adjacent connecting valves or equipment.

3.04 INSTALLING FLANGED PIPING
A. Set pipe with the flange bolt holes straddling the pipe horizontal and vertical centerline. Install pipe without springing, forcing, or stressing the pipe or any adjacent connecting valves or equipment. Before bolting up, align flange faces to the design plane within 1/16 inch per foot measured across any diameter. Align flange bolt holes within 1/8-inch maximum offset.

B. Inspect each gasket to verify that it is the correct size, material, and type for the specified service and that it is clean and undamaged. Examine bolts or studs, nuts, and washers for defects such as burrs or cracks and rust and replace as needed.

C. Clean flanges by wire brushing before installing flanged fittings. Clean flange bolts and nuts by wire brushing, lubricate carbon steel bolts with oil and graphite, and tighten nuts uniformly and progressively.

D. Bolt lengths shall extend completely through their nuts. Any that fail to do so shall be considered acceptably engaged if the lack of complete engagement is not more than one thread.

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E. Do not use more than one gasket between contact faces in assembling a flanged joint.

F. Tighten the bolts to the manufacturer’s specifications, using the recommended cross bolt pattern in multiple steps of increasing torque, until the final torque requirements are achieved.

Do not over torque.

G. If flanges leak under pressure testing, loosen or remove the nuts and bolts, reset or replace the gasket, reinstall or retighten the bolts and nuts, and retest the joints. Joints shall be watertight.

3.05 INSTALLING BLIND FLANGES
A. At outlets not indicated to be connected to valves or to other pipes and to complete the installed pipeline hydrostatic test, provide blind flanges with bolts, nuts, and gaskets.

B. Coat the inside face of blind flanges per Section 09 90 00, System No. 7.

3.06 INSTALLING GROOVED-END PIPING
A. Install grooved-end pipe and fittings in accordance with the coupling manufacturer's recommendations and the following.

B. Clean loose scale, rust, oil, grease, and dirt from the pipe or fitting groove before installing coupling. Apply the coupling manufacturer's gasket lubricant to the gasket exterior including lips, pipe ends, and housing interiors.

C. Fasten coupling alternately and evenly until coupling halves are seated. Use torques as recommended by the coupling manufacturer.

D. Provide separate hangers and supports at both sides of flexible joints.

3.07 INSTALLATION OF STAINLESS STEEL BOLTS AND NUTS
Prior to assembly, coat threaded portions of stainless steel bolts and nuts with lubricant.

END OF SECTION

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40 05 15 – PRESSURE TESTING OF PIPING
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SECTION 40 05 15

PRESSURE TESTING OF PIPING
PART 1 - GENERAL

1.01 DESCRIPTION
This section specifies the cleaning and hydrostatic, pneumatic, and leakage testing of pressure piping and pressure vessels for water treatment plants and associated facilities.

1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Disinfection of Piping and Structures: 33 13 00.

B. Manual, Check, and Process Valves: 40 05 20.

1.03 SUBMITTALS
A. Submit shop drawings in accordance with the General Provisions and Section 01 33 00.

B. Submit test bulkhead locations and design calculations, pipe attachment details, and methods to prevent excessive pipe wall stresses.

C. Submit test records to the Owner’s Representative upon completion of the testing.

1.04 TEST PRESSURES
Test pressures for the various services and types of piping are shown in the drawings. Test pressures for pressure vessels shall be equal to the test pressure of the piping supplying the pressure vessel unless noted otherwise in the pressure vessel specification.

1.05 TESTING RECORDS
Provide records of each piping installation during the testing. These records shall include:

A. Date and times of test.

B. Identification of process, pipeline, or pipeline section tested or retested.

C. Identification of pipeline material.

D. Identification of pipe specification.

E. Test fluid.

F. Test pressure at low point in process, pipeline, or pipeline section.

G. Remarks: Leaks identified (type and location), types of repairs, or corrections made.

H. Certification by Contractor that the leakage rate measured conformed to the specifications.

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PART 2 - MATERIALS

2.01 VENTS AND DRAINS FOR ABOVEGROUND PIPING
Install vents on the high points of aboveground piping, whether shown in the drawings or not.

Install drains on low points of aboveground piping, whether shown in the drawings or not.

Provide a valve at each vent or drain point. Valves shall be 3/4 inch for piping 3 inches and larger and 1/2 inch for piping smaller than 3 inches. Valves shall be as specified in Section 400520, Type 300, unless otherwise shown in the drawings.

2.02 MANUAL AIR-RELEASE VALVES FOR BURIED PIPING
Provide temporary manual air-release valves for pipeline test. Construct the pipe outlet in the same manner as for a permanent air valve and after use, seal with a blind flange, pipe cap, or plug and coat the same as the adjacent pipe.

2.03 TEST BULKHEADS
Design and fabricate test bulkheads per Section VIII of the ASME Boiler and Pressure Vessel Code. Materials shall comply with Part UCS of said code. Design pressure shall be at least 2.0 times the specified test pressure for the section of pipe containing the bulkhead. Limit stresses to 70% of yield strength of the bulkhead material at the bulkhead design pressure. Include airrelease and water drainage connections.

2.04 TESTING FLUID
A. Testing fluid shall be water unless a pneumatic test is indicated on the Piping Schedule.

B. For potable water pipelines and pressure vessels, obtain and use only potable water for hydrostatic testing.

C. Submit request for use of water from waterlines of Owner 48 hours in advance.

D. The Contractor may obtain the water from the Owner at the Owner's rate of charges.

2.05 TESTING EQUIPMENT
Provide calibrated pressure gauges, pipes, bulkheads, pumps, compressors, chart recorder, and meters to perform the hydrostatic and pneumatic testing.

PART 3 - EXECUTION

3.01 TESTING PREPARATION
A. Pipes and pressure vessels shall be in place, backfilled, and anchored before commencing pressure testing.

B. Conduct pressure tests on exposed and aboveground piping and vessels after the piping has been installed and attached to the pipe supports, hangers, anchors, expansion joints, valves, and meters.

C. For buried piping, the pipe may be partially backfilled and the joints left exposed for inspection during an initial leakage test. Perform the final pressure test, however, after completely backfilling and compacting the trench.

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D. Provide any temporary piping needed to carry the test fluid to the piping that is to be tested.

After the test has been completed and demonstrated to comply with the specifications, disconnect and remove temporary piping. Do not remove exposed vent and drain valves at the high and low points in the tested piping; remove any temporary buried valves and cap the associated outlets. Plug taps or connections to the existing piping from which the test fluid was obtained.

E. Provide temporary drain lines needed to carry testing fluid away from the pipe being tested.

Remove such temporary drain lines after completing the pressure testing. Drain the pipes after they have been tested unless startup will occur within 30 days of testing. Test water must be flushed from potable water lines prior to water being conveyed to the City’s water distribution system.

F. Prior to starting the test, the Contractor shall notify the Owner’s Representative.

3.02 CLEANING
A. Before conducting hydrostatic tests, flush pipes with water to remove dirt and debris. For pneumatic tests, blow air through the pipes. Maintain a flushing velocity of at least 3 fps for water testing and at least 2,000 fpm for pneumatic testing. Flush pipes for time period as given by the formula
T =
2L
3 in which:

T = flushing time (seconds)
L = pipe length (feet)

3.03 TESTING AND DISINFECTION SEQUENCE FOR POTABLE WATER PIPING A. Perform required disinfection after hydrostatic testing, except when pipeline being tested is connected to a potable waterline.

B. Locate and install test bulkheads, valves, connections to existing pipelines, and other appurtenances in a manner to provide an air gap separation between existing potable water pipelines and the pipeline being tested. Disinfect water and pipeline being tested before hydrostatic testing when connected to a potable waterline.

3.04 INITIAL PIPELINE FILLING FOR HYDROSTATIC TESTING
Maximum rate of filling shall not cause water velocity in pipeline to exceed 1 fps. Filling may be facilitated by removing automatic air valves and releasing air manually.

3.05 TESTING NEW PIPE WHICH CONNECTS TO EXISTING PIPE
Prior to testing new pipelines that are to be connected to existing pipelines, isolate the new line from the existing line by means of test bulkheads, spectacle flanges, or blind flanges. After successfully testing the new line, remove test bulkheads or flanges and connect to the existing piping.

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3.06 HYDROSTATIC TESTING OF ABOVEGROUND OR EXPOSED PIPING A. Open vents at high points of the piping system to purge air while filling the pipe with water.

Venting during system filling may also be provided by temporarily loosening flanges.

B. Subject the piping system to the test pressure indicated on the Piping Schedule in the drawings.

Maintain the test pressure for a minimum of four hours. Examine joints, fittings, valves, and connections for leaks. The piping system shall show zero leakage or weeping. Correct leaks and retest until zero leakage is obtained.

3.07 HYDROSTATIC TESTING OF BURIED PIPING
A. Where any section of the piping contains concrete thrust blocks or encasement, do not perform the pressure test until at least 10 days after placing the concrete. When testing mortar-lined or PVC piping, fill the pipe to be tested with water and allow it to soak for at least 48 hours to absorb water before conducting the pressure test.

B. Apply and maintain the test pressure by means of a positive displacement hydraulic force pump.

C. Maintain the test pressure for the following duration by restoring it whenever it falls an amount of 5 psi:

Pipe Diameter
(inches) Hours
18 and less 4
D. After the test pressure is reached, use a meter to measure the additional water added to maintain the pressure. This amount of water is the loss due to leakage in the piping system. The allowable leakage volume is defined by the formula
L = HND(P)½
C
in which:

L = allowable leakage (gallons)
H = specified test period (hours)
N = number of rubber-gasketed joints in the pipe tested D = diameter of the pipe (inches)
P = specified test pressure (psig)
C = 7,400
E. The allowable leakage for buried piping having threaded, brazed, or welded (including solvent welded) joints shall be zero.

F. Repair and retest any pipes showing leakage rates greater than that allowed in the above criteria.

3.08 PNEUMATIC TESTING
A. Perform pneumatic testing using dry air or nitrogen. Perform tests only after the piping has been completely installed including supports, hangers, and anchors. Protect test personnel and

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Owner's operating personnel. Secure piping to be tested to prevent the pipe from moving and to prevent damage to adjacent piping and equipment. Remove or isolate from the piping any appurtenant instruments or devices that could be damaged by the test prior to applying the test.

B. Apply an initial pneumatic leakage test of 25 psig to the piping system prior to final leak testing.

Examine for leakage, detected by soap bubbles, at joints and connections. After correcting visible leaks, gradually increase the pressure in the system to not more than one-half of the test pressure. Then increase the pressure in steps of approximately one-tenth of the test pressure until the required test pressure has been reached. Continuously maintain the pneumatic test pressure for a minimum time of four hours and for such additional time as may be necessary to conduct a soap bubble examination for leakage. The piping system shall show no leakage.

Correct any visible leakage and retest.

3.09 REPETITION OF TEST
If the actual leakage exceeds the allowable, locate and correct the faulty work and repeat the test. Restore the work and all damage resulting from the leak and its repair. Eliminate visible leakage.

3.10 BULKHEAD AND TEST FACILITY REMOVAL
After a satisfactory test, remove the testing fluid, remove test bulkheads and other test facilities, and restore the pipe coatings.

END OF SECTION

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40 05 20 – MANUAL, CHECK, AND PROCESS VALVES
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SECTION 40 05 20

MANUAL, CHECK, AND PROCESS VALVES
PART 1 - GENERAL

1.01 DESCRIPTION
This section includes materials, testing, and installation of manually operated valves, check valves, and process valves including gate, butterfly, ball, hose bibbs, globe, angle, eccentric plug, check, pet cocks and flap valves.

1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Painting and Coating: 09 90 00.

B. Cold-Applied Wax Tape Coating: 09 97 52.

C. Polyethylene Sheet Encasement (AWWA C105): 09 97 54.

D. Pressure Testing of Piping: 40 05 15.

1.03 SUBMITTALS
A. Submit shop drawings in accordance with the section 01 33 00.

B. Submit manufacturer's catalog data and detail construction sheets showing all valve parts.

Describe each part by material of construction, specification (such as AISI, ASTM, SAE, or CDA), and grade or type. Identify each valve by tag number to which the catalog data and detail sheets pertain.

C. Show valve dimensions including laying lengths. Show port sizes. Show dimensions and orientation of valve actuators, as installed on the valves. Show location of internal stops for gear actuators. State differential pressure and fluid velocity used to size actuators. For worm-gear actuators, state the radius of the gear sector in contact with the worm and state the handwheel diameter.

D. Show valve linings and coatings. Submit manufacturer's catalog data and descriptive literature.

E. Submit report verifying that the valve interior linings and exterior coatings have been tested for holidays and lining thickness. Describe test results and repair procedures for each valve. Do not ship valves to project site until the reports have been returned by the Construction Manager and marked "Resubmittal not required."
F. For butterfly and eccentric plug valves, show the clear diameter or size of the port. Show the actual area of the port as a percentage of the area as calculated for the nominal valve size.

G. Submit NSF 61 certification for all valves in potable water service.

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PART 2 - MATERIALS

2.01 GENERAL
A. Valves are identified in the drawings by size and type number. For example, a callout in the drawings of 2-inch V-300 or 2-inch Type 300 refers to Type 300 valve in these specifications, which is a ball valve.

B. Install valves complete with operating handwheels or levers, chainwheels, extension stems, floor stands, gear actuators, operating nuts, chains, and wrenches required for operation.

C. Valves shall have the name of the manufacturer and the size of the valve cast or molded onto the valve body or bonnet or shown on a permanently attached plate.

D. For buried locations, valves with mechanical joint ends may be substituted for the flanged ends specified provided the mechanical joint ends are compatible with the pipe ends and the joints are restrained.

2.02 VALVE ACTUATORS
A. Provide lever or wrench actuators for exposed valves 6 inches and smaller. For larger valves, provide handwheels.

B. Where manually operated valves (size 4 inches and larger) are installed with their centerlines more than 6 feet 9 inches above the floor, provide chainwheel and guide actuators.

C. Provide stem extensions when valves are installed in insulated piping. Stem extensions shall be of a length sufficient to bring the bottom of the operating lever, handle, or wheel 1 to 2 inches above the outside of the insulation.

D. Provide 2-inch AWWA operating nuts for buried and submerged valves.

E. Provide enclosed gear actuators on butterfly, ball, and plug valves 6 inches and larger, unless electric motorized valve actuators are shown in the drawings. Gear actuators for valves 6 through 20 inches shall be of the worm and gear, or of the traveling nut type.

F. Provide gear actuators on gate valves 14 inches and larger, unless electric motorized valve actuators are shown in the drawings. Gear actuators shall be of the bevel or spur gear type.

Provide grease case. Gearing shall comply with AWWA C500.

G. Design gear actuators assuming that the differential pressure across the plug, gate, or disc is equal to the test pressure of the connecting piping or pressure rating of the valve and assuming a fluid velocity of 10 fps for valves in liquid service and 80 fps for valves in air or gas service and a line fluid temperature range of 40°F to 115°F unless otherwise required in the detailed valve specifications. Size actuators using a minimum safety factor of 1.5 for valves in open/close service and 2.0 in modulating service.

