1. Graphics Printer: The Graphics Printer shal l be a Hewlett-Packard LaserJet 5500dn. The printer shall include paper trays for 8 ½ x 11 printing. The printer shall have a built -in 10/100 network card, and a minimum of 96 MB RAM.
2. Report Printer: The Report Printer shall be a Hewlett -Packard LaserJet 5500dn. The printer shall include paper trays for 8 ½ x 11 printing. The printer shall have a built -in 10/100 network card, and a minimum of 96 MB RAM.
I. SWITCHES:
1. To minimize collisions, the system will utilize switches for network control. Hubs will not be accepted. At a minimum, each control panel will consist of a switch. This switch will insure that in panel networking will not cause collisions with the overall network.
Each control panel supplier shall be responsible for providing switches that meet this specification.
2. Basis of Design: Etherwan Network Switches:
3. General:
a. Copper Cable Ports shall be as specified below unless otherwise noted:
1) 100 BASE-T/1000 BASE-T communication
2) RJ-45 connections
3) Shielded Twisted Pair Cat 6E cable
4) Total Length: 100 meter
b. Fiber Optic Ports: shall be specified below unless otherwise noted:
1) 1000 BASE-FX ports
2) LC connectors managed switches.
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3) Total Length: up to 32,500 meters.
4) Attenuation Analysis less then 16db
4. Unmanaged:
a. 24 VDC SELV suitable for P1 and P2 redundant power supplies. b. Minimum 0-60 degree C. operating temperature.
c. Multimode or single mode optical fiber
d. Switches shall be configured for project conditions. If a switch is not available with the proper configuration, then switch cascading is allowed.
5. Managed Switches:
a. 24 VDC SELV.
b. Multimode or Single mode optical fiber
c. 0-60 degree C. operating temperature or greater
d. Switches shall be configured for project conditions. Switch cascading is not allowed.
J. UNINTERRUPTIBLE POWER SUPPLIES:
1. Uninterruptible Power Supplies (UPS) will be provided for the workstations, servers, and major switches in the project. As a general rule, provide a dedicated UPS for each workstation and server. Sharing of UPS’s is allowed as long as a single point of UPS failure cannot disable the system. The UPS system shall be able to run on Utility or generator power without any disruption in service. The UPS shall also be able to absorb the transients generated by ATS changeover. UPS’s will be sized according to the following:
a. 5000VA to 10000VA
1) 160 to 280 VAC Input with automatic 50/60 detection, with full time multi- pole noise filtering, 0.3% IEEE surge let -through, zero clamping response time, and meets UL 1449. The UPS shall have a TVSS screw for connection to telephone and network surge protection.
2) The UPS shall have audible alarms, automatic internal bypass, automatic load restart after UPS shutdown, automatic self test, and predictive failure notification.
3) Continuous battery recharging, even if the power button is set to OFF. The UPS sh all have a battery replacement indicator, disconnected battery notification, and shall allow batteries to be replaced with equipment energized.
4) The UPS shall have a minimum of 16 NEMA 5-20R, 2 NEMA L14-30R, 6 NEMA L6 -20R, and 3 NEMA L6 -30R plugs. The UPS shall be able to support 50% full load for a minimum of 15 minutes, and shall be able to startup without mains power.
5) The UPS shall be in compliance with CSA,FCC Part 15 Class A, and UL 1778.
6) The UPS shall have a 2 year repair or replace warranty. 7) The UPS shall have a USB port and communications cable for connection to the workstation. The UPS will use InfraStruXure Manager Incident Management software. The UPS shall have a power management software package suitable for Windows.
8) Basis of design: Basis of design is the APC UPS by Schneider Electric.
K. MISCELLANEOUS REQUIREMENTS:
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1. All material shall be new, unused and actively marketed for new applications when shipped for configuration. All acquired hardware and software shall be registered to “THE OWNER”, as user, and “Owner’s Company’s Name”, as the organization.
2.3 SCADA SOFTWARE
A. GENERAL
1. Description: The SCADA software package shall support dual core and multi -processor CPU’s. The SCADA software shall be part of a complete SCADA system. This system shall include personal computer(s) and industry standard networking hardware.
2. Core SCADA functionality: All core SCADA functionality offered, such as communications drivers, graphics capabilities, reporting, historical storage, trend and alarm displays and the d evelopment environment are offered as a single integrated software package or suite of packages. The software must be designed with the ability to make changes to the graphics while the system is running. Shutting down the system for graphic changes is not acceptable.
3. Operating Systems: As a minimum, the SCADA software shall run development and runtime implementations on the following Microsoft operating systems. a. Windows 2016 Server
b. Windows 10
4. Windows Services: It shall be possible to run the SCADA softw are as a service under Windows.
5. Global Database: The SCADA software shall be configurable as a single global database regardless of the number of nodes in the system. Configuration changes to the global database shall be made at any node on the system, an d in a manner that is completely transparent to the user. Each SCADA node shall either access the database locally or remotely in a file serving environment.
6. Application size: The SCADA software and engineering configuration shall initially be priced based on the following criteria:
a. SCADA servers: 2 Configured fully redundant which will also function as operator stations.
b. SCADA operator stations: In addition to the operator stations that double as servers, the project will require 5 additional operator stations. c. Internal Data tags: Internal data tags are those used within SCADA software to perform internal calculations. Internal data tags are also used to exchange data between operator stations and server databases.
B. CONNECTIVITY:
1. Description: The SCADA software shall employ I/O Servers to manage the reading and writing of data from PLC’s and RTU’s. The I/O Servers shall provide the data on request to any client on the Network.
2. General I/O Server capabilities: The I/O servers shall have the following:
a. PCs running I/O servers shall have the same graphical display capabilities of any other display station on the network.
b. The I/O Servers shall maintain a cache of data for a configurable time, such that requests from multiple display station clients do not g enerate unnecessary requests to the field controllers and will read from the I/O Server cache and not directly poll the field devices.
c. The SCADA software shall support Primary and Standby I/O Servers to provide automatic redundancy in the event of a Primary I/O Server failure without any user
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intervention or special scripting required. This switch over from a Primary to a Standby I/O Server shall be accomplished in under 1 second when a communication failure is detected. The system shall support automatic switching of I/O communications at least 5 standby I/O servers for a single field controller if installed at a latter date.
3. As a minimum the software shall be provided with the following connectivity options to 3rd party programs or databases:
a. OPC Client
b. OPC Server
c. ODBC Client
d. ODBC Server
e. DDE Client
f. DDE Server
g. Open API
1) Open API shall allow third party applications written in C, C++, C#, VBA, Pascal or Fortran access to tag, alarm and trend data. This API shall support the standard SCADA security model provided and should allow both read and write access to the SCADA data.
4. Custom Driver Generation:
a. The SCADA software vendor shall have a package available that allows the generation of user -written device drivers. The package shall include source code for various types of working drivers that are similar to the requirements of the user (e.g. Serial Driver, TCP/IP Driver, report by exception, proprietary board etc).
C. COMMUNICATIONS
1. Description: The SCADA software shall be capable of communicating to PLCs connected to the network, remote PLCs, I/O servers, and other devices on the network.
2. General communication capabilities. The SCADA software shall have the following communications capabilities:
a. Support of redundant communication paths to field controllers, and pr ovision for automatic changeover to the standby path in the event of a communications failure. b. Support of communication to redundant field controllers. If a primary processor fails, the software shall automatically detect the failure and switch to communicating to the standby processor. This shall require no user intervention, special scripting or use of redundant tags within the software. c. Built in diagnostic alarms shall be provided with the system that will automatically notify the operator of the failure of any communications path. d. A package of communication drivers that shall include the following as a minimum:
1) GE SRTP
2) Modbus over Ethernet (TCPIP)
3) DF1 Driver
4) EthernetIP Driver
5) DH+
6) Profibus Driver
7) Siemens S5 and S7 family of controllers Ethernet Driver 8) GE Fanuc 90/30 and 90/70 Serial and Ethernet Drivers
3. Communication re-establishment:
a. Despite the failure, upon re -establishment of communications all historical alarm, event and trend data archived by the remote field device (RTU) shall be
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automatically backfilled into the native SCADA alarm and trend history files. The data shall be fully viewable via the standard SCADA alarm and trend viewers.
D. SECURITY
1. Description: Security features shall be fully integrated to allow only users with appropriate security levels access to individual parts of the system.
2. Security Capabilities: The SCADA software shall have the following:
a. Encrypted passwords that are checked on the server side. b. Passwords hidden in both the configuration and runtime environments to ensure that other personnel cannot access another account.
c. Monitoring and logging of each control action of each user. This shall include all operator control actions, including system log in and log out. The sequence of actions shall be viewable within the SCADA package and also stored in an external open file format (e.g. txt, csv, dbf, sql) for later analysis. d. Automatically log out a user after an adjustable time period. Logging out a user will only cause the system shall revert to a view only security status. Logging out will not shutdown the system.
e. A minimum of 8 privilege levels for each user. The software shall ensure that a user has access to all tasks for his privilege level. If the user does not have the correct privilege for a task a message will indicate insufficient privilege. f. Assign each graphic object to a plant area, define the privilege level, define whether operator input is enabled or disabled, and if the object will be visible or not based on the operator’s current privilege levels within the plant area.
E. GRAPHICAL DISPLAYS
1. Description: Graphical displays are windows that are used to represent part or all of a process in a graphical manner.
2. General Graphical Display Capabilities: The SCADA software shall have the following graphical display features:
a. Unlimited number of graphical displays:
b. Capable of a minimum of 2000 analog variables, with real time updates of less than 500ms (for all data to appear or change on the page) c. Capable of automatically re- sizing to match the screen resolution of the computer on the network, irrespective of the resolution the pages were developed in or configured for, and irrespective of whether vector or bitmap graphics are used on the page, without shutting down the SCADA software, without recompiling, and without having multiple copies of graphic pages for different resolutions. d. Support a screen resolution of up to 4000 x 4000 pixels. e. Support full 32 bit graphics, and capable of displaying images from 3 rd party packages for use within the SCADA displays, including animating and color flooding the image
f. Capable of pop-up windows for trends, loops, device status, and device control by clicking on hot spots or objects on the main graphics page. 100 simultaneously opened popup display windows shall be supported by the graphics display system. g. Inclusion of page name, current time and date together with details of the last 3 alarms that have occurred on all graphical displays.
h. Ability to allow the user to navigate around the graphics system utilizing a variety of navigation methods.
i. Ability to have Hot Key links to specific graphics pages from the keyboard.