H. Gear actuators shall be enclosed, oil lubricated, with seals provided on shafts to prevent entry of dirt and water into the actuator. Gear actuators for valves located above ground or in vaults and structures shall have handwheels. The actuators for valves in exposed service shall contain a dial indicating the position of the valve disc or plug. Gear actuators for buried or submerged valves shall have 2-inch-square AWWA operating nuts.

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I. For buried or submerged service or valves installed in buried vaults, provide watertight shaft seals and watertight valve and actuator cover gaskets. Provide totally enclosed actuators designed for buried or submerged service.

J. Traveling nut and worm and gear actuators shall be of the totally enclosed design so proportioned as to permit operation of the valve under full differential pressure rating of the valve with a maximum pull of 60 pounds on the handwheel or crank. Provide stop limiting devices in the actuators in the open and closed positions. Actuators shall be of the self-locking type to prevent the disc or plug from creeping. Design actuator components between the input and the stop-limiting devices to withstand without damage a pull of 200 pounds for handwheel or chainwheel actuators and an input torque of 300 foot-pounds for operating nuts when operating against the stops.

K. Handwheel diameters for traveling nut actuators shall not exceed 8 inches for valves 12 inches and smaller and shall not exceed 12 inches for valves 20 inches and smaller.

L. Self-locking worm gear shall be a one-piece design of gear bronze material (ASTM B427; or ASTM B84, Alloy C86200), accurately machine cut. Actuators for eccentric and lubricated plug valves may use ductile-iron gears provided the gearing is totally enclosed with spring-loaded rubber lip seals on the shafts. The worm shall be hardened alloy steel (ASTM A322, Grade G41500 or G41400; or ASTM A148, Grade 105-85), with thread ground and polished. Support worm-gear shaft at each end by ball or tapered roller bearings. The reduction gearing shall run in a proper lubricant. The handwheel diameter shall be no more than twice the radius of the gear sector in contact with the worm. Worm-gear actuators shall be Limitorque Model HBC, EIM Series W, or equal.

M. Design actuators on buried valves to produce the required torque on the operating nut with a maximum input of 150 foot-pounds.

N. Valve actuators, handwheels, or levers shall open by turning counterclockwise.

2.03 CAST-IRON VALVE BOXES FOR BURIED VALVES
A. Valve boxes shall be two-piece sliding type, cast iron, with extension shafts. Units shall be as manufactured by Tyler Pipe, Geneco, Star Pipe Products, or equal. Extension pipes shall be cast iron.

B. Coat buried cast-iron pieces per Section 09 90 00, System No. 21.

2.04 EXTENSION STEMS FOR BURIED AND SUBMERGED VALVE ACTUATORS Where the depth of the valve is such that its centerline is more than 4 feet below grade, provide operating extension stems to bring the operating nut to a point 6 inches below the surface of the ground and/or box cover. Where the valve is submerged, provide operating extension stems to bring the operating nut to 6 inches above the water surface. Extension stems shall be Pipeline Products Fiberplas or approved equal and shall be complete with 2-inch-square operating nut.

The connections of the extension stems to the operating nuts and to the valves shall withstand without damage a pull of 300 foot-pounds.

2.05 PAINTING AND COATING
A. Coat metal valves located above ground or in vaults and structures the same as the adjacent piping. If the adjacent piping is not coated, then coat valves per Section 09 90 00, System No. 10 or 15. Apply the specified prime coat at the place of manufacture. Apply intermediate and

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finish coats in field. Finish coat shall match the color of the adjacent piping. Coat handwheels the same as the valves.

B. Coat buried metal valves at the place of manufacture per Section 09 90 00, System No. 21.

C. Coat submerged metal valves, stem guides, extension stems, and bonnets at the place of manufacture per Section 09 90 00, System No. 7.

D. Line the interior metal parts of metal valves 4 inches and larger, excluding seating areas and bronze and stainless steel pieces, per Section 09 90 00, System No. 7. Apply lining at the place of manufacture.

E. Test the valve interior linings and exterior coatings at the factory with a low-voltage (22.5 to 80 volts, with approximately 80,000-ohm resistance) holiday detector, using a sponge saturated with a 0.5% sodium chloride solution. The lining shall be holiday free.

F. Measure the thickness of the valve interior linings per Section 09 90 00. Repair areas having insufficient film thickness per Section 09 90 00.

2.06 PACKING, O-RINGS, AND GASKETS
Unless otherwise stated in the detailed valve specifications, packing, O-rings, and gaskets shall be one of the following non-asbestos materials and be NSF 61 certified for potable water service:

A. Teflon.

B. Kevlar aramid fiber.

C. Acrylic or aramid fiber bound by nitrile. Products: Garlock Multi-Swell 3760-U or equal.

D. Buna-N (nitrile).

2.07 RUBBER SEATS
Rubber seats shall be made of a rubber compound that is resistant to free chlorine concentrations up to 10 mg/L in the fluid conveyed.

2.08 VALVES
A. Gate Valves:

1. Type 102—Aboveground Bronze Gate Valves 3 Inches and Smaller (Low Lead):

Aboveground threaded end or solder end gate valves, 1/4 through 3 inches, for water service shall be rising stem, screwed bonnet, solid wedge disc type, Class 200, having a minimum working pressure of 200 psi CWP at a temperature of 150°F and conforming to MSS SP-80. Ends shall be female threaded, ASME B1.20.1 or solder ends. Materials of construction shall be as follows:

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Component Material Specification
Body and bonnet,
wedge
Bronze ASTM B584, Alloy C87850,
C89833, or C89836
Stem Bronze or copper
silicon
ASTM B99 (Alloy 651), B584
(Alloy C87600), B371 (Alloy
C69400 or C69700)
Bronze alloys having a maximum lead content of 0.25%, a maximum zinc content of

7.0%, and a minimum copper content of 80% may be substituted for the bronze alloys specified above.

Handwheels shall be aluminum, brass, or malleable iron. Packing shall be Teflon or Kevlar aramid fiber. Valves shall be Nibco T-113-LF or S-113-LF or equal.

2. Type 150—Stainless Steel Gate Valves:

Stainless steel gate valves, 1/2 through 2 ½ inches, shall be of the single wedge type with rising stem and handwheel. Minimum working pressure shall be 200 psig. Bonnet shall be of the screwed type. Ends shall be threaded, ASME B1.20.1. Materials of construction shall be as follows:

Component Material Specification
Body, bonnet, plug, disc, and
follower
Stainless steel ASTM A351, Grade CF8M
Packing gland, nut, retainer
ring, and stem
Stainless steel ASTM A276, Type 316
Handwheel Malleable iron ASTM A47, A197
Stuffing box packing Teflon —
Valves shall be Powell Figure 1832, Crane/Alloyco Figure 90, or equal.

3. Type 180—Cast-Iron Resilient Wedge Gate Valves 3 Through 20 Inches (AWWA C509):

Valves shall comply with AWWA C509 and the following. Valves shall be of the boltedbonnet type with nonrising stems. Valve stems shall be Type 304 or 316 stainless steel or cast, forged, or rolled bronze. Provide operating nut for buried valves. Provide handwheel for exposed valves. Stem nuts shall be made of solid bronze. Bronze for internal working parts, including stems, shall not contain more than 2% aluminum or more than 7% zinc.

Bronze shall conform to ASTM B62 or ASTM B584 (Alloy C83600), except the stem bronze shall have a minimum tensile strength of 60,000 psi, a minimum yield strength of 30,000 psi, and a minimum of 10% elongation in 2 inches (ASTM B584 or B763, Alloy C87600 or C99500). Body bolts shall be Type 316 stainless steel. End connections for exposed valves shall be flanged. End connections for buried valves shall be mechanical joint or push-on type.

Provide reduction thrust bearings above the stem collar. Stuffing boxes shall be O-ring seal type with two rings located in stem above thrust collar. Each valve shall have a smooth unobstructed waterway free from any sediment pockets.

Valves shall be lined and coated at the place of manufacture with either fusion-bonded epoxy or heat-cured liquid epoxy. Minimum epoxy thickness shall be 8 mils.

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Manufacturers: Clow R/W, AVK, American Flow Control CRS-80, Waterous Series 500, Kennedy Ken-Seal, or equal.

Type 185 valves may be substituted for Type 180 valves.

4. Type 185—Ductile-Iron Resilient Wedge Gate Valves 4 Through 36 Inches (AWWA C515):

Valves shall comply with AWWA C515 and the following. Valves shall be of the boltedbonnet type with nonrising stems. Valve stems shall be Type 304 or 316 stainless steel or cast, forged, or rolled bronze. Provide operating nut for buried valves. Provide handwheel for exposed valves. Stem nuts shall be made of solid bronze. Bronze for internal working parts, including stems, shall not contain more than 2% aluminum or more than 7% zinc.

Bronze shall conform to ASTM B62 or ASTM B584 (Alloy C83600), except the stem bronze shall have a minimum tensile strength of 60,000 psi, a minimum yield strength of 30,000 psi, and a minimum of 10% elongation in 2 inches (ASTM B584 or B763, Alloy C87600 or C99500). Body bolts shall be Type 316 stainless steel. End connections for exposed valves shall be flanged. End connections for buried valves shall be mechanical joint or push-on type.

Provide reduction thrust bearings above the stem collar. Stuffing boxes shall be O-ring seal type with two rings located in stem above thrust collar. Each valve shall have a smooth unobstructed waterway free from any sediment pockets.

Valves shall be lined and coated at the place of manufacture with either fusion-bonded epoxy or heat-cured liquid epoxy. Minimum epoxy thickness shall be 8 mils.

Manufacturers: Clow, AVK, American Flow Control, Waterous, Kennedy, or equal.

B. Butterfly Valves:

1. Thrust Bearings for Butterfly Valves:

Provide thrust bearings to hold the valve disc in the center of the valve seat. No bearings shall be mounted inside the valve body within the waterway. Do not use thrust bearings in which a metal bearing surface on the disc rubs in contact with an opposing metal surface on the inside of the body.

2. Bronze Components in Butterfly Valves:

Bronze components in contact with water shall comply with the following requirements:

Constituent Content
Zinc 7% maximum
Aluminum 2% maximum
Lead 0.25% maximum
Copper + Nickel + Silicon 83% minimum

3. Port Sizes for Butterfly Valves:

For valves 24 inches and smaller, the actual port diameter shall be at least 93% of the nominal valve size. The dimension of the port diameter shall be the clear waterway diameter plus the thickness of the rubber seat.

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4. Corrosion-Resistant Materials in Butterfly Valves:

Where AWWA C504 requires “corrosion resistant” material, such material shall be one of the following:
a. Bronze as described above.
b. Type 304 or 316 stainless steel.
c. Monel (UNS N04400).
d. Synthetic nonmetallic material.

5. Seating Surfaces in Butterfly Valves:

Seating surfaces in valves having motorized actuators shall be stainless steel or nickelcopper per AWWA C504 or nickel-chromium alloy containing a minimum of 72% nickel and a minimum of 14% chromium.

6. Factory Leakage Testing:

Perform factory leakage tests per AWWA C504 on both sides of the seat.

7. Type 220—Flanged, Rubber-Seated Butterfly Valves 4 Through 48 Inches, Class 250:

Butterfly valves shall be short body, flanged type for exposed valves and valves in vaults or structures, and either flanged or mechanical joint for buried valves. Valve shall conform to AWWA C504, Class 250. Minimum working pressure across the valve disc shall be 250 psi. Flanged ends shall be Class 250, ASME B16.1, with bolt hole drilling and bolt circle to match ASME B16.1, Class 250, flanges. Mechanical joint ends shall comply with AWWA C111. Provide the specified end connections on each end of the valve. Minimum working differential pressure across the valve disc shall be 250 psi in either direction. Valve shafts shall be stub shaft or one-piece units extending completely through the valve disc. Where the rubber seat is applied to the disc, it shall be bonded to a stainless steel seat retaining ring which is clamped to the disc by Type 304 or 316 stainless steel screw fasteners or secured to a stainless steel seat by a combination of cap screws, a serrated disc retaining ring, and molded shoulders in the seat mating with machined registers in the disc. Materials of construction shall be as follows:

Component Material Specification
Body Ductile iron AWWA C504
Exposed body cap
screws and bolts and
nuts
Stainless steel ASTM A276, Type 316
Shaft Stainless steel ASTM A564, Grade S17400
Disc ductile iron, AWWA C504
Disc fasteners, seat
retainer segments, and
seat fasteners
Stainless steel ASTM A276, Type 316
Seat material Buna-N —
Valves shall be Pratt, DeZurik, or equal.

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C. Ball Valves:

1. Type 300—Full Port Threaded Bronze Ball Valves 2 Inches and Smaller (Low Lead) for air and water service:

Ball valves, 2 inches and smaller, for water service shall have a pressure rating of at least 600 psi WOG at a temperature of 100°F. Provide full port ball and body design. Valves shall comply with MSS SP-110. Materials of construction shall be as follows:

Component Material Specification
Body Bronze ASTM B584, Alloy C89836
Ball Bronze ASTM B584, Alloy C89836 or Alloy
C27450, chromium plated
Ball retainer Bronze ASTM B584, Alloy C89836 or ASTM
B371, Alloy C69430
Stem Bronze Alloy C27450
Seats Reinforced Teflon —
Bronze alloys having a maximum lead content of 0.25%, a maximum zinc content of

7.0%, and a minimum copper content of 80% may be substituted for the bronze alloys specified above. Valves shall have threaded ends (ASME B1.20.1), nonblowout stems, and have plastic-coated lever actuators. Valves shall be Apollo 77CLF Series or equal.

2. Type 310—Double Union PVC Ball Valves 3 Inches and Smaller:

Thermoplastic ball valves, 3 inches and smaller, for water and chemical service shall be rated at a pressure of 150 psi at a temperature of 105°F. Body, ball, and stem shall be PVC conforming to ASTM D1784, Type 1, Grade 1. Seats shall be Teflon. O-ring seals shall be EPDM unless otherwise specified for the specific application. Valve ends shall be of the double-union design. Ends shall be socket welded except where threaded or flanged-end valves are specifically shown in the drawings. Valves shall have handle for manual operation. Valves shall be as manufactured by Chemtrol, Hayward, R & G Sloan, Spears Manufacturing Company, Plast-O-Matic, IPEX Series VK or VKD, or equal.

3. Type 320—Regular Port Threaded Stainless Steel Ball Valves 2 Inches and Smaller:

Stainless steel ball valves, 2 inches and smaller, for water service shall be rated at a minimum pressure of 1,500 psi WOG at a temperature of 100°F. Valve body, ball, and stem shall be Type 316 stainless steel, ASTM A276 or A351. Seat and seals shall be reinforced Teflon. Valves shall have lever actuators, plastic coated. Valves shall have threaded ends (ASME B1.20.1) and nonblowout stems. Valves shall be McCanna Figure M402, Worcester Series 48, Stockham Figure SD 2120-SSMO-R-T, Apollo 76-100 Series, or equal.

D. Globe Valves, Angle Valves, Hose Valves, and Hose Bibbs:

1. Type 400—Bronze Globe Valves 2 Inches and Smaller:

Globe valves, 2 inches and smaller, shall be all bronze (ASTM B62 or ASTM B584, Alloy C83600) with screwed ends, union bonnet, inside screw, rising stem, and composition or PTFE disc. Valves shall have a pressure rating of at least 300 psi at a temperature of 150°F. Stem shall be bronze: ASTM B371 (Alloy C69400), ASTM B99 (Alloy C65100), or

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ASTM B584 (Alloy C87600). Valves shall be Crane No. 7TF, Walworth Figure 3095, Stockham B-22T, or equal.

2. Type 420—Bronze Hose Bibbs:

Hose bibbs of size 1/2 inch, 3/4 inch, and 1 inch shall be all bronze (ASTM B62 or ASTM B584, Alloy C83600) with rising or nonrising stem, composition disc, bronze or malleable iron handwheel, and bronze stem (ASTM B99, Alloy C65100; ASTM B371, Alloy C69400; or ASTM B584, Alloy C87600). Packing shall be Teflon or graphite. Valves shall have a pressure rating of at least 125 psi for cold-water service. Threads on valve outlet shall be American National Standard fire hose coupling screw thread (ASME B1.20.7). Provide atmospheric vacuum breaker conforming to ASSE Standard 1011 and IAPMO codet.

Valves shall be Nibco Figure T-113; or equal.

E. Check Valves:

1. Type 720—Cast-Iron Swing Check Valves 3 Inches and Larger, Class 125:

Swing check valves, 3 inches and larger, shall be iron body, bronze mounted complying with AWWA C508 with the following materials of construction:

Description Material Specification
Disc or clapper seat
ring and valve body
seat ring
Bronze or brass ASTM B62 or B584 (Alloy
C84400 or C87600)
Body and cap (bonnet) Cast iron ASTM A126, Class B
Disc and hinge or arm
(valves 4 inches and
smaller)
Bronze ASTM B62 or ASTM B584
(Alloy C84400)
Disc and hinge or arm
(valves larger than 4
inches)
Cast iron or bronze ASTM A126, Class B; ASTM
B62.

Hinge pin Stainless steel Type 303, 304, or 410
stainless
Cover bolts and nuts Stainless steel ASTM A193, Grade B8M; ASTM A194, Grade 8M
Internal fasteners and
accessories
Bronze or Type 304
or 316 stainless
steel
Bronze or brass components in contact with water shall comply with the following requirements:

Constituent Content
Zinc 7% maximum
Aluminum 2% maximum
Lead 8% maximum
Copper + Nickel + Silicon 83% minimum

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Ends shall be flanged, Class 125, ASME B16.1. Minimum valve working pressure shall be 150 psi. Provide check valves with outside lever and weight.

The shop drawing submittal shall include a detail showing how the hinge pin extends through the valve body. Show packing gland, hinge pin gland, cap, and other pieces utilized.

Valves shall be APCO 6000A, Val Matic or equal.

F. Plug Valves:

Plug valves shall comply with AWWA C517 and the following. Provide a rectangular or circular plug design, with 100% of port area, and an associated rectangular or round seat.

Provide bidirectional seating design. The valve shall seat with the rated pressure both upstream and downstream of the closed plug. Provide geared actuators sized for bidirectional operation.

1. For Types 500 and 510 eccentric plug valves, the metallic portion of the plug shall be one-piece design and shall be without external reinforcing ribs which result in there being a space between the rib and the main body of the plug through which water can pass.

Valves shall be repackable without any disassembly of valve or actuator. The valve shall be capable of being repacked while under the design pressure in the open position.

Nowhere in the valve or actuators shall the valve shaft be exposed to iron on iron contact.

Sleeve bearings shall be stainless steel in valve sizes 20 inches and smaller and bronze or stainless steel in valve sizes 24 inches and larger. Provide enclosed worm-gear actuators for valves 6 inches and larger.

2. Rubber compounds shall have less than 2% volume increase when tested in accordance with ASTM D471 after being immersed in distilled water at a temperature of 73.4°F ±2°F for 70 hours.

3. Type 500—Eccentric Plug Valves 3 Inches and Smaller:

Eccentric plug valves, 1/2 through 3 inches, shall be nonlubricated type. Minimum pressure rating shall be 175 psi. Bodies shall be made of cast iron per ASTM A126, Class B. Ends shall be threaded or flanged (ASME B16.1, Class 125). Plug shall be cast iron (ASTM A126, Class B). Where shown on the plans, provide a stainless steel valve.

Design plugs to seat over a pressure range of 25 psi to the valve design pressure rating.

Body cap screws and bolts and nuts shall be Type 316 stainless steel. Packing shall be nitrile butadiene-filled Teflon. Provide 100% port area. Valves shall be DeZurik, Clow, Val-Matic or equal.

4. Type 510—Eccentric Plug Valves 4 Through 12 Inches:

Eccentric plug valves, 4 through 12 inches, shall be nonlubricated type. Minimum pressure rating shall be 175 psi. Bodies shall be cast iron per ASTM A126, Class B. Ends shall be flanged, Class 125 per ASME B16.1. Plugs shall be cast iron (ASTM A126, Class B), or ductile iron (ASTM A536, Grade 65-45-12). Design plugs to seat over a pressure range of 25 psi to the valve design pressure rating. Valve body seats shall be Type 304 or 316 stainless steel or have a raised welded-in overlay at least 1/8-inch thick of not less than 90% nickel. Body cap screws and bolts and nuts shall be Type 316 stainless steel. Packing shall be butadiene-filled Teflon. Provide 100% port area. Valves shall be DeZurik, Clow, Val-Matic or equal.

G. Flap Valves:

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Type 1060—Flap Valves:

Flap valves shall have cast-iron body (ASTM A48 or A126) with bronze (ASTM B62) hinge pin, flap ring, and seat. Ends shall be flanged to match the connecting pipe. Products: Clow F-3012, F-3014, F-3016; Waterous Flap Valves; Waterman Industries; or equal.

H. Pet Cocks and Drain Cocks:

1. Type 1000—Pet Cocks 1/2 Inch and Smaller:

Pet cocks shall be all bronze (ASTM B62) or brass (ASTM B16), rated at 125 psi. Provide lever or tee handle operator. Pet cocks shall be Crane Figure 724, Lunkenheimer Figure 478 or 479, or equal.

2. Type 1010—Drain Cocks 1/2 Inch and Smaller:

Drain cocks shall be all bronze (ASTM B62) or brass (ASTM B16), rated at 125 psi.

Provide lever or tee handle operator. Drain cocks shall be Crane Figure 702, Lunkenheimer Figure 476 or 980, or equal.

PART 3 - EXECUTION

3.01 VALVE SHIPMENT AND STORAGE
A. Provide flanged openings with metal closures at least 3/16-inch thick, with elastomer gaskets and at least four full-diameter bolts. Install closures at the place of valve manufacture prior to shipping. For studded openings, use all the nuts needed for the intended service to secure closures. Alternatively, ship flanged valves 3 inches and smaller in separate sealed cartons or boxes.

B. Provide threaded openings with steel caps or solid-shank steel plugs. Do not use nonmetallic (such as plastic) plugs or caps. Install caps or plugs at the place of valve manufacture prior to shipping. Alternatively, ship valves having threaded openings or end connections in separate sealed cartons or boxes.

C. Store resilient seated valves in sealed polyethylene plastic enclosures with a minimum of one package of desiccant inside. Store resilient seated valves in the open or unseated position.

Valves with adjustable packing glands shall have the packing gland loosened prior to storage.

Inspect valves at least once per week, replace desiccant if required and repair damaged storage enclosures. Do not store valves with resilient seats near electric motors or other electrical equipment.

D. Inspect valves on receipt for damage in shipment and conformance with quantity and description on the shipping notice and order. Unload valves carefully to the ground without dropping. Use forklifts or slings under skids. Do not lift valves with slings or chain around operating shaft, actuator, or through waterway. Lift valves with eyebolts or rods through flange holes or chain hooks at ends of valve parts.

E. Protect the valve and actuators from weather and the accumulation of dirt, rocks, and debris. Do not expose rubber seats to sunlight or ozone for more than 30 days. Also, see the manufacturer’s specific storage instructions.

F. Make sure flange faces, joint sealing surfaces, body seats, and disc seats are clean. Check the bolting attaching the actuator to the valve for loosening in transit and handling. If loose, tighten

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firmly. Open and close valves having manual or power actuators to make sure the valve operates properly and that stops or limit switches are correctly set so that the valve seats fully.

Close valve before installing.

3.02 FACTORY PRESSURE TESTING
A. Hydrostatically test the valve pressure-containing parts at the factory per the valve specification or per the referenced standard. If no testing requirement is otherwise specified or described in the referenced standards, then test with water for 30 minutes minimum at a pressure of 1.5 times the rated pressure but not less than 20 psig. Test shall show zero leakage. If leaks are observed, repair the valve and retest. If dismantling is necessary to correct valve deficiencies, then provide an additional operational test and verify that the valve components function.

B. The chloride content of liquids used to test austenitic stainless steel materials shall not exceed 50 ppm. To prevent deposition of chlorides as a result of evaporative drying, remove residual liquid from tested parts at the conclusion of the test.

3.03 INSTALLING VALVES—GENERAL
A. Remove covers over flanged openings and plugs from threaded openings, after valves have been placed at the point to which the valves will be connected to the adjacent piping. Do not remove valves from storage cartons or boxes until they are ready to be installed.

B. Handle valves carefully when positioning, avoiding contact or impact with other equipment, vault or building walls, or trench walls.

C. Clean valve interiors and adjacent piping of foreign material prior to making up valve to pipe joint connection. Prepare pipe ends and install valves in accordance with the pipe manufacturer’s instructions for the joint used. Do not deflect pipe-valve joint. Do not use a valve as a jack to pull pipe into alignment. The installation procedure shall not result in bending of the valve/pipe connection with pipe loading.

D. Make sure valve ends and seats are clean. Check exposed bolting for loosening in transit and handling and tighten to manufacturer’s recommendations. Open and close the valve to make sure it operates properly and that stops or limit switches are correctly set so that the vane, ball, gate, needle, diaphragm, disc, plug, or other seating element seats fully. Close the valve before installing. Check coatings for damage and repair. Handle valves carefully when positioning, avoiding contact or impact with other equipment or structures.

E. Prior to assembly, coat threaded portions of stainless steel bolts and nuts with lubricant.

3.04 INSTALLING EXPOSED VALVES
A. Unless otherwise indicated in the drawings, install valves in horizontal runs of pipe having centerline elevations 4 feet 6 inches or less above the floor with their operating stems vertical.

Install valves in horizontal runs of pipe having centerline elevations between 4 feet 6 inches and 6 feet 9 inches above the floor with their operating stems horizontal.

B. Install valves on vertical runs of pipe that are next to walls with their stems horizontal, away from the wall. Valves on vertical runs of pipe that are not located next to walls shall be installed with their stems horizontal, oriented to facilitate valve operation.

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3.05 INSTALLING BURIED VALVES
A. Connect the valve, coat the flanges, apply tape wrapping or polyethylene encasement, and place and compact the backfill to the height of the valve stem.

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

C. Mount the upper slip pipe of the extension in midposition and secure with backfill around the extension pipe. Pour the concrete ring allowing a depression so the valve box cap will be flush with the pavement surface.

3.06 FIELD COATING BURIED VALVES
A. Coat flanges of buried valves and the flanges of the adjacent piping, and the bolts and nuts of flanges and mechanical joints, per Section 09 90 00, System No. 24.

B. Wrap buried metal valves smaller than 6 inches with cold-applied wax tape per Section 09 97

52. C. Wrap buried metal valves 6 inches and larger with polyethylene sheet per Section 09 97 54.

3.07 ASSEMBLING JOINTS
A. Bolt holes of flanged valves shall straddle the horizontal and vertical centerlines of the pipe run to which the valves are attached. Clean flanges by wire brushing before installing flanged valves. Clean flange bolts and nuts by wire brushing, lubricate threads with oil and graphite, and tighten nuts uniformly and progressively. If flanges leak under pressure testing, loosen or remove the nuts and bolts, reseat or replace the gasket, reinstall or retighten the bolts and nuts, and retest the joints. Joints shall be watertight.

B. Clean threaded joints by wire brushing or swabbing. Apply Teflon joint compound or Teflon tape to pipe threads before installing threaded valves. Joints shall be watertight.

C. Install lug-type valves with separate hex head machine bolts at each bolt hole and each flange (two bolts per valve bolt hole).

3.08 INSTALLING EXTENSION STEM GUIDE BRACKETS
Install at 6- to 8-foot centers. Provide at least two support brackets for stems longer than 10 feet, with one support near the bottom of the stem and one near the top.

3.09 MOUNTING GEAR ACTUATORS
The valve manufacturer shall select and mount the gear actuator and accessories on each valve and stroke the valve from fully open to fully closed prior to shipment.

3.10 FIELD INSTALLATION OF GEAR ACTUATOR
Provide the actuator manufacturer's recommended lubricating oil in each actuator before commencing the field testing.

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3.11 VALVE FIELD TESTING
A. Test valves for leakage at the same time that the connecting pipelines are hydrostatically tested. See Section 33 11 60 for pressure testing requirements. Protect or isolate any parts of valves, actuators, or control and instrumentation systems whose pressure rating is less than the pressure test. Valves shall show zero leakage. Repair or replace any leaking valves and retest.

B. Operate manual valves through three full cycles of opening and closing. Valves shall operate from full open to full close without sticking or binding. Do not backfill buried valves until after verifying that valves operate from full open to full closed. If valves stick or bind, or do not operate from full open to full closed, repair or replace the valve and repeat the tests.

C. Gear actuators shall operate valves from full open to full close through three cycles without binding or sticking. The pull required to operate handwheel- or chainwheel-operated valves shall not exceed 60 pounds. The torque required to operate valves having 2-inch AWWA nuts shall not exceed 150 ft-lbs. If actuators stick or bind or if pulling forces and torques exceed the values stated previously, repair or replace the actuators and repeat the tests. Operators shall be fully lubricated in accordance with the manufacturer's recommendations prior to operating.

END OF SECTION

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40 07 22 – FLEXIBLE PIPE COUPLINGS
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SECTION 40 07 22

FLEXIBLE PIPE COUPLINGS
PART 1 - GENERAL

1.01 DESCRIPTION
This section includes materials and installation of flexible gasketed sleeve-type compression pipe couplings for steel and ductile-iron pipe; flexible expansion joints; and couplings for connecting different pipe materials. Where shown on the plans, provide thrust restraint couplings.

1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Painting and Coating: 09 90 00.

B. Cold-Applied Wax Tape Coating: 09 97 52.

C. Polyethylene Sheet Encasement (AWWA C105): 09 97 54.

D. General Piping Requirements: 40 05 00.

E. Pressure Testing of Piping: 40 05 15.

1.03 SUBMITTALS
A. Submit shop drawings in accordance with the General Provisions and Section 01 33 00.

B. Submit manufacturer's catalog data on flexible pipe couplings. Show manufacturer's model or figure number for each type of coupling or joint for each type of pipe material for which couplings and joints are used. Show coatings.

C. Submit manufacturer's recommended torques to which the coupling bolts shall be tightened for the flexible gasketed sleeve-type compression pipe couplings.