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j. Windows style navigation menus allowing access to any configured page in the system from any other page.
k. Configured with “hot spots”, where as a user can click on the area and drill down into a detailed view (if available) of the plant area.
l. Ability to display communication loss for a particular I/O point wherever that data is displayed in the software.
3. Dynamic Objects: Dynamic objects are symbols that visually change when a property, tag or expression changes. Dynamic objects shall be as described below:
a. Support the following graphical dynamic objects as a minimum:
1) freehand lines
2) straight lines
3) poly-lines
4) rectangles (including the latest curved corner style) 5) ellipses
6) pie slices
7) text
8) buttons
9) 3D Pipes
10) Bitmaps
b. Dynamic objects shall have a series of properties that can be used independently or concurrently. Each dynamic object shall have the following properties:
1) Horizontal, Vertical and Rotational movement
2) Up, Down, Left or Right Level Fill
3) Gradient Level Fill
4) On-Off, Multi-State, Integer, Threshold or Gradient Color Change 5) Horizontal and Vertical Size
6) Visibility
7) Keyboard Input
8) Touch (Mouse Up, Down, While Down) input
9) Horizontal and Vertical or Rotational Slider
10) Ability to disable the object based on security levels. 11) Popup information in a “tool tip” form by rolling the mouse over the object
4. ActiveX: The SCADA software will be an ActiveX container and allow for insertion of ActiveX objects into standard graphics pages. The SCADA software shall interact with ActiveX objects in the following ways:
a. Dynamically change properties of an ActiveX object via a Tag from an I/O Device b. Dynamically change properties from SCADA software high level language. c. ActiveX object to trigger acti ons in the SCADA software based on events in the ActiveX Object.
d. ActiveX property values can be read by the SCADA software.
5. Live Video: The software shall support full screen live camera video, and video from disk (MPEG, AVI) concurrently with screen displ ays without interruption to data collection. Update times in the Process Control System windows shall not be affected.
F. DISPLAY CLIENT
1. Description: Display clients shall connect to the individual station servers to allow personnel on the network to view gr aphics pages, alarms and trends from all the compressor stations simultaneously.
2. General display client functionality: The display client shall have the following:
a. Response times less than 2 seconds to access any real time data on the network.
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b. Support casual web browser clients so that personnel on the WAN can have access to the system with the correct security settings. The web browser client shall have the following:
1) Identical functionality to the standard client software including but not limited to graphics displays, trend pages, alarm pages and system security. 2) Support view and control capabilities, controlled by both login security and license types.
3) No requirement for additional engineering or specialized software other than a web server such as MS I IS or Apache Tomcat. The standard graphics pages, alarm pages and trend pages used for operator display stations shall be available via the web browser clients without any additional engineering requirements. Configuration changes shall be automatically re cognized and used by the web clients without any additional engineering. 4) Browser clients shall support page changes of under 2 seconds and data updates of under 500ms on the corporate WAN.
G. ALARMS
1. Description: Alarms are meant to alert and operator of an abnormal condition. They are logged, and often times require operator intervention.
2. General Alarm functionality: The alarm functionality shall have the following:
a. No software limit to the number of alarms supported
b. A minimum or 100 million alarm summary e vents shall be stored in the native trend archive to recall through standard trend display screens. c. Acknowledgement on one operator station shall be globally acknowledged and as such shown as Acknowledged on all operator stations. This shall be configured as one common database, with no other programming necessary to enable global acknowledgment of alarms from any PC on the network.
3. Alarm Types: The SCADA software shall monitor analog and discrete variables and calculated conditions, and determine if the v ariable is in an alarm condition. The SCADA software shall perform the following:
a. All analog alarm conditions shall have adjustable dead bands and delay timers to minimize nuisance alarms. All analog alarm properties shall be adjustable without the need to shut the system down. For each Analog Tag, an alarm for each of the following conditions shall be assignable:
1) LOW-LOW,
2) LOW,
3) HI,
4) HI-HI
5) Deviation LO
6) Deviation HI
7) Rate of Change
b. Discrete alarms shall have an assignable alarm for each of the following:
1) Variable ON
2) Variable OFF
c. Multi-Digital Alarms based on a combination of discrete tags. Any combination of states of the discrete tags may be configured to be an alarm. Furthermore, alarming will occur whenever a new alarm state is encountered.
d. All alarm processing shall have the facility for time stamping and can track time to a precision of 1 millisecond.
4. Alarm Display: Alarm display shall have the following:
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a. Depending on user’s log- in privileges, it shall be possible to display or acknowledge any alarm and/or the most recent alarm on any page. b. Alarm shall be configurable in multiple levels. The color of the text of the alarm message shall indicate priority. Text color shall be configurable by engineers. c. Sound indication for each alarm category shall be configurable. This must be possible at each node via internal or external speaker. The sound indication shall support the playing of any standard .WAV file.
d. Provided with a standard alarm user modifiable display page. The alarm page shall allow for scrollin g of alarms, and acknowledgment of individual alarms or all alarms on the page
e. Possibility to display the following information for each alarm as it appears on an alarm display page:
1) Alarm Tag Name
2) Alarm Description
3) Value of the Variable
4) Trip point
5) Alarm Status - Disabled, Acknowledged, Unacknowledged 6) Alarm Category or Priority
7) Alarm Priority
8) Time & Date
9) Privilege
10) Category
11) Operator Comments
12) Value of any Tag or result of any calculation.
f. Ability to display each alarm state in a different color (including flashing colors). g. Support for both proportional and fixed fonts with all alarm fields displayed in properly aligned columns.
h. Based on user’s privileges, it shall be possible to disable alarms on individual basis, by page or by alarm category or all alarms. A disabled alarm page shall indicate to every user what alarms have been disabled.
i. Based on user’s privileges, it shall be possible for user comments to be attached to any alarm. These comments shall either be displayed with the alarm or by clicking on the alarm.
j. Possibility to automatically display any graphic display when an alarm occurs or to dynamically change the appearance of any graphical object based on whether an alarm is On, Off, Acknowledged, Communications Error or Disabled. k. A mechanism for operators to dynamically define filtering of alarms by alarm name, tag name, date /time range, state or type
5. Alarm Logging: The following alarm functionality shall be provided:
a. The alarms shall be able to be logged to any designated network or local printer, disk file or database with alarm text, time and date labels. Alarms shall be printed or filed in a user -configurable format. The software shall be able to redirect printing to another printer while the system is on-line. b. It shall be possible to define a different method of logging alarms for each alarm category. It shall be possible to define if alarms are to be logged when the alarm transitions to ON, to OFF or on Acknowledgement.
c. Alarms that are logged to disk shall be viewable while the system is onli ne or offline without interrupting data collection. The software shall not limit the number of alarms logged to disk. The alarm logging shall be capable of logging an instantaneous burst of at least 4000 alarms without losing a single alarm.
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6. Alarm Redundancy: All alarm calculations and management shall be performed in the Primary Server. The software shall automatically ensure that if the Primary Server fails, all alarm functions shall continue to operate normally in the standby server. The software shall automatically generate a diagnostic alarm to indicate that the Primary or Standby Server has failed. Adding, deleting or modifying alarms shall not require any changes to the software that handles the redundancy. On restoration of a failed Server, the hist orical alarm history must synchronize between the Primary and Standby servers so that there are no miss matches in historical alarm history.
H. TRENDS
1. Description: Trends are a collection of data points over time. When viewed over time, the trends will indicate general progression of the data.
2. General Trend Functionality: The software shall have the following functionality. a. The number of trends collected shall not be limited by the software. b. The software shall be capable of logging historical trend informat ion at configurable sample periods from 1 Millisecond to 24 Hours. c. Trend data shall be stored in a circular file system with the number of files, the size of each file, the sample period, file location, privilege and area being user definable individually for each trend. File names and paths shall support file names up to 255 characters in length.
d. Every tag defined in the system configuration shall be trended. Each trend shall contain a minimum of seven years historical data at a 10 second sample rate. The trends shall be maintained online for operator call back without the need to backup or restore history files.
3. Trend Display: The software shall have the following in its native functionality:
a. Each operator and login shall be able to see their own fully customized trend pages. These pages must be customizable on line by each user in a drop and drag manor. Any setting available to be made in a configuration environment shall be available to the user to modify the trend graphs in run time. These include the color, scaling, pen selection as examples.
b. Line graphs with time on a linear, continuous horizontal or vertical axis and the trended variable on the vertical or horizontal axis. Resolution of each graph shall be to within 0.1% of full scale.
c. Where more than one variable is displayed on the same graph, the pen color of each variable and associated information shall be displayed in a different color. d. Each trend graph shall be capable of displaying a minimum of 32 trend pens with adjustable time base to one sec ond samples and shall be capable of viewing the entire archived trend history.
e. Historical system alarms shall be able to be overlaid on the trend pages showing the alarms state transitions.
f. A standard graphics page shall support a minimum of 100 individual trend windows embedded within the display so that an overview of multiple site levels can easily be produced.
g. Possibility to trend multiple pens or multiple plots of the same pen over various time spans for comparison purposes (i.e. previous day to today’s results). h. Each pen shall display individual ranges and engineering units. Each pen shall be scalable for display purposes independent to each other pen displayed on a page. i. Include the capability to pan backward and forward within a selected time range t o read the exact value of any displayed variable, by selecting a point on the graph or chart. The system shall display historical information as far back in time as desired, with all information being displayed within 1 second.
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j. The trend display shall be d ynamic, scrolling through time, with the capability to ‘replay’ or scroll through historical time as well as current time. There shall also be the capability to stop the automatic scrolling of the trend for detailed analysis of a point in history. Pens on the same pane shall be able to be separated both in the time axis and the range axis.
k. The trend display shall have a minimum of 2 slide wire that can be moved over the page. The slide wire will provide indication of the date, time, and value at the intersection of the slide wire and the trend point.
l. The software shall provide "zoom" and "pan" facilities for both the trended variable range and the time axis range. The "zoom" facility shall allow an operator to compress or expand the axis range whilst the "pan" facility shall allow an operator to shift the origin of the axis. The software shall allow a user to define any zoom area by dragging a mouse across the trend.
m. The software shall make available trending data from the historical database for export to disk files or external databases. It shall be possible to define the section of the trend to be exported by clicking and dragging the mouse across the trend.