D. Show materials of construction by ASTM reference and grade. Show dimensions.

E. Show number, size, and material of construction of tie rods and lugs for each thrust harness on the project.

PART 2 - MATERIALS

2.01 COUPLING SYSTEM DESIGN AND COMPONENT UNIT RESPONSIBILITY The coupling manufacturer shall furnish the gaskets, bolts, nuts, glands, end rings, restraints, and hardware for pipe couplings of all types and shall design these components as an integral system. Design the gaskets for the coupling and appropriately size to provide a watertight seal at the design pressure and temperature. Ship gaskets, bolts, nuts, glands, end rings, and hardware for pipe couplings with the pipe coupling and clearly label indicating the origin of the material, including place and date of manufacture. Package the manufacturer's printed installation instructions with each pipe coupling.

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2.02 CARBON STEEL FLEXIBLE PIPE COUPLINGS AND FLANGED COUPLING ADAPTERS A. Steel couplings shall have center sleeves and end rings made of carbon steel conforming to AWWA C219, Section 4. Minimum center sleeve length shall be 5 inches for pipe sizes 3/4 inch through 4 1/2 inches, 7 inches for pipe sizes 5 inches through 24 inches, and 10 inches for pipe sizes larger than 24 inches.

B. Sleeve bolts in exposed service shall be carbon steel per AWWA C219, Section 4. Sleeve bolts in buried or submerged service shall be Type 304 or 316 stainless steel per AWWA C219, Section 4.

C. End rings shall be cast, forged, or hot rolled in one piece. Do not use rings fabricated from two or more shapes.

D. Wall thickness of sleeve shall be at least that specified for the size of pipe in which the coupling is to be used.

2.03 DUCTILE-IRON FLEXIBLE PIPE COUPLINGS
A. Couplings shall have center sleeves and end rings made of ductile iron conforming to AWWA C219, Section 4.

B. Sleeve bolts in exposed service shall be carbon steel per AWWA C219, Section 4. Sleeve bolts in buried or submerged service shall be Type 304 or 316 stainless steel per AWWA C219, Section 4.

2.04 FLEXIBLE PIPE COUPLINGS FOR PLAIN-END STEEL PIPE
Couplings shall be steel, Dresser Style 38, Smith-Blair Type 411, Baker Series 200, or equal.

2.05 FLEXIBLE PIPE COUPLINGS FOR PLAIN-END DUCTILE-IRON PIPE A. Couplings for pipe 12 inches and smaller shall be cast iron, Dresser Style 253 or 253 long sleeve, Smith-Blair Type 441, Baker Series 228, or equal.

B. Couplings for pipe larger than 12 inches shall be cast iron or steel, Dresser Style 38 or 253, Smith-Blair Style 411, Baker Series 228, or equal.

2.06 TRANSITION COUPLINGS
Couplings for connecting different pipes having different outside diameters shall be steel:

Dresser Style 62 or 162, Smith-Blair Series 413, Baker Series 212 or 220, or equal. Couplings shall have an internal full circumference ring pipe stop at the midpoint of the coupling. Inside diameter of coupling pipe stop shall equal inside diameter of smaller diameter pipe.

2.07 FLANGED COUPLING ADAPTERS FOR CAST- AND DUCTILE-IRON PIPE A. Adapters for cast- and ductile-iron pipe 12 inches and smaller shall be cast iron: Dresser Style 127, Smith-Blair Series 912, or equal.

B. Adapters for cast- and ductile-iron pipe larger than 12 inches shall be steel: Dresser Style 128, Smith-Blair Type 913, or equal.

C. Flange ends shall match the flange of the connecting pipe; see detail piping specifications.

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2.08 DISMANTLING JOINTS
A. The dismantling joint shall consist of a flanged steel spigot piece, a flanged sleeve, and a follower ring containing a gasket through which the spigot piece slides into the sleeve. The joint shall accommodate up to 2 inches of longitudinal movement. The longitudinal adjustability shall be provided by a telescopic action of a flanged spigot and associated sleeve, which inserts into the spigot. A system of tie bolts or rods shall connect the end flange on the sleeve to the end flange on the spigot piece. Provide washers and nuts on the tie bolts on both sides of the sleeve and flange and the spigot end flange to allow for adjustment of the extension length for the sleeve.

B. The minimum design pressure shall be 250 psi. Design stresses shall not exceed 40% of the yield strength of the materials. Minimum factory test pressure shall be 150% of the design pressure.

C. The gasket shall be compressed by a separate bolting and gland system, independent of the tie bolts. Gasket shall be EPDM.

D. Dismantling joints shall have a spigot piece made of steel conforming to ASTM A36, A53 (Type E or S), or A283, Grade C having a minimum yield strength of 30,000 psi and a flange adapter and follower ring made of ductile iron conforming to ASTM A536, Grade 65-45-12.

E. Sleeve and follower ring bolts shall have a minimum yield strength of 105,000 psi, a minimum tensile strength of 125,000 psi, and shall conform to ASTM A193, Grade B7.

F. Steel flanges and gasket follower rings shall be cast, forged, or hot rolled in one piece. Do not use flanges or rings fabricated from two or more shapes. Flanges shall conform to AWWA Class E.

G. Wall thickness of spigot piece and sleeve shall be at least that specified for the size of pipe in which the coupling is to be used.

H. Manufacturers: Romac Industries Style DJ405 CLSE or equal.

PART 3 - EXECUTION

3.01 SHIPMENT AND STORAGE OF FLEXIBLE PIPE COUPLINGS, DISMANTLING JOINTS,

EXPANSION JOINTS, AND FLEXIBLE HOSE CONNECTORS
A. Inspect on receipt for damage in shipment and conformance with quantity and description on the shipping notice and order. Unload carefully to the ground without dropping. Do not load or unload by inserting forklift tines or lifting chains inside the waterway. Use nonmetallic slings, padded chains, or padded forklift tines to lift items. Lift with eyebolts or rods through flange holes or chain hooks at ends.

B. Protect from weather and the accumulation of dirt, rocks, and debris. Do not expose rubber seats to sunlight or ozone for more than 30 days. Also, see the manufacturer’s specific storage instructions.

C. Make sure flange faces, joint sealing surfaces, body seats, and disc seats are clean.

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3.02 INSTALLATION OF FLEXIBLE PIPE COUPLINGS AND EXPANSION JOINTS A. Clean oil, scale, rust, and dirt from pipe ends. Clean gaskets in flexible pipe couplings before installing.

B. Install expansion joints per manufacturer's recommendations, so that 50% of total travel is available for expansion and 50% is available for contraction.

C. Do not spring flanges or ends of connecting piping into position. Separately work connecting piping system into position to bring the piping flanges or ends into alignment with the matching coupling flanges or joints. Do not move couplings to achieve piping alignment.

D. Line up pipe flange bolt holes with coupling or joint flange bolt holes within 1/16 inch maximum offset from the center of the bolt hole to permit insertion of bolts without applying any external force to the piping.

E. Flange face separation shall be within the gasket spacing ±1/16 inch. Use only one gasket per flanged connection.

F. Lubricate bolt threads with graphite and oil prior to installation.

G. Thoroughly clean contact surfaces of gaskets and pipe ends of flexible pipe couplings just prior to assembly for a distance equal to center-sleeve length plus 2 inches. Install flexible pipe couplings such that the center sleeves are centered over the gap between the ends of the pipes being joined. Install centerline gaps per AWWA C219, Table 5 unless otherwise indicated.

Install harnessed flexible pipe couplings in straight-run piping such that 50% of the total travel of the center sleeve or permissible centerline gap is available for expansion and 50% of the travel is available for contraction. In assembling the bolted or studded harnesses of flexible pipe couplings, tighten the nuts gradually and equally at diametrically opposite sides until snug. Do not misalign the harness bolts or studs. Tighten such that bolts or studs carry equal loads. Do not use wrenches or power fastening tools to tighten the nuts.

3.03 PAINTING AND COATING
A. Coat buried flexible pipe couplings (including joint harness assemblies), transition couplings, segmented sleeve couplings, and flanged coupling adapters per Section 09 90 00, System No. 21 or 22. Coat buried bolt threads, tie bolt threads, and nuts per Section 09 90 00, System No. 24 Then wrap the couplings with cold-applied wax tape per Section 09 97 52 and with polyethylene wrap per Section 09 97 54.

B. Coat flexible pipe couplings (including joint harness assemblies), transition couplings, and flanged coupling adapters located indoors, in vaults and structures, and above ground with the fusion bonded epoxy.

C. Line carbon steel and iron flexible pipe couplings and segmented sleeve couplings per Section 09 90 00, System No. 7.

D. Alternatively, line and coat carbon steel and iron flexible pipe couplings and segmented sleeve couplings with fusion-bonded epoxy.

3.04 HYDROSTATIC TESTING
Hydrostatically test flexible pipe couplings and expansion joints, in place with the pipe being tested. Test in accordance with Section 40 05 15.

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END OF SECTION

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40 20 40 – DUCTILE IRON PIPE
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SECTION 40 20 40

DUCTILE-IRON PIPE
PART 1 - GENERAL

1.01 DESCRIPTION
This section describes materials, testing, and installation of ductile-iron pipe and fittings 18 inches and smaller.

1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Trenching, Backfill, and Compaction: 31 23 16.

B. Painting and Coating: 09 90 00.

C. Cold-Applied Wax Tape Coating: 09 97 52.

D. Polyethylene Sheet Encasement (AWWA C105): 09 97 54.

E. Disinfection of Piping and Structures: 33 13 00.

F. General Piping Requirements: 40 05 00.

G. Pressure Testing of Piping: 40 05 15.

H. Flexible Pipe Couplings: 40 07 22.

1.03 SUBMITTALS
A. Submit shop drawings in accordance with the General Provisions and Section 01 33 00.

B. Provide an affidavit of compliance with standards referenced in this specification, e.g., AWWA C151. Submit copy of report of pressure tests for qualifying the designs of all sizes and types of AWWA C153 fittings that are being used in the project. The pressure test shall demonstrate that the minimum safety factor described in AWWA C153, Section 5.5 is met.

C. Provide the following information:

1. Mortar lining thickness.

2. Wall thickness.

3. Show deflections at push-on and mechanical joints.

4. Submit joint and fitting details and manufacturer’s data sheets.

D. Submit calculations and test data proving that the proposed restrained joint arrangement can transmit the required forces with a minimum safety factor of 1.5.

E. Submit certificate that cement for mortar lining complies with ASTM C150, designating type.

F. Submit test report on physical properties of rubber compound used in the gaskets.

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G. Submit drawing or manufacturer's data sheet showing flange facing, including design of facing serrations.

H. Submit weld procedure specification, procedure qualification record, and welder's qualifications prior to any welding to ductile-iron pipe.

PART 2 - MATERIALS

2.01 PIPE
Pipe shall be cast ductile (nodular) iron, conforming to AWWA C151.

2.02 PIPE MARKING
Plainly mark each length of straight pipe to identify the design pressure class, the ductile-iron wall thickness, and the date of manufacture. Mark the spigot end of restrained joint pipe to show clearly the required depth of insertion into the bell.

2.03 PIPE WALL THICKNESS
A. Minimum wall thicknesses for pipe having grooved-end joints shall be as shown in the following table:

Pipe and Fitting Sizes
(inches) Wall Thickness*
16 and smaller Special Class 53
18 Special Class 54
*Special Class and Pressure Class per AWWA C151.

B. Minimum wall thickness for pipe having push-on or mechanical joints, restrained joints, plain ends, or cast flange ends shall be Special Class 53, unless otherwise shown in the drawings.

C. Minimum wall thickness for pipe having threaded flanges when mating to Type 790 check valves, or when mating to wafer or lug-style butterfly valves shall be Special Class 53 or Pressure Class 350.

D. Minimum pipe wall thickness required for corporation stops and tapped outlets shall be in accordance with Table A.1 of AWWA C151 for three full threads for design pressures up to 250 psi and four full threads for design pressures over 250 to 350 psi.

2.04 FITTINGS
A. Fittings 18 inches and smaller shall conform to AWWA C110 with a minimum pressure rating of 250 psi. Material shall be cast or ductile iron. Flanges shall be flat faced.

B. Mechanical joint fittings conforming to AWWA C153 may be used in lieu of AWWA C110 fittings.

C. Grooved-end fittings shall conform to AWWA C110 with grooved ends conforming to AWWA C606, radius cut rigid joints. Fitting material shall conform to ASTM A48, Class 30; ASTM A126, Class B; or ASTM A536, Grade 65-42-10. Wall thickness of ductile-iron (ASTM A536) fittings shall conform to AWWA C110 or C153; wall thickness of cast-iron fittings shall conform to AWWA C110. Fittings and couplings shall be furnished by the same manufacturer.

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D. Material for fittings with welded-on bosses shall have a Charpy notch impact value of minimum 10 ft-lbs under the conditions defined in AWWA C151. Test completed welds by the liquid penetrant method per ASTM E165.

2.05 FLANGES
A. Flanges shall be solid back, Class 250 per AWWA C115. Flanges on pipe shall be either cast or threaded. Material shall be ductile iron.

B. Flanged pipe and fittings shall be shop fabricated, not field fabricated. Threaded flanges shall comply with AWWA C115. Flanges shall be individually fitted and machine tightened in the shop, then machined flat and perpendicular to the pipe barrel. Flanges shall be backfaced parallel to the face of flange. Prior to assembly of the flange onto the pipe, apply a thread compound to the threads to provide a leak-free connection. There shall be zero leakage through the threads at a hydrostatic test pressure of 250 psi without the use of the gasket.

2.06 PIPE LINING--CEMENT MORTAR
A. Line pipe interior and fittings with cement-mortar per AWWA C104. Lining thickness shall be the double thickness listed in AWWA C104, Section 4.7. Cement for lining material shall conform to ASTM C150, Type II.

B. Maintain a moist environment inside the lined pipe and fittings by sealing the ends with polyethylene sheet.

C. Loose areas of cement-mortar lining are not acceptable. Remove and reconstruct lining in areas where quality is defective, such as sand pockets, voids over sanded areas, blisters, drummy areas, cracked areas, and thin spots. Repair longitudinal cracks in excess of 1/32 inch in width or where crack extends to metal with epoxy. Repair all cracks larger than 1/16 inch with epoxy.

2.07 GROOVED-END COUPLINGS
A. Grooved-end pipe couplings shall be ductile iron, ASTM A536 (Grade 65-45-12). Gaskets shall be halogenated butyl rubber or EPDM or Buna-N and shall conform to ASTM D2000.

B. Bolts in exposed service shall conform to ASTM A183, 110,000-psi tensile strength or ASTM A193, Grade B8, Class 2. Bolts in buried or submerged service shall be ASTM A193, Grade B8, Class 2.

C. Couplings for pipe 18 inches and smaller shall conform to AWWA C606 for flexible radius ductile-iron pipe, except where rigid radius couplings are required to connect to fittings.

Couplings shall be Victaulic Style 31, Gustin-Bacon No. 500, or equal.

D. Grooved-end adapter flanges for piping 18 inches and smaller having an operating pressure of 150 psi and less shall be Victaulic Style 341 or 342 or equal. Flange dimensions shall conform to ASME B16.1, Class 125.