Data shall be exported to csv, dbf or txt formatted files. It shall also be possible to export any portion of the historical trend database via ODBC, DDE, dbf, CSV and TXT formats.
n. The software shall provide the capability of printing out either instantaneous or historical based trends on the designated trend printer. The software shall have the capability to perform a trend print (not a screen print). The trend print function shall print to the printer using objects, not bitmaps. The trend printout shall include the engineering units and ranges for each trend, a trend grid and the time base for each tre nd. Each trend shall be identified by a different line style (i.e. dotted, dashed, solid etc) on monochrome printers, and a different color for color printers.
4. Trend Redundancy: Trend collection and management shall be performed utilizing primary and standby servers; both shall contain all the historical trend information. If the primary server fails then the standby server shall ensure all trend functions continue to operate. Upon restoration of the primary, the standby shall automatically update the primary server such that there are no gaps in the historical trend data. No operator involvement shall be required. Failure of the primary and standby servers shall be monitored such that a failure at anytime will produce a diagnostic alarm.
I. DEVELOPMENT ENVIRONMENT
1. Description: The development environment is the area that allows generation of graphic screens, alarms screens, tag database, trend screens etc.
2. General Development Environment Functionality: The SCADA software shall include a development environment with the following:
a. An integrated development package utilizing menu driven, fill in the forms style configuration to develop the runtime system.
b. All development functions shall be available at every node on the system, and allow multiple users at separ ate nodes to simultaneously modify the same master database. A minimum of 5 simultaneous developers shall be supported. c. Comprehensive on-line help shall be available for all development functions, the on-line help shall contain all information provided in the hard copy manuals. d. A utility to back -up or restore an entire database including all graphic displays, configuration data and source code, as well as online configuration (such as menu navigation, trend groups and alarm groups), via a simple point and c lick method.
The backup/restore utility shall prompt the user prior to over writing any existing files. The utility shall employ automatic file compression/decompression.
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e. Ability to import field controller tag definitions shall be included as a standard feature. Automatic updating upon a change of a definition in the I/O device tag names, addresses, ranges etc will automatically be imported into the SCADA software database. In addition it shall be possible to manually initiate the import of tag definitions at any time. The Tag import function shall be user configurable such that a user can specifically define which definition fields must not be overwritten or define how the import will operate. The import function shall support generic OPC data sources and CSV file imports in conjunction to native field controller programming software database imports.
J. GRAPHIC BUILDER
1. Description: The graphic builder allows for development of graphic screens.
2. General Graphic Builder functionality: The graphics builder shal l be interactive and menu-driven, requiring no programming. It shall consist of the following:
a. Directly import graphics and text in the following file formats:
1) Autocad DXF
2) Windows BMP
3) Windows Meta File WMF
4) GIF
5) TIF
6) PCX
7) TXT
8) DIB
9) RLE.
b. The graphics builder sha ll be capable of creating screens composed of both static and dynamic objects. To create these objects, the software shall provide sample screens and a set of standard shapes in a library. The developer shall be able to include these symbols by reference, or create new symbols/objects. c. The following Tools:
1) Grid and guidelines (which can be displayed on screen) together with snap to grid and snap to guidelines to assist in aligning objects precisely. 2) Horizontal and vertical alignment together with even spacing. 3) Send to front/back. Bring Forwards one layer, Send backwards one layer. 4) Bitmap editing including pixel drawing, image resizing, image cropping. 5) Color swap from one color to another for a group of selected objects including colors within a bitmap. Col or swap shall also include swapping a range of colors such as all reds to all greens so that shaded objects can be color changed without redrawing or re-rendering.
6) Editing of nodes on polylines that provides the addition or removal of nodes plus movement of nodes.
d. Unlimited “undo” and “redo” feature.
3. ActiveX: The graphics builder shall be an ActiveX container. ActiveX objects shall be inserted and edited in a visually interactive manner. It shall be possible to connect ActiveX properties to tags, allowing read/write between properties and tags without the need for script or code. ActiveX objects must have the same security as native graphics objects and ActiveX objects shall be visible or hidden based on the users’ privilege level.
K. CUSTOM SCRIPTING LANGUAGE
1. Description: The scripting language shall be used to develop custom routines, and algorithms not supplied as part of the standard package.
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2. Standard Functionality: Scripting shall not be needed to develop any custom code to achieve standard functionality including redundancy failover, recovery and backfilling of historical data.
3. General Custom Scripting Functionality: The SCADA software’s scripting functionality shall include the following.
a. An integrated high level language specifically designed for SCA DA applications that shall be inherently multi-tasking and multi-threading. b. Fully integrated and multi-threaded Visual Basic (VB) scripting. c. Access to all field tags, alarms, graphics displays, database and ASCII files. The languages shall include functions with clear and precise syntax. The languages shall support user written functions and function libraries supported by the computer's operating system. The language shall have the capability to export or import data from other applications.
d. Creation of ca lculated (inferred) variables based upon formulae including constants, measured variables and other calculated variables. All facilities available for logging, reporting, trending, monitoring, controlling, alarming and displaying measured variables shall also be available for calculated variables. e. Support of mathematical and Boolean operators including:
1) Addition
2) Subtraction
3) Division
4) Multiplication
5) AND
6) OR
7) XOR
8) NOT
9) Greater Than
10) Less Than
11) Equal
12) Parenthesis.
f. Support for the following mathematical functions:
1) Absolute
2) ArcCos
3) ArcSin
4) ArcTan
5) Cos
6) DegToRad
7) Exponent
8) Factorial
9) HighByte
10) HighWord
11) Ln
12) Log
13) LowByte
14) LowWord
15) Max
16) Min
17) Pi,
18) RadToDeg
19) Random
20) Round
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21) Sign
22) Sin
23) Sqrt
24) Tan.
g. Prevention of any functions from interfering with proper SCADA functionality. h. Permit users to create the ir own functions and integrate them in the language; functions shall be reusable without the need to copy and paste. It shall be possible to call the same function multiple times from different locations, with different parameters simultaneously.
i. Provisions to run functions automatically on start up, on page entry, on page exit, while a page is open, on button down, while button down, embedded in reports, alarm on, alarm off, on any keystroke, any keyboard entry on any mouse button click, etc.
j. Ability to te st and debug the languages on line. The debug tool shall display the source code as it executes with a pointer identifying the current line of code being executed, the value of local and global variables and any output as the user single steps through the code. Facility to set break points, single step, step over sub functions, step out of sub functions and continue execution shall be included.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas, surfaces, and substrates to receive SCADA System and associated control panels for compliance with requirements, installation tolerances, and other conditions affecting performance.
B. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 APPLICATIONS
A. Select SCADA Software based on application type, tag count, type of node. It is recommended that a manufacturer’s representative be consulted during the selection.
3.3 INSTALLATION
A. Anchor servers, control panels, and other devices over 36 inches high and at least 19 inches across.
B. Ventilation slots shall not be blocked, or obstructed by any means.
C. SCADA Computers shall be installed in an environment as indicated by the computer supplier.
Insure that the computers are protected from exposure to high levels of dirt and dust. Also D. SCADA System Supplier shall insure that all cables are neatly routed and bundled.
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3.4 IDENTIFICATION
A. Identify components, and wiring according to all applicable codes, standards and contract document sections.
3.5 FIELD QUALITY CONTROL
A. Field Service:
1. The SCADA system supplier shall provide a qual ified service representative to perform the following:
a. Inspect wiring, components, connections, and equipment installation. b. Assist in field testing of equipment
c. Install and test SCADA software as detailed below
d. Install and test SCADA application as detailed below e. Report results in writing. As detailed below.
B. Installation and Start-Up:
1. The SCADA System Provider shall develop a specific plan for the startup of the new SCADA system and for cutover of control to the new system. No startup or cutover activities shall be performed until the plan has been successfully approved by the Engineer. The sections below give some guidelines and suggestions for cutover.
C. Factory Acceptance Test (FAT):
1. Description:
a. Thorough testing and verification for all deliverable equipm ent, software, and associated documentation shall be performed on all SCADA System Provider proposed system components. The tests shall be performed to verify that the equipment is manufactured and assembled correctly, is operating as designed, and complies with the contractual requirements. The tests shall be performed to verify that the software and hardware will meet the functional and performance requirements of this document. The equipment shall be interconnected and subjected to comprehensive system t esting that simulates field conditions and operations. The Factory Acceptance Test (FAT) shall include the test and verification activities specified in this section. The FAT will be attended by the Engineer. The FAT will be conducted by the SCADA System Provider.
2. System Configuration Verification:
a. Prior to beginning the Factory Acceptance Testing, the system/subsystem/elements shall be subjected to deliverable configuration and serialization verification. A copy of the System Inventory List annotated to reflect this verification shall be included with the Factory Acceptance Test Report. No equipment replacement or substitutions shall be permitted without rigorous quality control ac counting and retesting of affected equipment.
3. Equipment Test and Verification:
a. Hardware Tests:
1) The Factory Acceptance Test shall include individual end -item verification and integrated tests of all hardware. These tests shall include visual inspection verification, running standard hardware diagnostic programs, and running all special diagnostic programs used by the SCADA System Provider to demonstrate that the hardware integration task has been completed. Performance testing of all Individual Servers and Workstations,
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including demonstration of CPU, Memory and Storage functions shall be conducted. All hardware enclosures shall be inspected. As a minimum, the following shall be inspected and verified:
a) Cabinet enclosures
b) Frame structure
c) Paint work and finish
d) Dimensions
b. Inspections:
1) As a minimum the following inspections shall be performed:
a) Power supply mounting
b) Power cable routing
c) Data cable routing
d) Wiring runs across hinges properly installed
e) Fans and blowers are unobstructed
f) Power conditioning correctly installed.