E. Grooved-end transition couplings for connecting ductile-iron pipe 12 inches and smaller to steel pipe shall be Victaulic Style 307 or equal.

2.08 GASKETS FOR MECHANICAL, PUSH-ON, AND RESTRAINED JOINTS Synthetic rubber in accordance with AWWA C111.

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2.09 BOLTS AND NUTS FOR FLANGES
See Section 40 05 00.

2.10 OUTLETS AND NOZZLES
A. Provide outlets 2 inches and smaller by tapping the pipe and attaching a service clamp for buried pipe only or use a threaded welded-on boss for buried and exposed piping.

B. For outlets larger than 2 inches in exposed piping, use a tee with a flanged outlet.

C. For outlets larger than 2 inches in buried piping, use a tee with a restrained joint outlet.

2.11 JOINTS
A. Joints in aboveground or submerged piping or piping located in vaults and structures shall be grooved end or flanged as indicated in the drawings.

B. Joints in buried piping shall be of the restrained push-on or mechanical-joint type per AWWA C111 except where flanged joints are required to connect to valves, meters, and other equipment or are specifically called out on the drawings. Provide restrained buried joints except where unrestrained joints are specifically shown in the drawings.

C. Restrained joints for piping 6 inches and larger shall be American Cast Iron Pipe "Lok-Ring" or "Flex-Ring," U.S. Pipe "TR-Flex," or equal. Weldments for restrained joints shall be tested by the liquid penetrant method per ASTM E165. Restrained joints for field closures shall be “Megalug” by EBAA Iron.

D. Restrained joints in 4-inch-diameter buried piping shall be American Cast Iron Pipe Company “Fast-Grip,” U.S. Pipe Field-lok gasket within Tyton joint pipe and fittings, or equal. Joint restraint shall be certified to four times rated pressure of 200 psi by Factory Mutual.

E. Where thrust restraint is called for in the drawings, provide pipe with restrained joints capable of transmitting 1.5 times the thrust, as calculated by the following equation:

T = 1.5 * (0.785 * P * D2)
where:

P = Pressure class of pipe in psi.

D = Outside diameter of pipe in inches.

T = Thrust in pounds.

2.12 MECHANICAL JOINT RESTRAINT SYSTEM USING FOLLOWER RING AND WEDGES The restraining mechanism shall consist of a follower gland having a seal gasket and individually actuated wedges that increase their resistance to pullout as pressure or external forces increase. The system manufacturer shall provide all the components (follower ring, wedges, and gaskets) for the restraining device. The device shall be capable of full mechanical joint deflection during assembly, and the flexibility of the joint shall be maintained after burial.

The joint restraint ring and its wedging components shall be constructed of ductile iron conforming to ASTM A536, Grade 60-42-10. The wedges shall be ductile iron, heat-treated to a minimum hardness of 370 BHN. Dimensions of the gland shall be such that it can be used with mechanical joint bells conforming to AWWA C111 and AWWA C153. The design shall use torque limiting twist-off nuts to provide actuation of the restraining wedges. The mechanical joint

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restraint shall be available in the size range of 3 through 18 inches. Minimum rated pressure shall be 350 psi for sizes 16 inches and smaller and 250 psi in sizes 18 inches and larger.

Products: Megalug Series 1100 as manufactured by EBAA Iron, Inc., or equal.

2.13 DUCTILE-IRON PIPE WELDMENTS
A. All welding to ductile-iron pipe, such as for bosses, joint restraint, and joint bond cables, shall be done at the place of manufacture of the pipe. Perform welding by skilled welders experienced in the method and materials to be used. Welders shall be qualified under the standard qualification procedures of the ASME Boiler and Pressure Vessel Code, Section IX, Welding Qualifications.

B. Welds shall be of uniform composition, neat, smooth, full strength, and ductile. Completely grind out porosity and cracks, trapped welding flux, and other defects in the welds in such a manner that will permit proper and complete repair by welding.

C. Completed welds shall be inspected at the place of manufacture by the liquid penetrant method.

Conform to the requirements specified in ASTM E165, Method A, Type I or Type II. The materials used shall be water washable and nonflammable.

PART 3 - EXECUTION

3.01 DELIVERY, UNLOADING, AND TEMPORARY STORAGE OF PIPE AT SITE A. Use unloading and installation procedures that avoid cracking of the lining. If necessary, use plastic sheet bulkheads to close pipe ends and keep cement-mortar lining moist.

B. Do not move pipe by inserting any devices or pieces of equipment into the pipe barrel. Field repair linings damaged by unloading or installation procedures.

3.02 SANITATION OF PIPE INTERIOR
A. During laying operations, do not place tools, clothing, or other materials in the pipe.

B. When pipelaying is not in progress, close the ends of the installed pipe by a child- and verminproof plug.

3.03 INSTALLING FLANGED PIPE AND FITTINGS
Install in accordance with Section 40 05 00. Cut the bore of the gaskets such that the gaskets do not protrude into the pipe when the flange bolts are tightened.

3.04 INSTALLING GROOVED-END PIPE AND FITTINGS
See Section 40 05 00.

3.05 INSTALLING BURIED PIPING
A. Install in accordance with AWWA C600, and as follows.

B. Assemble restrained joints per manufacturer's instructions.

3.06 JOINT DEFLECTIONS FOR BURIED PIPE
A. Do not exceed the following deflection angles for unrestrained buried pipe joints:

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Pipe Size
(inches)
Maximum Deflection (degrees)
Push-On Joint Mechanical Joint
4 4 6 1/2
6 4 5 1/2
8 4 4
10 4 4
12 4 4
14 2 1/2 3
16 2 1/2 3
18 2 1/2 2 1/2
B. For restrained joints, do not exceed 80% of the manufacturer's recommended maximum deflections.

C. Assemble joints in accordance with AWWA C600 and the manufacturer's recommendations.

3.07 INSTALLING ABOVEGROUND OR EXPOSED PIPING
See Section 40 05 00.

3.08 PAINTING AND COATING
A. Coat pipe located above ground and in vaults and structures per Section 09 90 00, System No.

10. B. Provide asphaltic coating on buried pipe per AWWA C151.

C. Coat buried flanges and buried mechanical and restrained joint bolts, nuts, and glands per Section 09 90 00, System No. 21 or 22.

D. Line and coat exposed grooved-end couplings the same as the pipe exterior coating or with fusion-bonded epoxy.

E. Line and coat buried grooved-end couplings with fusion-bonded epoxy per System No. 21 or 22.

3.09 POLYETHYLENE ENCASEMENT OF BURIED PIPE AND FITTINGS Wrap buried pipe, fittings, grooved-end couplings, and joints with polyethylene per Section 09 97 54.

3.10 CLEANING PIPE
After interior joints have been pointed and mortar has hardened, sweep pipe clean of all dirt and debris. If hardened mud exists in the pipe, remove with the use of pressurized water hoses.

3.11 FIELD HYDROSTATIC TESTING
Test pressures are shown in the drawings. Test in accordance with Section 40 05 15. .

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3.12 BURIED WARNING AND IDENTIFICATION TAPE
Provide detectable warning tape. Warning and identification shall read “CAUTION BURIED WATER PIPING BELOW” or similar wording.

END OF SECTION

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40 20 57 – FUSION BONDED EPOXY LINED AND COATED STEEL PIPE 1 of 5
SECTION 40 20 57

FUSION EPOXY-LINED AND COATED STEEL PIPE
PART 1 - GENERAL

1.01 DESCRIPTION
This section includes materials, fabrication, installation, and testing of fusion-bonded epoxy-lined and -coated steel pipe in potable water service having a maximum design pressure of 250 psi for manifold piping in facilities, such as surge tanks, pumping stations, metering structures, flow control and pressure-reducing stations, and other piping associated with mechanical equipment.

Sizes are 2 through 36 inches.

1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Painting and Coating: 09 90 00.

B. Polyethylene Sheet Encasement (AWWA C105): 09 97 54
C. Trenching, backfill, and Compaction: 31 23 16.

D. Pressure Testing of Piping: 40 05 15.

1.03 SUBMITTALS
Submit shop drawings in accordance with the general provisions.

PART 2 - MATERIALS

2.01 GENERAL
A. Apply fusion-bonded epoxy lining and coating to steel pipe per AWWA C213 except as modified herein. The pipe or fitting size in inches refers to the pipe size per ASME B36.10.

B. The Contractor shall require the pipe supplier to provide bare pipe that is free of salts, oil, and grease to the coating applicator.

2.02 STEEL PIPE CYLINDERS
A. Steel pipe 18 inches and smaller in diameter shall be API 5L, Grade B; ASTM A53 (Type E or S), Grade B; ASTM A106, Grade B; or ASTM A135, Grade B.

B. Steel pipe larger than 18 inches in diameter shall be API 5L, Grade B; ASTM A106, Grade B; ASTM A135, Grade B; ASTM A134; or AWWA C200 or shall comply with the requirements of ASTM A53, Grade B. Pipe conforming to ASTM A134 or to AWWA C200 shall be made of steel conforming to ASTM A283, Grade C or D, or ASTM A285, Grade C.

C. Pipes shall be schedule 40 per ASME B36.10.

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2.03 SHOP-APPLIED EPOXY LINING AND COATING
Lining and coating shall be a 100% solids, thermosetting, fusion bonded, dry powder epoxy resin: Scotchkote 134 or 206 N, Valspar "Pipe Clad" 1500 Red, or equal. Epoxy lining and coating shall meet the following requirements:

Hardness (minimum) Barcol 17 (ASTM D2583)
Rockwell 50 ("M" scale).

Abrasion resistance (minimum) 1,000 cycles: 0.05 gram removed 5,000 cycles: 0.115 gram removed
ASTM D1044, Tabor CS 17 wheel, 1,000-gram
weight
Adhesion (minimum) 3,000 psi (Elcometer)
Tensile strength 7,300 psi (ASTM D2370)
Penetration 0 mil (ASTM G17)
Adhesion overlap shear, 1/8-inch
steel panel, 0.010 glue line
4,300 psi, ASTM D1002
Impact (minimum value) 100 in-lb (Gardner 5/8-inch radius tup)

2.04 SHOP- AND FIELD-APPLIED EPOXY COATING FOR PATCHING Use a two-component, minimum 80% solids liquid epoxy resin, such as Scotchkote 306 or 323 or equal.

2.05 FITTINGS
A. A fitting is defined as a special piece of pipe other than a normal straight section. Elbows, manhole sections, reducers, and sections with outlets are fittings.

B. Fittings 2 through 12 inches shall be flanged, conforming to ASME B16.9 or grooved-end as shown on the plans, or steel (ASTM A53, Grade B). Material for flanged steel fittings shall conform to ASTM A234, Grade WPB. Wall thickness (except for grooved ends) shall be the same as the pipe.

C. Grooved-end fittings smaller than 24 inches shall be square-cut grooved, flexible type, with the groove dimensions as shown in AWWA C606, Table 3. Grooved-end fittings 24 inches and larger shall have AWWA C606 Type "D" collars for use with the grooved-end couplings.

2.06 JOINTS
A. Joints for aboveground, exposed, or submerged pipe shall be flanged or grooved end, except where flanged joints are required to connect to valves, pumps, and other equipment.

B. Buried joints shall be plain end with flexible pipe couplings or grooved end, except where flanged joints are required to connect to valves and other items.

C. Grooved-end joints for pipes 20 inches and smaller shall be flexible, square-cut grooved, per AWWA C606, Table 3. Grooved-end joints for pipes 24 inches and larger shall have AWWA C606 Type "D" collars.

D. Do not field weld to join pipe and fittings. If connections in addition to those shown in the drawings are required to field join pieces, use either flanged or grooved-end joints.

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E. Couplings for pipe smaller than 24 inches shall be flexible type, square-cut grooved, per AWWA C606: Victaulic Style 77, Gustin-Bacon Figure 100, or equal. Use Victaulic Style 44 couplings, or equal, for pipe 24 inches and larger having AWWA C606 Type "D" collars.

F. Line and coat grooved-end couplings the same as the pipe. Color shall match the color of the pipe fusion epoxy coating.

PART 3 - EXECUTION

3.01 SHOP APPLICATION OF FUSION EPOXY LINING AND COATING A. Apply lining and coating per AWWA C213.

B. Grind 0.020 inch (minimum) off the weld caps on the pipe weld seams before beginning the surface preparation and heating of the pipe.

C. Grind surface irregularities, welds, and weld spatter smooth before applying the epoxy. The allowable grind area shall not exceed 0.25 square foot per location, and the maximum total grind area shall not exceed 1 square foot per pipe section. Do not use any pipe section in which these requirements cannot be met.

D. Grind outside sharp corners, such as the outside edges of flanges, to a minimum radius of 1/4 inch.

E. Uniformly preheat the pipe prior to blast cleaning to remove moisture from the surface. The preheat shall be sufficient to ensure that the pipe temperature is at least 5°F above the dew point temperature during blast cleaning and inspection.

F. Sandblast surfaces per SSPC SP-5. Protect beveled pipe ends from the abrasive blast cleaning.

G. After cleaning and surface preparation, test the pipe surface for residual chloride concentration.

If the residual chloride concentration exceeds 5 g/cm2, then apply a phosphoric acid wash to the pipe after sandblasting. The average temperature of the pipe, measured in three different locations, shall be 80°F to 130°F during the acid wash procedure. The acid wash shall be a 5% by weight phosphoric acid solution. The duration in which the acid is in contact with the pipe surface shall be determined by using the average pipe temperature as tabulated below:

Pipe Temperature
(°F)
Contact Time
(seconds)
80 52
85 45
90 36
95 33
100 28
105 24
110 21
130 10
After the acid wash has been completed, remove the acid from the pipe with demineralized water having a maximum conductivity of 5 micromhos/cm at a minimum nozzle pressure of 2,500 psi.

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H. Apply epoxy lining and coating by either the fluidized bed or the electrostatic spray process.

Minimum thickness of lining and coating shall be 15 mils each. Heat and cure pipe linings and coatings per the resin manufacturer's recommendations. The heat source shall not leave a residue or contaminant on the metal surface. Do not allow oxidation of surfaces to occur prior to coating. Do not permit surfaces to flash rust before coating.

3.02 FACTORY TESTING OF LINING AND COATING
A. Test lining and coating with a low-voltage wet sponge holiday detector in accordance with AWWA C213, Section 5.3.3. If the number of holidays or pinholes exceeds one per 20 square feet for pipe smaller than 14-inch outside diameter or one per 6 linear feet of pipe length for pipe 12 inches and smaller, remove the entire pipe lining and coating and recoat the entire pipe or fitting.

B. Check for coating defects on the weld seam centerlines. There shall be no porous blisters, craters, or pimples lying along the peak of the weld crown.

C. Measure the coating thickness at three locations on each pipe section using a coating thickness gauge calibrated at least once per eight-hour shift. Record each measured thickness value.

Where individual measured thickness values are less than the specified minimum thickness, measure the coating thickness at 3-foot intervals along the pipe length. The average of these measurements shall exceed the specified minimum thickness value, and no individual thickness value shall be more than 2 mils below or 3 15mils above the specified minimum value. If a section of pipe does not meet these criteria, remove the entire lining and coating and recoat.

3.03 QUALITY OF LINING AND COATING APPLICATION
The cured lining or coating shall be smooth and glossy, with no graininess or roughness. The lining or coating shall have no blisters, cracks, bubbles, underfilm voids, mechanical damage, discontinuities, or holidays.

3.04 SHOP REPAIR OF DEFECTIVE COATINGS AND LININGS
A. Apply a two-part epoxy coating to defective linings and coatings to areas smaller than 20 square inches. Patched areas shall overlap the parent or base coating a minimum of 0.5 inch. If a defective area exceeds 20 square inches, remove the entire lining and coating and recoat.

B. Prepare the defective area per SSPC SP-10 or SP-11T. Lightly abrade or sandblast the pipe coating and lining on either side of the area before applying the liquid epoxy coating. Apply the liquid epoxy coating to a minimum dry-film thickness of 15 mils.

3.05 SHIPPING, STORAGE, AND HANDLING
A. When loading piping, fittings, couplings, or other coated items for shipment to the project site, use spacers and other protective devices to separate pipes or other coated items to prevent damaging the coated surfaces during transit and unloading. If wood spacers are used, remove wood splinters and particles from the coated surfaces after separation. Use padded chains or ribbon binders to secure the loaded pipe or other coated items and minimize damage.

B. Do not load or unload pipe, fittings, couplings, or other coated items by inserting forklift tines or lifting chains inside the pipe or item. Use nonmetallic slings, padded chains, or padded forklift tines to lift pipe or other coated items.

C. Cover piping or other coated items 100% with protective coverings or tarpaulins to prevent deposition of road salts, fuel residue, and other contaminants in transit.

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D. Provide stulls, braces, and supports for piping during shipping and storage such that out-ofroundness or deflection does not exceed 0.5% of the pipe diameter.

E. Handle piping and other coated items with care during the unloading, installation, and erection operations to minimize damage. Do not place or store pipe or other coated items on the ground or on top of other work unless ground or work is covered with a protective covering or tarpaulin.

Place pipe or other coated items above the ground upon platforms, skids, or other supports.

F. Store piping or other coated items at the site on pallets to prevent direct contact with ground or floor. Cover pipe or coated items during storage with protective coverings or tarpaulins to prevent deposition of rainwater, salt air, dirt, dust, and other contaminants.

G. Do not allow piping or other coated items to contact metal, concrete, or other surfaces during storage, handling, or installation and erection at the site that could damage or scratch the coating.

3.06 INSTALLING BURIED PIPING
A. Inspect the interior and exterior protective coating, and repair damaged areas in the field with the coating manufacturer's field repair kit. Field test coating with a low-voltage wet sponge holiday detector in accordance with AWWA C213, Section 5.3.3.

B. Use only fabric straps to lift pipe; do not use chains or cables.

C. Polyethylene sheet encase all buried fusion bonded epoxy steel pipe/fittings per Section 09 97

54. D. At flanged coupling adapters with thrust restraint lugs, follow coupling manufacturer recommendations to insure the lugs will grip the steel pipe and develop full thrust resistance strength and not have the fusion bonded epoxy coating clog the lugs.

3.07 FIELD PRESSURE TESTING
See Section 40 05 15.

3.08 PAINTING EXPOSED PIPING
Coat per Section 09 90 00, System No. 66.

END OF SECTION

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SECTION 40 20 76

STAINLESS-STEEL PIPE
PART 1 - GENERAL

1.01 DESCRIPTION
This section includes materials and installation of stainless-steel pipe and fittings 3 inches in diameter and smaller conforming to ASTM A312 or A778 and having a maximum design pressure of 175 psi.

1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Manual, Check, and Process Valves: 40 05 20.

B. Reciprocating Air Compressor System: 43 12 16.

1.03 SUBMITTALS
Submit shop drawings in accordance with general provisions.

PART 2 - MATERIALS

2.01 PIPE
A. Pipe smaller than 3 inches shall conform to ASTM A312, Grade TP 304L or 316L.

B. Pipe sizes and wall thicknesses shall conform to ASME B36.19 as follows:

Pipe Size Wall Thickness
1 inch and smaller Schedule 40S
1 1/4 inches through 3 inches Schedule 40S

2.02 FITTINGS
Fittings 3 inches and smaller shall be threaded or socket welded, conforming to ASME B16.11, 3,000-pound CWP. Material for threaded fittings shall conform to ASTM A403, Class WP 304 or 316. Material for socket welded fittings shall conform to ASTM A403, Class WP 304L or 316L.

2.03 PICKLING, PASSIVATING, AND FINAL CLEANING
Pipe and fittings shall be final cleaned, pickled, and passivated per ASTM A380. Passivation shall be the removal of exogenous (not inherent in the base metal) iron or iron compounds from the surface of the stainless-steel by means of a chemical dissolution, by a treatment with an acid solution that will completely remove the surface contamination but will not significantly affect the stainless-steel itself. After final cleaning, wet surfaces with water and inspect for rust spots after 24 hours. Reclean if there is any evidence of rusting.

2.04 QUALITY CONTROL
Include the "Hydrostatic Test" and "Flattening Test" requirements described in ASTM A999. A nondestructive electric test per ASTM A999 may be substituted for the hydrostatic test.

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2.05 UNIONS
Unions shall be 3,000-pound WOG forged stainless-steel, with dimensions conforming to MSS SP-83. Ends shall be threaded per ASME B1.20.1. Material shall conform to ASTM A182, Grade F304 or F316 for threaded end unions.

2.06 JOINTS
A. Joints for pipes 3 inches and smaller shall be threaded or socket welded, same material as specified for fittings, 3,000-pound WOG, conforming to ASME B16.11.

B. Joints for buried or submerged pipe larger than 3 inches shall be butt-welded.

2.07 THREAD LUBRICANT
Use Teflon thread lubricating compound or Teflon tape.

2.08 FLANGES
Provide weld-neck flanges (conforming to ASME B16.5) for piping 3 inches and smaller to connect to flanged valves, fittings, or equipment. Provide weld-neck or Van Stone flanges (per ASTM F2015) for piping larger than 3 inches. Flanges shall be Class 150 per ASME B16.5.

Flanges shall match the connecting flanges on the adjacent fitting, valve, or piece of equipment.

Flanges shall be flat face.

2.09 PROTECTIVE END CAPS
Provide protective end caps on each piece of pipe or fabricated section, completely sealing the piece from contamination during shipment and storage. Provide the same type of seals on each fitting, or ship and store fittings in sealed boxes or containers.

2.10 OXYGEN INDICATOR FOR WELDING OPERATIONS
Use an oxygen indicator to determine the oxygen level in the purged atmosphere (rest oxygen) in the welding area. The oxygen indicator shall be of the zirconium cell type having a range of 1- to 100-ppm oxygen. Products: Intercon Enterprises Pro-2 or equal.

PART 3 - EXECUTION

3.01 SHIPPING, STORAGE, AND HANDLING
A. Ship, store, and handle piping (including both pipe and fittings) per AWWA C220, Section 6.2 and AWWA C226, Section 6.3 and the following.

B. When loading piping for shipment to the project site, use spacers and other protective devices to separate pipes to prevent damaging the surfaces during transit and unloading. If wood spacers are used, remove wood splinters and particles from the pipe surfaces after separation.

Use padded chains or ribbon binders to secure the loaded pipe and minimize damage.

C. Cover piping 100% with protective coverings or tarpaulins to prevent deposition of road salts, fuel residue, and other contaminants in transit.

D. Provide stulls, braces, and supports during shipping and storage such that out-of-roundness or deflection does not exceed 0.5% of the pipe diameter.

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E. Handle piping with care during unloading, installation, and erection operations to minimize damage. Do not place or store pipe on the ground or on top of other work unless ground or work is covered with a protective covering or tarpaulin. Place pipe above the ground upon platforms, skids, or other supports.

F. Store piping at the site on pallets to prevent direct contact with ground or floor. Cover pipe during storage with protective coverings or tarpaulins to prevent deposition of rainwater, salt air, dirt, dust, and other contaminants.

G. Do not allow piping to contact carbon steel surfaces during storage, handling, or installation and erection at the site.

3.02 FABRICATION, ASSEMBLY, AND ERECTION
A. Welded butt joints (both longitudinal and circumferential) shall comply with AWWA C220 and AWWA C226, Section 4. Do not use backing rings. Provide full penetration and smooth internal diameters for the root bead of welds. Grind the inside weld of socket welds flush with the pipe internal diameter. Welds shall be of smooth finish. Use anti-spatter compounds specifically formulated or designed for use with stainless-steel. Do not allow heat tint to form in the heataffected zone or remove heat tint completely from the heat-affected zone of the finished weld.

The maximum depth of grinding or abrasive blasting to remove defects shall not exceed 10% of the wall thickness. Do not perform abrasive blasting with steel shot, grit, or sand.

B. No iron or steel surfaces shall come into contact with the stainless-steel. This includes placing on steel tables, racks, pipe supports, etc. Do not use carbon steel wire brushes or grinders.

C. Welding electrodes shall comply with AWS A5.4. Bare wire shall comply with AWS A5.9. Use electrodes as follows:

Pipe Material Welding Electrode Material
Type 304 E 308
Type 304L E 347
Type 316 E 316
Type 316L E 318

3.03 INSTALLING THREADED PIPING
Ream, clean, and remove burrs from threaded piping before making up joints. Apply thread lubricant to threaded ends before installing fittings, couplings, unions, or joints.

3.04 INSTALLING UNIONS
Provide unions on exposed piping 3 inches and smaller as follows:

A. Where shown in the drawings.

END OF SECTION

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SECTION 43 12 16

RECIPROCATING AIR COMPRESSOR SYSTEM
PART 1 -- GENERAL

1.01 GENERAL REQUIREMENTS
A. SCOPE:

1. Materials, testing, and installation of reciprocating air compressor and accessories, including receiver, aftercooler, moisture traps/filters and oil water separator. The air compressor shall be included in the equipment supplied by the surge tank supplier.

B. Tag Numbers

1. Receiver Tank: RT-1

2. Compressor: CP-1

3. Oil Water Separator SEP-1

1.02 REFERENCES
A. DEFINITIONS:

1. Terms shall be as defined in the ASME PTC-9.

1.03 SUBMITTALS
A. The following information shall be submitted for review in accordance with the SUBMITTAL PROCEDURES Section (01 33 00):

1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations.

2. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the product.

3. Submit manufacturer's catalog data and detail drawings showing all compressor parts and auxiliary equipment, described by material of construction, specification (such as AISI, ASTM, SAE, or CDA), and grade or type. Show capacities and rated pressure.

Show linings and coatings.

4. Submit ASME Forms U-1 or U-1A for receiver tank after tank fabrication. For Code UM vessels, submit Form U-3 certificate of compliance only.

5. Submit certifications that receiver meets the ASME Boiler and Pressure Vessel Code and that air compressor mounted on receiver tank meets OSHA requirements.

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1.04 OPERATION AND MAINTENANCE INSTRUCTIONS
A. Submit Operation and Maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 93 10). O&M instructions shall be submitted after all submittals specified above have been returned marked “no exceptions taken” or “make corrections noted”. O&M instructions shall reflect the approved materials and equipment.

1.05 UNIT RESPONSIBILITY
A. Air compressor and all appurtenances required by this specification section shall be supplied by one manufacturer.

1.06 DELIVERY, STORAGE, HANDLING
A. Prepare equipment for shipment including blocking of the rotor when necessary. The preparation shall make the equipment suitable for six months of outdoor storage from the time of shipment, with no disassembly required before operation, except for inspection of bearings and seals.

B. Identify the equipment with item and serial numbers and project equipment tag numbers.

Material shipped separately shall be identified with securely affixed, corrosion-resistant metal tags indicating the item and serial number and project equipment tag numbers of the equipment for which it is intended. In addition, ship crated equipment with duplicate packing lists, one inside and one on the outside of the shipping container.

C. Pack and ship one copy of the manufacturer’s standard installation instructions with the equipment. Provide the instructions necessary to preserve the integrity of the storage preparation after the equipment arrives at the jobsite and before start-up.

D. Store and protect compressors per API 686 (first edition), Chapter 3, paragraphs 1.4 through

1.11, 1.20, and 1.21 and as described below.

E. Coat exterior machined surfaces with standard factory finishes and colors.

F. The interior of the equipment shall be clean and free from scale, welding spatter, and foreign objects. Spray or flush the interior with a rust preventive that can be removed with solvent.

Apply the rust preventive through all openings while the rotor or shaft is rotated.

G. Coat internal surfaces of bearing housings and carbon steel oil systems’ components with an oil-soluble rust preventive that is compatible with the lubricating oil. Paint exposed to lubricants shall be oil resistant. When synthetic lubricants are used, take precautions to assure compatibility with the paint.

H. Fully protect bearing assemblies from the entry of moisture and dirt. If volatile corrosion inhibitor crystals in bags are installed in large cavities to absorb moisture, attach the bags in an accessible area for ease of removal. Where applicable, install bags in wire cages attached to flanged covers. Indicate bag locations by corrosion-resistant tags attached with stainless steel wire.

I. Provide flanged openings with metal closures at least 3/16-inch thick, with elastomer gaskets and at least four full-diameter bolts. Provide closures at the place of compressor manufacture prior to shipping. For studded openings, use all the nuts needed for the intended service to secure closures.

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J. Provide threaded openings with steel caps or solid-shank steel plugs. Do not use nonmetallic (such as plastic) plugs or caps. Provide caps or plugs at the place of compressor manufacture prior to shipping.

K. Clearly identify lifting points and lifting lugs on the equipment or equipment package. Identify the recommended lifting arrangement on boxed equipment.

L. Wrap exposed shafts and shaft couplings with waterproof, moldable waxed cloth or volatilecorrosion-inhibitor paper. Seal the seams with oil-proof adhesive tape.

M. If electric motors are stored or installed outside or in areas subject to temperatures below 40°F or are exposed to the weather prior to permanent installation, provide the manufacturer’s recommended procedures for extended storage. Provide temporary covers over the motor electrical components. Provide temporary conduits, wiring, and electrical supply to space heaters. Inspect electrical contacts before start-up.

1.07 MANUFACTURER'S SERVICES
A. Provide equipment manufacturer's services at the jobsite for the minimum labor days listed below, travel time excluded:

1. One labor day for the air compressor assembly listed in the subsection on "Service Conditions" to check the installation and advise during start-up, testing, and adjusting of the equipment. See Section 3.04 Training for additional manufacturer’s services.

1.08 WARRANTY
A. The supplied system/components shall carry a warranty of one year from completion/City acceptance of the construction or eighteen months from delivery to project site, whichever comes first.

PART 2 -- PRODUCTS

2.01 AIR COMPRESSOR
A. Each air compressor shall be of the self-contained, reciprocating type, consisting of a singleacting, air-cooled compressor and motor with v-belt drive and fully enclosed osha type belt guard. Each compressor shall be a multistage type, oil-lubricated, simplex mounted unit, as stated in the subsection on "service conditions." provide each compressor unit with fulldischarge size flexible discharge connection, aftercooler, and vibration isolators.

B. Provide each two-stage or multistage compressor with finned-tube, air-cooled intercoolers with relief valves between stages of compression.