4. System Functional Test
a. Test Functionalities:
1) The functional test s hall exercise and demonstrate the successful operation of every specified system function and shall include, but not be limited to, the following:
a) Rigorous exercising of all devices both individually and collectively. b) Verification of proper scanning and da ta acquisition of all status and data points.
c) Verification of proper Control Strategy up/down loading to the PLCs/RTUs.
d) Demonstration of analog input, pulse input, and analog output accuracy.
e) Testing of all user interface functions.
f) Verification of all con trol operations to ensure that they result in the correct sequence of operation at all the PLCs/RTUs using the test PLC/RTU.
g) Simulation of communication error conditions and demonstration of error detection and handling.
h) All specified display types, report s, and operator/user procedures must be shown to be implemented and verified for accuracy. i) Create and process device failure conditions including PLC failure, Operator Workstation failure, peripheral failures, etc. Special attention shall be given to creat ing failures in the middle of operator sequences and control actions such as:
j) Communication failure after a command is issued but before the result is recorded in the database.
k) Computer failure after a command is issued but before the result is recorded in the database.
l) Failure of a major communications component.
m) Incorrect operator entry in the middle of a multi-step action. n) Operator Workstation failure in the middle of a control action. o) Demonstration of all redundant functions and components. p) Demonstration of all required alarm processing functionality, including audible annunciation.
q) Demonstration of all required historical capture, storage, and retrieval functions.
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r) Demonstration of all required data logging functions. s) Demonstration of all required IT interface functions. t) Demonstration of all required device control functions. u) Demonstration of all required database management functionality. v) Demonstration of all required software support utilities. w) Demonstration of all system diagnostics, both on-line and off-line. x) Demonstration of correct operation of calculated quantities including totalized values
y) Demonstrate the proper operation of all changes to the system negotiated and approved during the implementation period. b. Configuration Testing:
1) The Factory Accep tance Test for the support software shall include the following, as a minimum:
a) Demonstration of restoration of system using backup media. b) Demonstration of system editing capabilities including the addition and deletion or modification of points in an RTU, displays, report formats, control strategies, and the modification of the database and all database parameters.
c) Demonstration of the editing of system parameters including timers, intervals, etc.
d) Demonstration of utility software facilities, including asse mbling, compiling, appending, and executing new programs.
e) On-line program debug facilities shall also be demonstrated, including downloading of a program from the central system to a remote PLC/RTU.
2) The FAT shall demonstrate compliance to each section in this specification. c. System Performance Testing:
1) The System Performance verification shall demonstrate that the system meets the performance requirements specified in this specification.
5. System Testing:
a. The SCADA System Provider shall stage the entire system in an integrated Factory Acceptance Test. The following system components shall be used for FAT. All components shall be interconnected using the LAN equipment:
1) All Workstations provided by this Contract
2) All Printers provided by this Contract
3) All com munication equipment and PLC/RTUs provided by this Contract, with final configuration loaded. These PLC/RTU programs shall include all Communication Strategies for the individual communication channels. 4) Complete SCADA Server provided by this Contract
5) Web Server provided by this Contract
6) Historian Server provided by this Contract
7) PLC/RTU test set provided by the Integrator
6. Simulation Software:
a. The SCADA System Provider shall utilize software that simulates system loading conditions equivalent to the Steady State and Heavy load conditions defined in this specification.
7. 72 Hour Continuous Test:
a. After the successful completion of the functional testing specified above, a 72-hour continuous test of the system shall be initiated. The test shall be deemed successful if no system function is lost, no hardware or software failure occurs, and no module automatic failover occurs (unless instigated by testing efforts). Hardware
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failure is defined for this test as the loss of a major piece of hardware, such as a peripheral, monitor, processor, I/O board, etc. Software failures will include, but not be limited to, server or workstation “lockups” or failure to respond to operator input. During this test, the system shall be exercised with simulated inputs, events, and conditions in a manner similar to an operational environment. No software "patches" or changes will be allowed to bypass failed modules during this test. Any software and/or hardware correction made to the system shall result in the mandatory rerun of the entire 72 -hour test. During the 72- hour period, at least 24 hours of unstructured testing shall be included, in which the Engineer or the end user’s representatives shall be allowed to operate the system without the SCADA System Provider's supervision (SCADA System Provider may observe).
8. I/O Point Checkout:
a. The SCADA System Provider shall perform a checkout of selected I/O points as the SCADA system is installed. The SCADA System Provider will provide testing support at the Control Center. As each PLC/RTU is switched to the new SCADA system, the integrator will test a representative sample of the I/O present on the PLC/RTU. Up to 25% of the I/O on each PLC/RTU shall be tested to confirm the database setup and HMI graphic connection. The SCADA System Provide r shall verify the tested points at the HMI database level and on the configured SCADA system screens. The testing shall be witnessed by the Engineer or end user’s Representative. The quantity of points selected for testing shall be controlled by the engineer, and shall be sufficient to confirm proper database configuration.
Should improper database configuration be found during the testing process, additional testing shall be conducted at no additional costs to the project. Test signals shall be injected to verify the operation of the selected Analog Input (AI), and Discrete Input (DI) point. The signal injection point shall be at the field instrument for each Analog Input or Discrete Input. Each Analog Output (AO) and Discrete Output (DO) shall be also tested for proper operation, to the Final Control Element. End-to-end testing shall use the process graphic displays to verify proper operation of the I/O points all the way to the Operator Workstation control console.
I/O point checks will also verify the p roper configuration of the Historical Data Storage and Alarm/Event Subsystems on the SCADA HMI Software. I/O point checks shall utilize final communications system and SCADA network. The SCADA software must be fully operational in order to conduct this tes t. The Contractor shall develop a complete I/O Point Checkout Test Procedure. The test procedure shall identify the method to be used by the Contractor for verifying the I/O signals in each database location. The Contractor shall develop a point checkout form for each I/O point. The point checkout form shall include the point ID, description, all checks performed for the point, date and time of the check, and a signoff block for both the Contractor’s representative and the Engineers’ representative. For each item checked, the form shall include both the expected value/result and the actual value/result witnessed.
1) For each analog input point tested, the following values shall be checked:
a) Value at 0% of full scale (ramped in both directions) b) Value at 100% of full scale (ramped in both directions) 2) For each analog input tested and its associated alarms, verify that the testing signals are stored in the Historical Database, if the signal is designed for historical data collection, that each alarm is displayed o n the alarm displays on the SCADA Software and that each alarm is shown on the hard- copy alarm log.
3) For each analog output point tested, the following values shall be checked:
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a) Milliamp reading at 0% of full scale (ramped in both directions) b) Milliamp reading at 100% of full scale (ramped in both directions). 4) For each analog output tested, verify that the change in each output is stored in the Replicated Database, Event Historian and that each event is shown on the hard-copy event log.
5) For each discrete input point tested, the following items shall be checked:
a) For status points, proper indication
b) For alarm points, proper alarm notification.
6) For each discrete input tested, verify that the testing signals are stored in the alarm/event historian, that each alarm is displayed on the alarm displays and each event on the event displays, and that each alarm/event is shown on the hard-copy alarm or event log.
7) For each discrete output point tested, the following items shall be checked:
a) Proper operation
b) Actuation time-out alarm (if value is entered in database). 8) For each discrete output, verify that the change in each output is stored in the Event Historian and that each event is shown on the hard-copy event log.
The completed I/O Checkout forms for all points shall be included as part of the I/O Checkout Test Report to be prepared and submitted at the conclusion of all I/O checkout activities.
D. Site Acceptance Test (SAT):
1. A Site Demonstration Test of the functions, software, and performance shall be conducted after all system elements have been installed and the I/O Point Checkout has been completed. The system site demonstration tests shall be performed to verify complete operation of the system, requiring a repeat of much of the comprehensive system tests but with the equipment installed at the permanent sites, and shall include additional tests required to verify field installed equipment, which was not available during the FAT. The SCADA System Provider shall:
a. Verify all the facility installations.
b. Demonstrate each f unctional requirement identified by the specification. This demonstration shall repeat the tests used during FAT, but using real rather than simulated conditions.
c. Demonstrate all equipment control functions, including the operation of automatic control str ategies. Actuation of field devices shall be closely coordinated with facility operations.
d. Verify system performance parameters and system responses under field operational conditions.
e. Verify accuracy of documentation, especially operator’s manuals, software documentation, and general system operating instructions.
2. The SCADA System Provider shall provide the appropriate technical representatives for the execution of the Site Demonstration Test. The SCADA System Provider's test support personnel shall be qualified to resolve and correct problems encountered with the system during the tests. In addition to test support personnel, the SCADA System Provider shall provide all test instruments and equipment necessary to troubleshoot any of the SCADA System Provid er’s proposed system problems encountered. The Engineer reserves the right to increase the requirements for test support personnel if support by the SCADA System Provider is inadequate.
E. Demonstration
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1. SCADA System Provider shall provide a qualified service representative to train Owner's maintenance personnel to adjust, operate, and maintain SCADA system as detailed below.
2. Site Availability Demonstration (SAD):
a. Test Requirements:
1) At the completion of Site Acceptance Test, the Integrator will conduct a Site Availability Demonstration (SAD) test utilizing all equipment, software, and services provided under this Contract in the normal day- to-day operation of the water treatment plant. During the test the system shall meet the availability criteria defined below and shall meet the performance requirements stated in the specification. SCADA System Provider personnel may participate in any and all parts of this demonstration as observers at the discretion of SCADA System Provider.
b. Scope of Test:
1) All equipment and software delivered with the system shall be subject to the availability measurements.
c. Test Equipment:
1) The Site Availability Demonstration shall be performed under field operating conditions. All functional and performance requirements specified in this document shall be met during the SAD.
d. Length of Test:
1) The system shall be subjected to Site Availability Demonstration evaluation for a period of not less than 60 days (1440 hours). If at the end of the 60 days, the system availability is determined to be less than that required, the test shall continue on a day- by-day basis, dropping off the oldest day's test results. This sliding window concept shall continue until the system passes the test or until 120 days time has passed, at which time the facility shall have the right to pursue other avenues as specified under the contract. e. Preventive Maintenance:
1) During the Site Availability Demonstration period, the SCADA System Provider shall perform preventive maintenance of the type and the frequency of service defin ed in the SCADA System Provider -provided maintenance manuals. The SCADA System Provider shall supply a recommended maintenance plan prior to start of the test. f. Test Prerequisites:
1) Prerequisites to starting the SAD are successful completion of the Comprehensive System Test and the Site Demonstration Test and resolution of all outstanding Discrepancy Reports. In addition, the following documentation shall be on hand at the facility:
a) Final copies of O&M manuals
b) Final copies of System Operator's manuals
c) Final copies of System Administrator manuals
d) Final Record Documents (prior to conclusion of SAD). g. Availability Definitions:
1) Availability Formula:
a) The system availability shall be determined using the following formula:
1. Availability=Uptime/(Downtime+Uptime)
2. Where the detailed definition of terms is as described below:
SCADA SOFTWARE AND HARDWARE 13449
a. Uptime means the total clock time from start to end of testing minus downtime and minus any suspension time that may be mutually agreed upon, as the testing is ongoing. b. Downtime accrues in three ways as defined below:
1.) Downtime accrues when one or more system functional capability required by the Specification cannot be
performed due to failure of equipment or software
provided and/or installed by SCADA System Provider.