C. Each compressor shall have means to vent the pressure in the compressor cylinders to atmosphere upon stopping.

D. Air inlet filter silencers shall be of the dry type with 4-micron replaceable element, as stated in the subsection on "service conditions."
E. Compressor control shall automatically start-stop based on pressure in the receiver. If the air compressor fails to start, send an alarm signal.

F. Motor driver shall be of sufficient horsepower to operate the compressor continuously at the maximum discharge pressure specified in the subsection on "service conditions," without

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exceeding its rated full-load current. Rated horsepower and service factor shall not be less than the values shown in the subsection on "service conditions." G. Provide a temperature switch and wiring to the control panel to shut off compressor when the temperature in the compressor head reaches the maximum allowable determined by the compressor manufacturer.

H. Oil-lubricated compressors and motors shall shut down at low oil level or low oil pressure and shall not restart until oil is added.

I. Protect rotating parts in conformance with CAL/OSHA requirements.

2.02 RECEIVER
A. Tank shall comply with section viii, division 1, of the ASME boiler and pressure vessel code.

Steel plates shall be selected from those listed in table UCS-23 of said code. Provide epoxy coating of exterior of receiver per manufacturer’s standard finish (application of 8-10 mils dry film thickness). Pressure rating shall be not less than the ASME design pressure rating specified in the section on "service conditions" below. Perform standard hydrostatic test in the shop. Test pressure shall be 130% of the ASME pressure rating.

2.03 SIMPLEX COMPRESSOR
A. Mount compressor on to a single vertical ASME receiver.

2.04 FLEXIBLE CONNECTORS
A. Flexible connectors 2 inches and smaller shall be of the corrugated metal hose type with an external braid. Connectors shall have a minimum pressure rating as stated in the subsection on "service conditions" for the particular compressor. Corrugation tubing material shall be type 316 or 316l stainless steel with type 316, 316l, or 321 stainless steel braid material. End connections shall be ground joint female union with ASME B1.20.1 NPT threads. Length shall be 12 inches unless otherwise indicated. Flexible connectors shall be American Boa type b4, Flexonics series 400h or type rw, or equal.

2.05 AFTERCOOLER
A. Provide a belt-guard type air-cooled aftercooler after the compressor.

B. Aftercooler shall be capable of cooling the compressed air to within 25°F of the ambient air temperature at the compressor air inlet.

C. Provide an automatic condensate trap to remove accumulated moisture from the aftercooler.

2.06 PRESSURE SWITCHES FOR RECEIVER
A. Provide 1/2-inch ASME B1.20.1 NPT inlet threaded, adjustable two-stage pressure switch to start compressor and to stop compressor. Pressure rating shall be at least 400 psi. Bourdon tubes, bellows, and diaphragms shall be type 303, 304, 316, or 403 stainless steel. Voltage rating shall be 120-volt, 60-hertz ac. Contacts shall be rated for at least 10 amperes. Provide Nema type 2 enclosure. Provide with stainless steel pipe nipples and fittings, two-way gauge cock, and stainless steel pulsation dampener. Pressure settings shall be as specified in "service conditions" in the detailed compressor specification. Manufacturers: Allen-Bradley, Barksdale, Mercoid, United Electric, or equal.

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2.07 PRESSURE GAUGE ASSEMBLIES/RELIEF VALVES FOR RECEIVER A. Provide one 1/2-inch ASME b1.20.1 npt threaded stainless steel pressure gauge assembly at the receiver tank. Assembly shall include 4-1/2-inch gauge, stainless steel pipe nipples and fittings, three-way gauge cock, stainless steel pulsation dampener.

B. Provide a safety pressure relief valve on receiver.

2.08 AUTOMATIC DRAIN TRAP FOR RECEIVER
A. Where aftercooler is plumbed to flow into receiver, provide an automatic drain trap with receiver tank to drain tank to an oil water separator as indicated in the drawings. The oil water separator shall be sized and provided by the air compressor manufacturer. The air compressor is expected to operate about 1 hour every 2-3 days.

2.09 CONTROLS
A. Provide control panel mounted on compressor assembly or common support system complete with flange-mounted fusible circuit breaker type disconnect switch, magnetic motor starter, control transformer, alternator wiring, and hand-off-auto control switch with springreturn to off position for each compressor. Enclosure shall be sheet metal; nema rated as shown in section on "service conditions," bonderized, and painted ANSI z55.1 no. 61 gray.

Starters and control devices shall conform to nema standards for the horsepower of the motor provided. Control transformer shall be dry type, with secondary voltage of 120-volt a-c.

Control switches shall be maintained contact, hand-off-auto selector switches with spring returns from hand to off positions.

B. Include wiring, indicating light, and time delay relay(s) to automatically shut off compressor motor when compressor head temperature reaches the preset maximum allowable and to allow the motor to restart after an adjustable 30-minute cool-down period. Light shall indicate while timer is timing.

C. Provide dry contacts for remote indication of the following:

1. Compressor 1 is running.

2. Compressor 1 common alarm.

3. Provide a common alarm dry contact for compressor. An alarm shall be generated on low oil level or high temperature.

4. All specific alarms shall be indicated on the control panel.

5. The air compressor will automatically start and stop based on the pressure inside the receiver tank.

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2.10 PROVIDE THE FOLLOWING SPARE PARTS FOR EACH SIZE OR MODEL OF COMPRESSOR:

Quantity Description
1 sets Piston rings
1 sets Gaskets, valve plates, valve springs
2 V-belts
1 Flexible connector
1 Safety relief valve
2 Air inlet filters
3 each Filter replacement kits for prefilter, coalescing filter
1 set Fuses for compressor motor disconnect
switch
A. Pack spare parts in a wooden box; label with the manufacturer's name and local representative's name, address, and telephone number; and attach list of materials contained within.

2.11 ANCHOR BOLTS
A. Air compressor assembly manufacturer shall provide size of anchor bolts. Anchor bolts shall be the concrete wedge anchor type (stainless steel) or embeded and be provided by the contractor.

PART 3 -- EXECUTION

3.01 GENERAL (NOT USED)

3.02 INSTALLATION
A. Embed anchor bolts in sleeves in portland cement concrete support slab per air compressor assembly manufacturer's instructions. Use templates to hold bolts and sleeves in position.

Mount air compressor assembly support feet on dry-packed mortar.

B. Verify that the installed compressor is fully self-supporting before making pipe connections, so that no strain is imparted on the pipe connections, pipes, or pipe supports from the compressor assembly. Adjust the position of the compressor assembly so that the compressor piping connections are plumb and aligned with the adjacent pipe. Do not use temporary shims or wedges for leveling, aligning, or supporting equipment.

C. Provide continuous protection of the equipment from the elements, dust, debris, paint spatter, or other conditions that will adversely affect the unit's operation until such time as the equipment is scheduled for start-up testing.

D. Provide the manufacturer's recommended lubricants and operating fluids and verify that each piece of equipment contains the amount recommended by the manufacturer.

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3.03 TESTING
A. Field Testing

1. Bump motor to ensure that motor has been connected for proper rotation.

2. Start up the compressor system in accordance with API 686, Chapter 9. Comply with Sections 5.2 and 5.4 in Chapter 9. Operate the equipment for 30 consecutive days, during which time no repairs or adjustments shall be required. Operate start-up and shutdown sequencing system and assure that compressors start and stop in the specified manner. Perform this starting sequence on each compressor at least once every five days.

3.04 TRAINING
A. The air compressor manufacturer shall provide 8 hours of training of City operations staff.

3.05 SERVICE CONDITIONS
A. Air compressor assembly performance conditions and design data shall be as shown below.

Location Existing control building site
Environment Inside the building
Service Indoor environmental temperature range
35 °F to 80°F
Elevation 45 feet above sea level
Average Relative humidity 35% to 55%
Barometric pressure 14.68 psia
Maximum inlet temperature 80 °F
Minimum inlet temperature 35°F
Compressor:

Type Two stage, oil-lubricated, simplex mounted
Maximum physical dimensions Length 38”, width 28” & height 77” Minimum compressor rated capacity 16.8 scfm
Rated compressor discharge pressure at
rated capacity (measured at aftercooler
outlet)
175 psig
Air filter silencer type Dry
Motor horsepower (minimum) 5
Motor service factor (minimum) 1.15
Motor type Totally Enclosed, Fan Cooled
Receiver:

Size 80 gallons
ASME design pressure rating 250 psig
Control panel enclosure rating NEMA 2
Manufacturers and models Ingersoll-Rand Model 2475N5-V, AtlasCoppco, Corken, Quincy, or equal.

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3.06 COMMISSIONING
A. Require manufacturer to inspect system before initial start-up and certify that system has been correctly installed and prepared for surge system start-up as specified. **END OF SECTION**

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`SECTION 43 41 17

HYDROPNEUMATIC SURGE TANK SYSTEM
PART 1 -- GENERAL

1.01 GENERAL REQUIREMENTS
A. SCOPE:

1. Materials, testing, and installation of ASME-rated vertical pressure vessel tank for surge control of a water transmission pipeline system. A surge analysis was performed by Flow Science to determine the size of the surge tank and provide design information. The system shall include air compressor assembly, water level controls, pressure vessel, magnetic level gauge, water level transmitter, pressure transmitter on connecting pipe, pressure gauges, accessory gauges, valves, and piping.

B. This surge tank system is considered Major Equipment and is subject to special progress payment procedures in accordance with the following:

1. Purchase Order = 5%. An executed surge tank system supplier purchase order must accompany the payment request.

2. Submittal Acceptance 5%. Approval of the equipment is required prior to payment of this amount.

3. Fabrication = 70%. Fabrication, including factory testing may be paid in part provided adequate documentation is presented and accepted by City.

4. Delivery = 5%. Proof of successful onsite delivery (with proper handling of stored materials) must accompany the payment request.

5. Site Pre-Operational system checkouts/Installation = 5%.

6. Site operation checkouts and successful performance testing/training = 7.5%

7. City approval and acceptance of surge system operation and maintenance manual = 2.5%.

8. The sum of items listed above shall not exceed the documented surge system supplier quotation amount or invoice amount.

1.02 REFERENCES
A. REFERENCE STANDARDS: The publications referred to hereinafter form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. The latest edition of the referenced publications in effect at the time of the bid shall govern. In case of conflict between the requirements of this section and the listed references, the Code requirements of this section shall prevail.

Reference Title
ASME BPVC American Society of Mechanical Engineers Boiler and Pressure Vessel

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Reference Title
Code Section VIII - Rules for Construction of Pressure Vessels, Division 1 ASTM A36 Specification for Structural Steel
CFR Title 49 Transportation Part 178 - Specifications for Packaging B. DEFINITIONS: Not used.

1.03 SUBMITTALS
A. The following information shall be submitted for review in accordance with SUBMITTAL PROCEDURES Section (01 33 00):

1. A copy of this specification section, with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations.

2. Manufacturer’s information and catalog data showing compliance with this specification and a full description of the product.

3. Contractor is responsible for completing the Pressure Vessel Inspection Request Form that can be found at the California's Department of Industrial Relations website http://www.dir.ca.gov/dosh/pressure.html#PresureVessel.

4. Product data:
a. Include a list of materials and coatings used.

5. Shop drawings and tank design calculations:
a. Submit layout drawings showing dimensions of equipment, accessories, supports, connections, and piping. Show equipment weights and anchor bolt design. Show weight of pressure vessel, both empty and filled with water. b. Provide dimensional drawings and layouts for magnetic level indicator with transmitter, pressure transmitter to be located on connecting pipe, access manhole, try valves, pressure relief valves, air-release valve, solenoid valves and control panel.
c. Submit manufacturer's catalog data on gauges, valves, water level control panel/system components, tank linings, and coatings.
d. Submit PLC control panel drawing with electrical schematic and wiring diagrams showing wiring, controls, interlocks, and terminals. Label each terminal showing which control or electrical power wire connects to which terminal. Submit manufacturer's catalog data for electrical equipment and enclosures.
e. Submit structural calculations prepared and signed by a Structural Engineer registered in California for design of the surge tank and its supports (including seismic).
f. Submit ASME Form U-1 for each of the pressure vessels. g. Submit certification that pressure vessels meet the ASME Boiler and Pressure Vessel Code requirements.

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1.04 OPERATION AND MAINTENANCE INSTRUCTIONS
A. Submit operation and maintenance (O&M) instructions in accordance with the OPERATION AND MAINTENANCE DATA Section (01 93 10) with each paragraph check marked to show compliance. O&M instructions shall be submitted after all the submittals specified above have been returned mark “No Exceptions Taken” or “Make Corrections Noted.” O&M instructions shall reflect the approved materials and equipment.

1.05 UNIT RESPONSIBILITY
A. Surge tanks and all appurtenances required (including the air compressor assembly) this specification section shall be supplied by one manufacturer/assembler.

1.06 SYSTEM DESCRIPTION
A. Design requirements:

1. Tank size: Tank size shall be as indicated on the Drawings:
a. The minimum tank volumes shall be as listed in the subsection on "Service Conditions".

2. Design the tank, steel leg supports and tie-down anchor bolts per the following requirements:
a. Seismic design: Conform to IBC, Section 1613 and ASCE 7, Chapter 15:
1) Risk Category: I.
2) Importance Factor: 1.
3) Seismic Design Category: D.
4) R: 2.0.
5) SS: 1.785.
6) S1: 0.875.
7) SDS: 1.428.
8) SD1: 0.992.
9) FA: 1.2.
10) FV: 1.70.
b. Wind design: 87 Vmph.
c. An unreinforced concrete housekeeping pad above the reinforced concrete structural slab shall not be considered to have structural value in the design of

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the anchor bolts. Tension and shear values for drilled or epoxied anchor shall conform to ICC-ER Reports.
d. Design the surge tanks for a 200 psi working pressure with no reactive load permitted through the inlet/outlet piping. The tank shall be designed for full vacuum conditions.
e. Support each tank by four legs. Material of construction shall comply with ASTM A36 or ASTM A285, Grade C. Weld the supports to the tank before it is lined.

1.07 WARRANTY
A. Provide a Manufacturer’s warranty meeting the requirements of the GENERAL CONDITIONS. The supplied components shall carry a warranty of one year from completion/City acceptance of the construction or eighteen months from delivery to project site, whichever comes first.

PART 2 -- PRODUCTS

2.01 MANUFACTURER'S SERVICES
A. Provide equipment manufacturer's services at the jobsite for the minimum labor days listed below, travel time excluded:

1. Two labor days to check the installation, including air compressor assembly, safety relief valves, air-release valves, electrical system, air compressor and level control system. Advise construction contractor during system start-up and also provide performance testing of surge system with adjustment to controls as required for optimum surge protection.

2.02 MANUFACTURERS
A. Acceptable Manufacturers:

1. Pulsco, Young Engineering, Pressure Vessels Technologies, South Gate Engineering or equal.

B. The surge tank manufacturer shall have complete unit responsibility for the tank design, fabrication, shop painting, factory hydrostatic pressure testing, delivery, startup, and tank performance testing.

2.03 MATERIALS
A. Construct tank shell and heads in accordance with ASTM 516-70 and support saddles/legs with ASTM A36 steel unless otherwise indicated on the Drawings.