For failures tha t occur outside of 8:00 AM to 4:30 PM
Monday through Friday, a four -hour travel time
allowance will be made before downtime begins to
accrue. It is the SCADA System Provider's responsibility to arrange suitable communications to enable the facility to promptly notify SCADA System Provider of failures.
2.) Downtime accrues if the same piece (or redundant pair) of equipment fails more than twice in the same 168 hour period or more than three times during the entire test. In other words, repeated failover to backup equipment will not be allowed even though each individual failover
action is successful and no functionality is lost.
3.) Downtime accrues if backup equipment remains
unavailable for more than a twelve -hour grace period,
allotted for repair, after the initial failure. Accrual begins after the grace period allotted for repair.
2) System Availability Exclusions:
a) The following assumptions apply in the determination of system availability:
1. All end user provided facilities and auxiliary support equipment are assumed to be 100% available. Any periods of failure of such equipment will be treated, therefore, as Uptime.
2. Any downtime caused by actions of engineers or facilities personnel will not be counted.
3. Outage of the system caused by malfunction of equipment not supplied by the SCADA System Provider will not be considered as downtime, unless malfunction of equipment was caused by a malfunction of the SCADA System.
4. System downtime will not accrue for outages caused by failure of the facilities supplied power.
3) Test Suspensions:
a) The availability test may be placed in suspension on mutual agreement between engineer and SCADA System Provider for such reasons as:
1. Performing preventive maintenance on an item that is not redundant.
2. SCADA System Provi der requires time to analyze a repetitive failure situation.
4) Record Keeping:
a) Records of system maintenance and equipment/software failure with the times of occurrence will be maintained continuously by SCADA System Provider personnel.
5) Corrective Action:
SCADA SOFTWARE AND HARDWARE 13449
a) All failures shall be analyzed to the extent necessary to provide a viable explanation. Recurrent failures may require the use of sophisticated hardware failure analysis techniques or software simulation. All such analysis shall be performed by the SCADA System Provider. Where such analysis indicates that a design modification is in order, such correction shall be completed by the SCADA System Provider and incorporated in all systems provided under the terms of the Contract by either retrofit or replacement. The availability demonstration shall be deemed successfully completed if the calculated availability for the system is equal to or greater than the specified availability requirement at the end of a 60 -day period. If the calculated availability achieved d uring the demonstration period is less than that specified, corrective action shall be implemented, and the demonstration shall be continued until the required availability is met for 60 consecutive days (1440 hours).
6) Site Availability Demonstration Considerations:
a) The SCADA System Provider shall submit to the facility and engineer a recommended preventive maintenance schedule prior to the test run. The downtime resulting from an intermittent failure that causes a system trip but does not preclude an immed iate restart, will be limited to the time that it takes to restart the system. However, repetitive occurrences of intermittent faults in either the on-line or the backup equipment shall constitute system failure until the flaw is corrected. Failure of bac kup hardware, if supplied, will not be considered downtime provided that this failure does not adversely affect the operation of the system. Uptime, under this condition, will continue while the backup hardware is being repaired. Alterations to the hardwa re/software shall not be permitted without the engineers and facilities approval. Replacement of failed boards is acceptable. 7) Progress Reports:
a) The SCADA System Provider will maintain the official record of operating time, recorded incidents and dispositio n, maintenance action, and calculated availability. At the completion of system availability demonstration, the SCADA System Provider shall prepare a separately bound test report for Engineer to evaluate and approve. 8) Letter of System Acceptance:
a) Upon review and approval of test report, the Engineer shall provide a letter of System Acceptance, which will be signed by all parties and serve as designation of the beginning of the warranty period.
F. Cutover Sequence:
1. Installation, field testing and cut -over shall consist of a sequence of activities and tests conducted as the SCADA components are installed and integrated at the job site.
G. Training:
1. Training Overview:
1) A comprehensive training program shall be provided by the SCADA System Provider covering the operati on and maintenance of all elements of the SCADA System Provider’s proposed system. Several specific requirements for the training program are listed below:
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2) Training classes shall be tailored to the specific needs of the class participants.
3) For training cl asses conducted on- site, spare PLCs / RTUs, spare workstations, and the development workstations and Server may be temporarily installed in a training area to be designated by the Facility. 4) All training classes shall be completed prior to the start of the Site Acceptance Test.
5) All instructors shall be highly qualified for technical training with demonstrated expertise in not only SCADA system functionality but also professional training techniques. During training, instructors should have no other duties that would interrupt training. Training shall not be combined with other activities such as system configuration or startup. 6) Complete, professional, training materials shall be provided for all training classes including course outline and schedule, training manuals (in addition to system documentation), and review/testing materials. 7) Training courses shall be a combination of classroom and hands-on training.
To the extent possible, hands -on training shall utilize components from the SCADA System Provider’s proposed system.
2. Training Plan
1) The training plan shall include complete descriptions of all training classes, a preliminary training schedule, a list of all proposed instructors along with resumes, examples of proposed training manuals, and a description of any special training tools available (simulators, self -paced modules, personal computer -based training, etc.). The Engineer and Facilities staff will review the training plan for assurance that the training planned by the SCADA System Provider will meet the training needs.
3. System Specific Training
a. Training Manuals:
1) Comprehensive training manuals shall be profe ssionally written to present the course material in a format that is easy to comprehend. The manuals shall serve as teaching aids during presentation of the training classes and shall additionally serve as reference material after the training has been completed. Portions of system documentation may be incorpo rated into training manuals provided that the overall manual achieves an instructional format. If the SCADA System Provider proposes to use standard training manuals, these manuals shall be appended to reflect system characteristics specific to the projects SCADA System.
b. Required Training Courses:
1) Training courses shall be tailored to meet the spe cific needs of facility personnel. Class sizes shall be restricted to the number of students that can easily be accommodated. Classes that involve extensive hands- on activities (such as operator training, maintenance training, and software engineering) shall be limited to five students per class. Supervisor and overview courses may include up to ten participants. Sufficient sessions of each course shall be presented to satisfy class size restrictions and conflicts in facility personnel scheduling. If the S CADA System Provider’s standard training curriculum includes applicable courses in addition to those discussed below, the SCADA System Provider shall also provide these courses. Following is a description of the categories of training to be provided. a) Operator Training:
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1. Training courses shall be presented that instruct the system operators in the efficient operation of all aspects of the SCADA.
The course material shall include the general operation of the SCADA system, and the operation of the specific syst em features incorporated in the SCADA system. In particular, the operator training shall include instruction on the use of all operational functionality.
b) Software Maintenance Training:
1. Training courses shall be presented that will enable facilities staff to develop and maintain all aspects of the system software.
Separate sessions shall be presented that deal with the following topics:
a. Process database development and modification
b. Historical database development and modification
c. Process display development and modification
d. Supervisory Control strategy development and
modification
e. Report development and modification
f. General software maintenance, including system backup, restoration and archiving.
g. Calculation additions, alarm and event logging additions, Graphic display, report and trend additions
h. Network training for adding additional equipment
(printers, workstations, etc) or additional PLCs / RTUs and I/O from the SCADA Network
i. Adding, editing, transporting and testing of data sent to historical database system
j. Any Third party tools for accessing data from any
database.
c) These courses shall address the procedures for the standard SCADA system software, plus material explaining the specific conventions and procedures used by the SCADA System Provider in develo ping the SCADA applications. The courses shall provide instruction in techniques for developing and maintaining current, comprehensive documentation for all applications.
END OF SECTION 13449
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-1 06/25/19
SECTION 13500
PROGRAMMABLE LOGIC CONTROLLER (PLC) CONTROL SYSTEM
PART 1 - GENERAL
1.01 SUMMARY
A. Section Includes:
1. Programmable logic controller (PLC) hardware and software requirements.
2. Startup of complete control system.
3. Owner to provide standard program for PLC. Contractor to adapt to this project.
4. Operator interface.
1.02 QUALITY ASSURANCE
A. Referenced Standards:
1. American National Standards Institute (ANSI) / Institute of Electrical and Electronic Engineers (IEEE):
a. C37.90.1, IEEE Standard Surge Withstand Capability (SWC) Tests for Protective Relays and Relay Systems.
b. C37.90.2, Trial Use Standard Withstand Capability of Relay Systems to Radiated Electromagnetic Interference from Transceivers.
2. Electronic Industries Association (EIA):
a. RS-232-C, Interface Between Data Terminal Equipment and Data Communication Equipment Employing Serial Binary Data Interchange. b. RS-422-A, Electrical Characteristics of Balanced Voltage Digital Interface Circuits.
3. National Electrical Manufacturers Association (NEMA):
a. ICS 1, General Standards for Industrial Control and Systems. b. ICS 1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid State Control.
c. ICS 4, Terminal Blocks for Industrial Use.
d. ICS 6, Enclosures for Industrial Controls and Systems. e. Publication No. 250, Enclosures for Electrical Equipment (1,000 V Maximum).
4. National Fire Protection Association (NFPA):
a. National Electric Code (NEC).
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-2 06/25/19
B. Qualifications:
1. Installation supervisor shall have had experience in overseeing installation and startup of at least three similar installations.
1.03 SUBMITTALS
A. Shop Drawings:
1. See Section 01340.
2. See Section 13440.
3. Product technical data including:
a. Results of factory testing procedures.
b. Arrangement drawings for PLC system components.
c. Panel and enclosure plans, sections and details.
d. Access opening locations and required clearances for each panel and enclosure.
e. Enclosure internal wiring and terminal blocks.
f. Full size diagrams of all CRT process control displays with identification of actual colors. Diagrams of all keyboards, included in PLC system. g. Tabular I/O listing including the following data:
1) Each I/O point.
2) Name of I/O device such as solenoid valve or limit switch. 3) Instrumentation tag number of the I/O device in the Contract Documents.
4) Electrical characteristics of I/O signal.
5) PLC system internal address of each I/O.
h. Index of all training offered by PLC system equipment manufacturer s including operations and maintenance.
i. Spare parts guarantee.
4. Certifications.
a. Qualifications of installation supervisor.
5. Factory test reports.
B. Operation and Maintenance Manuals:
1. See Special Provisions Section 1-09.09.
2. Submit maintenan ce procedures available to Owner. Include the location and phone numbers of service centers (including 24- hour “hot lines”). Provide specific information including operation and maintenance requirements, programming assistance, troubleshooting guide, part s ordering, field service personnel requests, and service contracts.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-3 06/25/19
1.04 WARRANTY
A. The availability of spares shall be guaranteed for a minimum of ten years.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following manufacturer is acceptable:
1. GE Fanuc, Series Rx32 PLC with CPU part no. IC695CPE305.
2.02 PERFORMANCE AND DESIGN REQUIREMENTS
A. See Section 13440.
B. The PLC system shall accomplish the c ontrol requirements of the loop descriptions, Drawings and Specifications.
C. The design application and installation of the PLC system shall conform to NEMA ICS 1.1.
D. The PLC system shall operate in ambient conditions of 32 to 140 degree F temperature and 0 to 95 percent relative humidity without the need for purging or air conditioning.
E. Utilize a power turn -on time delay circuit when powering up and down DC power supplies to ensure power supply output voltage has reached the proper value prior to application of power to solid state logic and output circuits.
F. Environmental Controls:
1. Furnish circulation fans in solid state control system enclosures, where required.
2. Over-temperature switches shall be utilized to provide special cooling if required to maintain operating temperatures within the manufacturer’s specified range.
G. Input/Output Condition Requirements:
1. Outputs shall be fused:
a. External fusing shall be provided if output module does not possess internal fusing.
b. Fuses provided external to output model shall:
1) Be in accordance with module manufacturer’s specifications. 2) Be installed at terminal block.
2. Make connections to I/O subsystem by terminating all field wiring on terminal blocks within the I/O enclosure.
3. Prewire I/O modules to terminal blocks.
4. Provide terminal blocks with continuous marking strip.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-4 06/25/19
5. Size terminals to accommodate all active and spare data base points with 20% extra spare.
6. Provide terminals for individual termination of each signal shield.
7. Field wiring shall not be disturbed when removing or replacing an I/O module.
H. All PLC control system components shall be capable of meeting of exceeding electromagnetic interference tests per ANSI/IEEE C37.90.2.
I. Incorporate the following minimum safety measures:
1. Master Safety Relay:
a. Cuts off power to I/O devices upon de-energization.
b. Multiple master safety relays shall be available as required to provide ability to control separate designated blocks of the control program.
2. External watchdog function to monitor:
a. Internal processor clock failure.
b. Processor memory failure.
c. Loss of communication between processor and I/O modules. d. Processor ceases to execute logic program.
3. Safety function wiring:
a. Emergency shutdown switches shall not be wired into the controller.
4. An emergency power disconnect shall be placed in the power circuit feeding the power supply as a means of removing power from the entire PLC system. a. Capacitor shall be placed across the disconnect to protect against current outrush through triacs.
5. Safe wiring:
a. Equipment failure mode shall be selected so that the loss of power or control signal to the equipment will result in the equipment either shutting down or operating safely.
b. Activation of alarms and stopping of equipment shall result from the de - energization of control circuits, rather than the energization of control circuits.
c. Lower voltage control signal wires:
1) Place in conduit segregated for that purpose only.
2) Twisted shielded wire pair.
3) Not located in the same conduit or bundle with power wiring.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-5 06/25/19
6. Initial safety conditions:
a. Utilize program module to dictate output states in a known and safe manner prior to running of control program.
b. Utilize program each time PLC is re -initiated and the control program activated.
7. PLC fault relay:
a. Placed in series with any other emergency stop conditions. b. Opening of PLC fault contact:
1) Upon unsafe or undesirable system operation, including:
a) Loss of memory.
b) Processor fault.
c) Power supply fault.
d) Isolation failure.
e) Communications failure.
f) Scan time overrun.
g) Module failure.
2) Results from de-energization of PLC fault relay.
3) Causes master safety relay to de-energize.
8. Monitoring of internal faults and displays:
a. Internal PLC system status and faults shall be monitored and displayed.
Monitored items shall include:
1) Memory okay/loss of memory.
2) Processor okay/processor fault.
3) Battery okay/battery low.
4) Power supply okay/power supply fault.
5) Isolation failure.
6) High CPU temperature.
7) Scan time overrun.
8) Module failure.
9. Effects of failure:
a. PLC system shall incorporate safe responses to the following failure effects.
1) Power losses, interruptions, excursions, dips, and transients. 2) Loss or corruption of memory.
3) Information transfer corruption or loss.
4) “Fail on” or “fail off” of inputs or outputs.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-6 06/25/19
5) Unreadable signals.
6) Addressing errors.
7) Processor faults.
10. Design PLC system with high noise immunity to prevent occurrence of false logic signals resulting from switching transients, relay and circuit breaker noise or conducted and radiated radio frequency interference.
11. Incorporate noise suppression and inductive load suppression design into input, output, and logic modules.
12. Operator intervention:
a. Logic system failure shall not preclude proper operator intervention. b. Safety shutdown of equipment or a system shall require manual operator intervention before the equipment or system operation may be reestablished.
J. Communications:
1. Provide the following communication provisions:
a. Provide communications coprocessor card GE IC695ETM001. b. Communication protocol with the operator interface: TCP/IP. c. Communication protocol with the radio: GE CCM.
2.03 COMPONENTS
A. PLC System Central Processor Unit (CPU):
1. Completely solid state CPU designed to provide:
a. Digital relay logic.
b. Analog loop control.
c. Other required control functions:
1) Counting.
2) Floating point math computations.
3) Timing.
2. To use electrical ladder diagram style programming for discrete logic applications.
3. Memory:
a. Battery-backed RAM.
4. Memory battery backup shall be capable of 60 days memory retention with fresh battery.
a. Provide visual indication of battery status and alarm low battery voltage. b. Memory battery backup shall be capable of 14 days memory retention after the “Battery Low” indicating LED is on.
5. Plug-in card design to allow quick field replacement of faulty devices.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-7 06/25/19
a. Provide unit designed for field replacement and expansion of memory without requiring rewiring or use of special tools.
6. Capable of executing all control functions required by the Specifications and Drawings including digital and analog loops.
a. As directly selectable algorithms requiring no user knowledge of programming languages.
7. On line reconfigurable.
8. Lighted status indicators for “RUN” and “FAILURE.”
B. Input/Output (I/O) Modules:
1. Provide plug- in modular -type I/O racks with cables to connect to all other required PLC system components.
2. Provide I/O system with:
a. I/O solid state boards with status lights indicating I/O status and board failure.
b. Electric isolation between logic and field device.
c. Individually fused outputs with blown fuse indication. d. Interchangeable boards for similar I/O type to allow subst itution of operating boards for failed units by the operator.
e. Capability of withstanding low energy common mode transient to 1,500V without failure.
f. Incorporate noise suppression design.
g. Capable of meeting or exceeding surge- withstand capability t ests, per ANSI/IEEE C37.90.1.
h. Capable of meeting or exceeding electrical noise tests, NEMA ICS 1 - 109.60-109.66.
i. Capable of being removed and inserted into the I/O rack under power, without affecting any other I/O modules in the rack.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-8 06/25/19
3. Discrete I/O modules:
a. Interface to ON/OFF devices.
b. I/O status indicator on module front.
c. Voltage rating to match circuit voltage.
d. Output module current rating:
1) Match maximum circuit current draw.
2) Minimum 1.5 A/point for 120 V AC applications.
e. Isolated modules for applications where one module interfaces with devices utilizing different sources of power.
f. Individually fused with blown fuse indication.
4. Analog I/O modules:
a. Input modules to accept signals indicated on Drawings or in Specifications. b. Twelve (12) bit resolution.
c. I/O chassis supplied power for powering connected field devices. d. Isolated (differential) inputs and outputs.
e. User configurable for desired fault-response state.
f. Provide output signals as indicated on Drawings and Specifications. g. Individual D/A converter for each output module.
h. Individual A/D converter for each input module.
C. Power Supply Units
1. Provide regulated power units:
a. Designed to operate with PLC system and shall provide power to:
1) All components of PLC system.
2) All two-wire field instruments.
3) Other devices as indicated on Drawings or in Specifications. b. Capable of supplying PLC system when all of the specified s pare capacity is utilized.
c. Each power supply shall be sized such that it will carry no more than 75 percent of capacity under normal loads.
2. Electrical service to PLC system is 105 to 125V, 60 HZ, + 1 percent, 1 pH power.
3. Separate AC circuit breakers shall be provided for each power supply.
4. If the PLC system is field expandable beyond the specified spare capacity, and if such expansion requires power supply modification, note such requirements in the submittals and allow room in the PLC system enclosure.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-9 06/25/19
5. Provide integral battery backup to maintain DC power for all DC power users for a minimum of 60 seconds upon loss of all AC power. This is required to ensure transient power surges and dips do not affect the operation of the PLC system.
6. Capable of meeting or exceeding electrical noise tests, NEMA ICS 1 -109.60- 109.66.
7. Capable of meeting or exceeding surge -withstand capability tests per ANSI/IEEE C37.90.1.
8. Power distribution:
a. Immune to transients and surges resultant from noisy environment. b. Shall provide constant voltage level DC distribution to all devices.
D. Process Control Operator Interface System:
1. The operator interface shall be flush mounted on the panel front on the panel swing-out door to allow easy access to panel back for maintenance.
2. Compatible with GE-90-30 SNP protocol.
3. Communication with the PLC through the CCM311 card.
4. The program for the operator interface for pumping station will be supplied to the Contractor in generic form by the Owner. The Contractor is responsible for making necessary modifications to the program for proper operation according to the Owner standard. Two configured graphic displays (pumping station and sodium hypochlorite storage/pumping) will be provided, as well as one alarm summary page.
5. The operator interface shall be a GE Quickpanel , or latest touch screen model, without exception.
6. Develop screens as follows (see also Table 3.1):
a. Control:
1) Well pump start pushbutton.
2) Well pump stop pushbutton.
3) Well pump run indicator.
4) Well pump stopped indicator.
5) Well pump running time.
6) Diversion valve open indicator.
7) Diversion valve closed indicator.
8) Pressure indication (analog).
9) Flow indication (analog), gpm and total flow.
10) Chlorine residual indication (analog).
11) Well level indication (analog).