B. Pressure Vessel:

1. Materials for the tank, design, and shop fabrication and inspection shall comply with Section VIII, Division 1, of the ASME Boiler and Pressure Vessel Code with only the plate steels in Table UCS-23 of said code being used. Provide ASME code stamp and pressure rating on pressure vessel.

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2. Minimum design pressure shall be as listed in the subsection on "Service Conditions". Provide corrosion allowance of 1/16 inch or one-sixth the calculated plate steel thickness at design pressure, whichever is greater. Perform hydrostatic test in shop. Test pressure shall be 130% of the design pressure.

3. Provide tank with steel support legs, bearing plate, and pads prepared to be bolted to a concrete base/slab. Provide tank lifting lugs and also tie-offs to help brace a portable ladder when operators are inspecting the pressure relief valves at top of tank.

2.04 COMPONENTS
A. Anchor bolts:

1. Anchor bolts shall have a nominal diameter of at least 3/4 inch, unless otherwise indicated on the Drawings, and shall be anchored to concrete foundations using methods designed to transfer the full ultimate strength of the anchor bolt to the concrete foundation.

2. Chairs or rings shall be designed to transfer 125 percent of the ultimate strength of the bolt, or 150 percent of the calculated load, whichever is less, to the tank shell.

B. Nameplates and code stamps: Design, fabricate, and test tanks in accordance with the ASME BPVC.

1. Each tank shall bear a stainless steel ASME nameplate.

2. Each nameplate shall bear the applicable code symbol.

3. Manufacturer shall be authorized by ASME to apply the applicable code symbols.

C. Fittings and attachments:

1. Fittings shall be as indicated on the Drawings.

2. Reinforce openings in accordance with the ASME BPVC.

3. Access manhole openings shall be flanged, hinged and, unless otherwise indicated on the Drawings, have a nominal diameter of at least 24 inches.

4. Provide vortex breaker at the tank internal inlet/outlet pipe to provide optimum hydraulic operation during a surge event.

D. Outlets and Nozzles:

1. Outlets shall be as shown on the drawings and shall be of the flanged nozzle type or grooved pipe connection. Nozzles shall be Schedule 80 per ASME B36.10.

Length from face of tank shell to face of flange shall be 6 to 12 inches. Flanges shall be slip-on or weld-neck type per ASME B16.5. Where connecting to piping smaller than 2 inches, provide a tapped blind flange or a companion flange with threaded connection per NACE SP0178-2007, Figure A10. Coat outlets the same as the tank. Flanges shall be flat faced.

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E. Attachments: Weld shell attachments for compressed air pipe supports, tank gauges, instruments, and other items as indicated on the Drawings before application of the tank lining.

2.05 APPURTENANCES
A. Pressure Gauges:

1. Provide stainless steel pressure gauges. Size of pressure gauge shall be 4 1/2 inches with a 1/2 inch connection pipe size. The gauges shall have a 0-200 psi pressure range.

2. Provide a regular Port Threated Stainless Steel Ball Valve for isolating the pressure gauge.
a. Acceptable Products:
1) McCanna Figure M402, Worcester Series 48, Stockham Figure SD 2120- SSMO-R-T, Apollo 76-100 Series, or equal.

B. Air Mufflers:

1. Provide muffler on air-vent solenoid valves/discharges.

2. Acceptable Products:
a. Allied-Witan, Norgren Quietaire, or equal.

C. Safety-Relief Valve:

1. Safety-relief valve shall comply with the ASME Boiler and Pressure Vessel Code for air service. Valves shall be of the spring-actuated type with an external lifting lever.

Valve shall close when pressure drops to allowable range. Valve size shall not be less than that required to maintain the hydropneumatic tank at its ASME design pressure while the air compressor is discharging at that pressure (with a 16.8+ scfm flow rate). Valves shall have a pressure rating as indicated in the subsection on “Service Conditions.” Bodies (including caps, bases, and bonnets) shall be bronze (ASTM B61 or B62) or Type 304 or 316 stainless steel with bottom inlet and side outlet. Inlet shall have male threads, ASME B1.20.1. Discs and springs shall be Type 304, 316, or 420 stainless steel. Valve shall incorporate a calibrated spring set to allow the valve to open at the pressure stated in the subsection on “Service Conditions.”

2. Acceptable Products:
a. Crosby Series 900, Consolidated Figure 1541, Birket-Richards Series B, or equal.

D. Air-Release Valve

1. Provide a stainless steel air-release valve near the bottom of the tank, as shown on the drawings. The valve shall serve to vent air from the tank in the event the air compressor fails to stop after the normal low-water level is reached. Size the valve orifice to release 16.8 scfm of air with a maximum 175 psig pressure from the air

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compressor. Pressure rating of the air-release and associated isolation valves shall be at least that of the tank.

2. Acceptable Products:
a. Vent-O- Mat, Vent-Tech, or equal.

E. Solenoid Valves:

1. Solenoid valves for air service shall have forged brass (Alloy UNS C23000) or bronze (ASTM B62) bodies with Teflon main seats. Internal plunger, core tube, plunger spring, and cage assembly shall be stainless steel (Type 302, 304, or 305).

Orifice size shall be not less than 75% of the nominal valve size. Valve actuators shall be 120-volt ac. Seals shall be Teflon. Solenoid valves shall be energized to open. Valves shall be ASCO "Redhat," Skinner-Lancer, Aktomatic, or equal.

F. Air Piping:

1. Piping for the compressed air lines shall be stainless steel, per the STAINLESS STEEL PIPE Section (40 20 76).

G. Air Compressor Assembly:

1. Air compressor assembly shall include simplex air compressor, motor driver, belt drive guard, single vertical receiver tank, support system, control panel, and accessories. Conform to the RECIPROCATING AIR COMPRESSOR SYSTEM Section (43 12 16).

H. The Automatic Level Control System includes Level Controller, Level Transmitter, Solenoid Valves and Air Compressor.

The purpose of the level control system is to control the air volume in the surge tank. This is accomplished by maintaining the water level within a designed operating range.

When water level is above the normal operating range, air shall be added to the surge tank from the air compressor, through the add air solenoid valve. When water is below the normal operating range, air shall be vented from the surge tank through the vent air solenoid valve. High and Low alarm signals shall be generated when the water level is out of range. Time delays shall be used to prevent false alarms and avoid adding or venting air during normal pump start up and shutdown and during/after a surge event or during minor fluctuations.

The Automatic Level Control System includes Level Controller, Level Transmitter, Pressure Transmitter, Solenoid Valves and Air Compressor.

1. The PLC based level controller shall be a PULSCO Skypark Series, Allen Bradley or approved equal.
a. All electronics shall be housed in a 304 SS NEMA 4X enclosure. b. Controller shall be equipped with a door mounted 12” HMI touch screen display with a built in proximity sensor that will put the display to sleep if no movement is detected for several minutes.
c. HMI shall contain screens that have continuous indication of water level and corresponding tank water volume and pipeline pressure in real time that displays current water level in relation to solenoid and alarm level set points.

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d. HMI shall contain screens that display and allow changes to current solenoid and alarm level set points and timers.
e. A button on the HMI shall be provided that resets all values to pre-programmed O&M values.
f. Vent and Add air solenoid control shall be selectable from hand, off, and auto from the controller display.
g. HMI shall contain an alarm screen that lists the alarms that have occurred and the number of occurrences that each alarm has had.
h. Controller shall log and save locally all alarms and input signals for a minimum 3 months.
i. All field wiring to the controller shall be done through heavy duty connectors.

There shall be no field wiring to components inside of the controller. j. Multiple heavy duty connectors shall be provided to separate AC and DC voltages.
k. Electrical surge suppression devices shall be installed on all analog input signals. Provide a 24 volt power supply to surge tank pressure/water level transmitter instruments and 120 volt power to air control station solenoid valves. l. Dry contacts shall be available for all alarm and solenoid relays. m. Controller shall contain a managed Ethernet switch to allow Ethernet communication with site PLC and/or SCADA system.

2. Magnetic Level Gauge. The length of the stainless steel magnetic level gauge shall long enough to measure the water level in the entire tank vertical shell. Acceptable products include Kenco Magna-Site model KMLC, Gems or equal.,

3. Water Level Transmitter. Level transmitter provides a 4-20 mA signal and shall be a R.F Capacitance probe type. Acceptable products include Endress & Hauser Liquidcap FMI51, Rosemount or equal. The length of the probe well with water level transmitter gauge shall long enough to measure the water level in the entire tank vertical shell.

4. Pressure Transmitter. Pressure transmitter provides a 4-20 mA signal and shall be mounted on the pipeline connecting to the surge tank and connect to the PLC controller. Transmitter shall provide continuous pressure information to the PLC with high and low pressure alarm adjustable setpoints and time delays. Calibrate transmitter for a 0 - 200 psi pressure range. Acceptable products include Rosemount Model 3051TG3A2B21AE5M5T1, Foxboro, or equal.

PART 3 -- EXECUTION

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3.01 GENERAL (NOT USED)

3.02 INSTALLATION
A. Install equipment as indicated on the Drawings and as specified in the manufacturer's written installation instructions.

1. Cast anchor bolts in concrete foundation piers as embedded items. Use rigid template for each set of bolts.

2. After installation of tank on its foundation, temporarily cap nozzles and fill the tank with water to surcharge the foundation. Allow tank to set for a minimum of thirty calendar days. When tank settlement ceases, drain tank and connect tank nozzle to connecting inlet/outlet pipe.

3.03 TESTING
A. Tank Field Testing:

1. Provide a field static tank pressure test at the tank code rated design pressure, immediately following installation and before any dynamic/surge testing. Do not connect water piping system and valves attached to tank not designed for this high test pressure. Test period shall be four hours minimum, and all leaks detected shall be immediately repaired.

2. The contractor shall fully charge the surge tanks with compressed air in accordance with tank manufacturer’s instructions prior to performance testing the system and make the necessary final adjustments in pressure prior to acceptance. The Contractor shall supply an air compressor with a large enough capacity for initial pressurization of the surge tanks. The proposed air compressor is sized for regular operations and not for initial high volume air filling requirements.

3. Adjust water level add-air and vent-air controls to the specified settings. Check the ability of these controls to restore proper water level with normal pressure variations in the surge tank.

4. Performance test the surge system, by operating the pumps and shutting off the main electrical power disconnect switch at the Ranney pumping station to simulate pump electrical power failure. Start with power failure and one pump operating.

Then operate with power failure for two pumps operating. Continue testing variable speed pumps in flow increments, selected by Owner, until the surge control system has been demonstrated to control surge pressures with power failure and maximum design flow rate of 4,400 gpm (three pumps operating). Install pressure detectors and a strip chart recorder to record the pressures in the transmission pipeline system upon commencement of power failure. Locate the detectors to cover the critical high-pressure and low-pressure surges in the pipeline as indicated in the surge analysis (at 2 pipeline locations)

5. Provide a complete report, of each test performed, within 10 days after test completion. Reports shall include:
a. Date and time of test.
b. Description of testing method, including pumping combinations, flows, surge tank/transmission pipeline pressures, surge tank water level changes, method

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of collecting pressure/level records, transmission system flow rates and other pertinent data.

3.04 TRAINING
The tank manufacture will provide the following field services listed below and excludes travel time.

A. Two labor days for inspection of tank installation, associated water/air piping systems, air compressors and control system.

B. Two labor days for field surge system performance testing and adjustment of the surge control equipment.

C. One labor days to instruct the Owner's personnel in the overall operation and maintenance of the surge control system. The construction contractor will also provide independent manufacturer’s training/services for the air compressors.

3.05 SERVICE CONDITIONS
A. Surge tank service conditions shall be as shown in the table below:

Location Surge Tank T-1
Service Typical outdoors environmental,
temperature range of 35°F to 80°F
Elevation of Concrete Base Slab 45.75 feet above sea level Nominal tank volume 6,600 gallons
Tank shell length 11 feet
Tank diameter 9 feet
Normal operating water depth, above tank
bottom head

9.85 feet
Minimum design pressure 200 psig
Pressure rating of flanged outlets Class 150 per ASME B16.5 Inlet/outlet pipe size 10 inches
Magnetic Liquid Level Indicator rating 250 psi (water service) Safety relief valve pressure rating 250 psi WOG
Safety relief valve pressure setting 190 psi
Air solenoid valve pressure rating and maximum
differential pressure 250 psi
Solenoid valve enclosure NEMA 4
Liquid level probe pressure rating at 100°F 250 psi

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3.06 PAINTING AND COATING
A. Painting and Coating

1. Coat the interior of the pressure vessel per the PAINTING AND COATING Section (09 90 00). Apply coating at shop. Metal surface preparation shall conform to SSPC –SP10/NACE 2 near-white blast cleaning with a minimum angular anchor profile of

1.5 mils. Paint materials shall be NSF 61 certified, Tnemec Pota-Pox Plus series L140F or equal. Provide 4 coats of paint with a total dry film thickness of 16 mils.

2. Coat the exterior of the pressure vessel per the PAINTING AND COATING Section (09 90 00), System10. Apply prime coat, intermediate and finish coats at shop.

Provide extra paint for contractor minor field touch up painting. Color of the finish coat shall be as selected by City.

3.07 WELDING AND WELDER QUALIFICATION FOR PRESSURE VESSEL AND OUTLETS A. Welding procedure and welder qualification shall be in accordance with the ASME Boiler and Pressure Vessel Code, Section IX.

B. The welded joint connecting nozzles and manways to the tank shall be full penetration welded extending through the entire thickness of the tank wall or nozzle wall and welded both sides.

C. Do not place longitudinal welds in steel plate sections adjacent to longitudinal welds in the adjoining section. Shell seams shall be butt welds.

D. There shall be no girth seams at the tank supports. No shell seams shall pass through manhole or nozzle connections.

E. Butt welds shall be full penetration with 100% fusion through the full thickness of the metal. Do not use lap welds.

F. Full penetration welds shall have at least three layers of weld metal. Between passes, clean welds with a powered grinding wheel.

G. The surface of butt welds for the tank interior, including both shell seams and nozzles, shall be in accordance with NACE SP0178-2007, NACE Weld Preparation Designation "A," Appendix C. Welds in the tank interior shall be ground smooth with no porosity, holes, high spots, lumps, or pockets. Apply weld metal to fill in undercuts or pits. The surface of fillet welds for the tank interior and exterior shall be in accordance with NACE SP0178-2007, Weld Preparation Designation "C."
H. Clean areas to be welded in accordance with NACE SP0178-2007, Section 5. Remove mill scale, weld flux, and weld spatter.

I. Provide rounded corners on flanged outlets where attached to the tank shell per NACE SP0178-2007, Figure A4. Minimum radius of corners shall be 1/4 inch.

3.08 CLEANING/INSPECTING TANK AND OTHER WORK
A. After installation has been completed and all connections have been made, all surge tank surfaces, interior and exterior, will be thoroughly cleaned and wiped dry.

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B. After the surge tank interior has been cleaned with potable water and dried, the contractor shall perform paint coating dry film thickness and holiday testing for the interior and exterior surfaces on all surge tanks. Touch up tank coating, as required, per the PAINTING AND COATING Section (09 90 00).

C. See section 33 13 00 for disinfection of surge tank and connecting piping. **END OF SECTION**