12) Sodium hypochlorite storage tanks level indications (analog). 13) Local remote selector for well pump.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-10 06/25/19
14) Hand-off-auto selector for diversion valve.
15) Diversion valve manual open pushbutton.
16) Diversion valve manual close pushbutton.
17) Hand-off-auto selector for prelubrication solenoid valve. 18) Hand-off-auto selector for thesodium hypochlorite feed pumps. 19) Prelubrication valve manual open pushbutton.
20) Prelubrication valve manual close pushbutton.
21) Pump motor kWh indication (analog).
22) NaOCl feed pumps on indications (two indications).
23) NaOCl feed pumps running time (two times).
24) Screen layout as shown on P&ID drawings with animated pump, pump control valve, waste line, storage tanks and metering pumps. b. Alarm:
1) Alarm reset pushbutton.
2) Normal power failure indicator.
3) High motor temperature alarm.
4) Starter phase failure alarm.
5) Security alarm indicator.
6) Low flow alarm with pump running or called to run.
7) Pump failure to start or to run when called, alarm.
8) Sodium hypochlorite feed pumps failure (two alarms). 9) Sodium hypochlorite storage tanks low level (two alarms). 10) Diversion valve failure alarm.
11) Chlorine residual high alarm.
12) Chlorine residual low alarm.
13) Fire common alarm.
14) Sodium hypochlorite feed pumps seal leak (two alarms). 15) Pump lockout shutdown
c. Service:
1) Prelube timer setting.
2) Time from start signal to sensing of flow timer (failure to start). 3) Diversion valve open timer.
4) Any other operator adjustable variables or choices.
d. Trend: Trends for all analog variables.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-11 06/25/19
2.04 ACCESSORIES
A. Provide all accessories required to furnish a complete PLC control system to accomplish the requirements of the Drawings and Specifications.
2.05 SOFTWARE
A. Provide PLC application software GE VersaPro Professional Edition, Cat no.
IC641VPP700 licensed to the City for its use on both 90/30 and 90/70 PLC’s.
B. City will furnish Contractor floppy disk with City standard water production facility control program software.
C. Contractor to adapt this software to Project, develop final software, and debug.
D. Contractor to supply a set of PLC and operator interface programming and configuration software running on PC, complete with all required communication hardware.
2.06 SOURCE QUALITY CONTROL
A. Provide a performance test after factory completion and prior to shipment.
1. Conduct a continuous 7- day burn- in period where the system is operated continuously and checked for correct operation including loop controls, displays, printing, keyboard functions, alarm responses, noise immunity (NEMA showering arc test), and on/off sequencing control.
2. Conduct testing with dummy I/Os to verify each control loop operation.
3. Allow for Owner and Engineer representatives to witness testing program.
4. Do not ship prior to successful completion of this testing program.
5. Provide information on mean time between failure for all major PLC components.
2.07 MAINTENANCE MATERIALS
A. Furnish Owner with the following extra materials:
1. 10 percent spare I/O points (installed).
2. A list of all the recommended spares for maintenance of the Vendor’s control system with each item separately priced. The list shall include all the special tools and test equipment necessary for the maintenance of the complete system.
City of Anaheim Programmable Logic Controller (PLC) Control System 13500-12 06/25/19
PART 3 - EXECUTION
3.01 INSTALLATION
A. Install PLC control system in accordance with manufacturer’s written instructions.
B. Ground PLC in strict accordance with manufacturer’s instructions.
C. Install PLC in control panel.
3.02 FIELD QUALITY CONTROL
A. Employ and pay for services of equipment manufacturer’s or integrator’s field service representative(s) to:
1. Inspect equipment covered by these specifications.
2. Supervise adjustments and installation checks.
3. Maintain and submit an accurate daily or weekly log of all commissioning functions.
a. All commissioning functions may be witnessed by the Engineer. b. All reports shall be cosigned by the Vendor and the Engineer if witnessed.
4. Conduct startup of equipment and perform operational checks.
5. Provide Owner with a written statement that manufacturer’s equipment has been installed properly, started up, and is ready for operation by Owner’s personnel.
3.03 DEMONSTRATION
A. Demonstrate system in accordance with Specifications.
B. On-Site Training:
1. Provide employee of the manufacturer or integrator to provide three sections at 8 hours per section of operating and maintenance training at the Project site after the system has successfully undergone all field testing and acceptance procedures. This is t o be system training covering control panels, PLC, and application to the particular facility/installation.
3.04 INPUT/OUTPUT SCHEDULE
For input/output schedule see attached I/O List.
END OF SECTION 13500
CITY OF ANAHEIM
INSTRUMENTATION AND CONTROL
PLC INPUT/OUTPUT LIST
THIS TABLE IS FOR GENERAL GUIDANCE ONLY. INSTRUMENTATION & CONTROL SUBCONTRACTOR SHALL PROVIDE ALL REQUIRED I/Os AS PER THE REQUIREMENTS OF THE PROJECT.
INSTRUMENTATION & CONTROL SUBCONTRACTOR SHALL COMPLETE THIS TABLE AS REQUIRED AND SUBMIT FOR APPROVAL TOGETHER WITH THE OTHER PANEL AND PLC DOCUMENTS.
LN TAG # TAG # SERVICE P&ID I/O SIGNAL RANGE STATUS ADDRESS TRANSMITTING RECEIVING TYPE TYPE CNTC'T EQUIP. (Note 2)
INSTRUMENT INSTRUMENT
1 AIT- 53 AI- 53 CHLORINATION RESIDUAL I-2 AI 4-20 mA 0-2 PPM 2 AS- 53 AA- 53 SMOKE DETECTION (FIRE) ALARM I-2 DI 120 VAC 3 FIT- 53 FI- 53 PIPELINE DISCHARGE FLOW I-2 AI 4-20 mA 0-4,000 GPM 4 HS- 531B HS- 531A P-531 START/STOP I-2 DO 120 VAC
5 HS- 532B HS- 532A P-532 START/STOP I-2 DO 120 VAC
6 HS- 53A HS- 53A P-53 START/STOP I-2 DO 120 VAC
7 HS- 53C SV- 53 DRAIN VALVE FCV-53 CLOSE/OPEN I-2 DO 120 VAC 8 HS- 53D ZI- 53D PUMP P-53 HOR SWITCH IN REMOTE I-2 DO 120 VAC 9 HS- 53G FV- 53
PRELUBRICATION VALVE FV-53
OPEN/CLOSE I-2 DO 120 VAC
10 LIT- 53A LI- 53A NaOCl STORAGE TANK T-53A LEVEL I-3 AI 4-20 mA 0-7 ft 11 LIT- 53B LI- 53B NaOCl STORAGE TANK T-53B LEVEL I-3 AI 4-20 mA 0-7 ft 12 LSH- 53C LAH- 53C TK-53A LEAK DETECTION I-3 DI 120 VAC 13 LSH- 53D LAH- 53D TK-53B LEAK DETECTION I-3 DI 120 VAC 14 LSL- 53A LAL- 53A NaOCl STORAGE TANK T-53A LEVEL LOW I-3 DI 120 VAC 15 LSL- 53B LAL- 53B NaOCl STORAGE TANK T-53B LEVEL LOW I-3 DI 120 VAC 16 LT- 53 LI- 53 WELL LEVEL I-2 AI 4-20 mA 0-250 ft
17 OIL CONSOLE XA- 53B DIESEL FUEL SYSTEM COMMON ALARM I-4 DI 120 VAC 18 PIT- 53 PI- 53 PUMP DISCHARGE PRESSURE I-2 AI 4-20 mA 0-200 PSIG 19 PUMP 531-FAIL XA- 531A NaOCl FEED PUMP P-531 MOTOR FAILURE I-3 DI 120 VAC 20 PUMP 531-RUN ZI- 531 NaOCl FEED PUMP P-531 RUNNING I-3 DI 120 VAC 21 PUMP 532-FAIL ZI- 532A NaOCl FEED PUMP P-532 MOTOR FAILURE I-3 DI 120 VAC 22 PUMP 532-RUN ZI- 532 NaOCl FEED PUMP P-532 RUNNING I-3 DI 120 VAC 23 PUMP 53-RUN ZI- 53A PUMP P-53 RUNNING I-2 DI 120 VAC 24 TIS- 53 ZA- 53 P-53 MOTOR FAILURE I-2 DI 120 VAC
LN TAG # TAG # SERVICE P&ID I/O SIGNAL RANGE STATUS ADDRESS TRANSMITTING RECEIVING TYPE TYPE CNTC'T EQUIP. (Note 2)
INSTRUMENT INSTRUMENT
25 VT- 53 VI- 53 P-53 VIBRATION I-3 AI 4-20 mA 0-1.9 in/sec 26 XS- 531 XA- 531B NaOCl FEED PUMP P-531 SEAL LEAK I-3 DI 120 VAC 27 XS- 532 XA- 532B NaOCl FEED PUMP P-532 SEAL LEAK I-3 DI 120 VAC 28 XS- 53A XA- 53A GENERATOR SYSTEM COMMON ALARM I-3 DI 120 VAC 29 XS- 53B XI- 53B NORMAL POWER ON I-3 DI 120 VAC
30 XS- 53C XI- 53C EMERGENCY POWER ON I-3 DI 120 VAC
31 XS- 53D XI- 53D STANDBY GENERATOR RUNING I-3 DI 120 VAC 32 XS- 53E XA- 53E NORMAL POWER FAIL I-3 DI 120 VAC
33 XS- 53F XA- 53F SECURITY SYSTEM ALARM I-2 DI 120 VAC 34 XS- 53G XA- 53G FIRE COMMON ALARM I-2 DI 120 VAC
35 XS- 53K XA- 53K
SMOKE DETECTION (FIRE) SYSTEM
FAILURE I-2 DI 120 VAC
36 XS- 53L XY- 53L
TRANSFER SWITCH TO EMERG
GENERATOR I-4 DO 120 VAC
37 XT- 53 XI- 53 WELL PUMP Kwh I-2 DI 120 VAC PULSE/KW
38 ZSC- 53A ZIC- 53A DIVERSION VALVE FCV-53 CLOSED I-2 DI 120 VAC 39 ZSO- 53A ZIO- 53A DIVERSION VALVE FCV-53 OPEN I-2 DI 120 VAC Notes: 1- SOFTWARE POINTS ARE NOT SHOWN
2- TO BE PROVIDED BY THE CONTRACTOR.
City of Abaheim 13502
SECTION 13502
OPERATOR INTERFACE TERMINAL
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Cont ract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
B. References:
1. NFPA 70 (NEC)
2. UL508
3. EN61131-2
4. IEC 61000-6-2
5. FCC (Class A)
6. UL 1604
7. CSA C22-2 #14
8. ANSI/NEMA ICS 6
9. API RP550
10. ISA S5.4
11. IAS S20
12. ISA S50.1
13. ISA S51.1
1.2 SUMMARY
A. This Section includes Human Machine Interface Terminals and associated configuration software for control and visualization of pro cess equipment, process-oriented machinery, and process systems.
B. Related Sections include the following:
1. Section 13500 Programmable Logic Controllers
2. Section 13449 SCADA Software and Hardware
1.3 DEFINITIONS
A. AI: Analog Input
B. AO: Analog Output
City of Abaheim 13502
C. Control Panel Designer: A firm or individual that is responsible for designing the layout of control panels. This entity will choose the devices to be included in the panel, and will decide on the actual layout.
D. CPU: Central Processing Unit
E. DI: Digital Input
F. DO: Digital Output
G. HMI: Human-Machine Interface
H. I/O Input and/or Output
I. Node: A network connection point. Examples include a PLC, PC, Operator Interface Terminal, Switch, Server, etc.
J. OIT: Operator Interface Terminal: A terminal usually embedded in a control panel that allows the operator to view and modify control system parameters. Operator Interface Terminals are not capable of running commercially available software.
K. Operator Station: A terminal that runs a commercially available operating system such as Windows or Linux. An Operator Station will usually execute the SCADA software. Operator Stations are usually desktop mounted personal co mputers. However, they may be computers that are designed to be embedded in the doors of control panels and motor control centers (MCC)
L. PID: Control action, proportional plus integral plus derivative.
M. PLC: Programmable Logic Controller.
N. SCADA: Supervisory Control and Data Acquisition. A SCADA System is a computer (typically a personnel computer), or a group of computers and servers running a software dedicated for SCADA purposes. This SCADA softwa re can exchange over industrial networks, with PLC’s, VFD’s, and other industrial devices. Typically, the SCADA software will allow for trending, graphic display, alarm tracking, and reporting of data.
O. SCADA System Supplier: A company that takes a commercially available SCADA software package, and then develops a project-specific a pplication. This company will typically supply hardware to run the SCADA software and project-specific application.
1.4 SUBMITTALS
A. Product Data:
B. For each type of Operator Interface Terminal include dimensions, mounting arrangements, and weights. Also include manufacturer's technical data on features, performance, electrical ratings, characteristics, terminal connections, and finishes.
C. Each Operator Interface Terminal type shall have a separate check sheet. This check sheet shall be an acknowledgement of all criteria in this specification. The check sheet will consist of three
City of Abaheim 13502
columns. The leftmost column will indicate the referenced section of the specification. The middle column will indicate whether the indicated sp ecification criteria are met, not met, or has a variance. The rightmost column will be u sed to describe reasons for variances or for not meeting the specified criteria. Each row on the check sheet will be for a dedicated specification section or sub-section. Each organization delin eation will have its own dedicated row. For instance, you cannot accept section 1.5B and its corresponding subparagraphs in a single row.
You must accept 1.5B in a row, and 1.5B1 in another row.
D. Operator Interface Terminal supplier shall be responsible for providing accurate and complete submittals in a timely fashion so as to not cause delay to the project schedule.
E. Once submitted, Operator Interface Terminal supp liers shall not proceed with their associated work until the reception of submittals marked as “Approved” or “Approved as noted”.
F. Operation and Maintenance Data: Provide for each Operator Interface Terminal component literature detailing routine maintenance requirements (if any).
1.5 QUALITY ASSURANCE
A. Manufacturer Qualifications: A qualified manufact urer shall have, within 100miles of Project site, a facility, system integrator, or panel s hop capable of providing training, parts, and coordination of emergency maintenance and repairs.
B. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a member company of the InterNational Electrical Testing Association or is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7, and that is acceptable to authorities having jurisdiction.
C. Source Limitations:
1. All Operator Interface Terminals shall be from a single manufacturer.
2. Operator Interface Terminals shall be from the same manufacturer of the PLC SCADA, and power distribution equipment.
D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.
E. Comply with NFPA 70.
F. Product Selection for Restricted Space: Drawings indicate maximum dimensions for Operator Interface Terminals, minimum clearances between Operator Interface Terminals, and adjacent surfaces and other items. Comply with indicated maximum dimensions and clearances, or with Operator Interface Terminal vendors required dist ances if they are greater than the distances indicated.
City of Abaheim 13502
1.6 DELIVERY, STORAGE, AND HANDLING
A. Deliver Operator Interface Terminals in pack aging designed to prevent damage from static electricity, and physical damage.
B. Store Operator Interface Terminals according to manufacturers’ requirements. As a minimum, store indoors in clean, dry space with uniform te mperature to prevent condensation. Protect Operator Interface Terminals from exposure to di rt, fumes, water, corrosive substances, and physical damage. Also, protect the Operator Interface Terminals from all forms of electrical and magnetic energy that could reasonably cause damage.
1.7 PROJECT CONDITIONS
A. Environmental Limitations: Rate equipment for continuous operation, capable of driving full load without derating, under the following conditions, unless otherwise indicated:
1. Ambient Temperature: 0 to 50 deg C.
2. Humidity: Less than 85 percent (non-condensing).
3. Altitude: Not exceeding 2000 meters (6500 feet).
1.8 PRODUCT PROTECTION
A. Control panel designer supply independent line fu ses or circuit breakers, per the manufacturers’ recommendation, for each Operator Interface Terminal.
B. Control panel designer shall insure that comm unication signals are properly conditioned for the Operator Interface Terminal and protected from all sources of radiated energy or harmonics.
1.9 SPARE PARTS
A. Furnish spare parts as described below for each ty pe of Operator Interface Terminal. Material shall be packaged for long term storage and identified with labels describing contents.
Coordinate with each Operator Interface Termin al based control panel vendor to optimize the amount of spares provided.
1. Provide a spare memory card for each Operator Interface Terminal.
2. Provide Five (5) spare fuses for each type of Operator Interface Terminal PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Wo rk include, but are not limited to, the following:
General Electric
City of Abaheim 13502
B. Qualified Manufacturers:
1. Only manufacturers that have been selling Operator Interface Terminals for a minimum of 10 years will be considered acceptable.
C. Basis-of-Design Product: General Electric; GE QuickPanel+.
2.2 TRADITIONAL OPERATOR INTERFACE TERMINALS
A. GENERAL:
1. All of the Operator Interface Terminals shall comply with the following general requirements as a minimum.
a. Certifications: The Operator Interface Term inal will have certifications by CE, CSA, UL Class 1 Division 2 T4A or T5 (UL and CSA), and C-Tick b. Power Supply: The Operator Interface te rminal will have a nominal voltage of 24VDC with a range of 19.2-28.8Volts DC . The power supply will have a voltage cut of </= 10milliseconds maximum and an Inrush current of </= 50A Maximum.
Connection of power will be via a 3 terminal screw terminal block. This block will be pitched at least 5mm, and will have a tightening torque of 0.5Nm. c. Real-time Clock: All Operator Interface Terminals shall have a built-in real-time clock.
d. To protect the municipality’s ability to competitively bid future projects, the Operator Terminal shall utilize Ethernet networks that are available for multiple vendors. Ethernet protocols shall either use Port 502 or be supported by the Open Device Net Vendors Association (ODVA). Conversion equipment to convert a non compliant Ethernet protocol will not be accepted.
B. ENVIRONMENTAL REQUIREMENTS:
1. All of the Operator Interface Terminals sha ll be capable of withstanding the following criteria as a minimum.
a. Temperature: The Operator Interface Termin al shall be rated to operate in a range of 0-50º C. (32-122 º F.). The unit shall be able to withstand a range of -20-60º C. (-4-140 º F.) while in storage.
b. Relative Humidity: The Operator Interface Terminal shall be capable of handling a minimum of non-condensation humidity of 0-85%.
c. Altitude: The Operator Interface Terminal shall be designed to operate between 0- 6500 feet above sea level minimum without derating.
d. Degree of Protection: The Operator Interface Terminal shall have a front panel rating of IP 65 and conform to IEC 60529. This rating shall be a NEMA 4X rating suitable for indoor use only. The back panel rating shall be IP 20 and conform to IEC60529.
e. Shock Resistance: The Operator Interface Terminal shall conform to one of the following
1) IEC 60068-2-27; Semi-sinusoidal Pulse for 11ms, and 15gn on 3 axes. 2) IEC 61131-3; 15gn 11ms
f. Vibration: The operator Interface Terminal shall conform to one of the following 1) IEC 60068-2-6. The Terminal shall be capable of 5-9Hz at 3.5 mm, and 9- 150Hz at 1g.
2) IEC 61131-3; 1gn 5Hz to 150Hz (maximum 3.5 mm (0.13 in.))
City of Abaheim 13502
g. Electrostatic Discharge: The Operator In terface Terminal shall conform to one of the following
1) IEC61000-4-2, level 3.
2) 6 kV direct contact, or 8Kv air contact
h. Electromagnetic Interference: The Operator Interface Terminal shall conform to one of the following
1) IEC 61000-4-3, 10 V/m.
2) 10 V/m / 80 MHz to 2.7GHz Sinus amplitude modulated 80 % 1 kHz + Internal clock frequency
C. OPERATOR INTERFACE TERMINAL
1. Description: Operator Interface Terminal s shall have viewable screen sizes between eleven (11) inches and sixteen (16) inches.
2. Screen Type: Large Operator Interface Terminals will use a color TFT screen with 65,536 solid colors, or 16,384 colors if flash ing. The screen shall have an 800x600 pixel (SVGA) resolution, with a backlighting service life of 50,000 hours of continual usage.
There shall be an embedded analog touch sens itive zone with a resolution of 1024x1024.
The screen shall have eight (8) levels of brightness via tactile feedback.
3. Primary Memory: The Operator Interface Terminals shall have a 32Mb flash EPROM memory and a Compact Flash expansion memory slot. The Compact Flash slot shall be capable of handling cards up to 1GB.
4. RAM: The Operator Terminal shall be s upplied with lithium batteries to back up 512Kb SRAM.
5. The Operator Interface Terminal shall have video and audio input jacks for connection to a video camera. The Operator Interface Terminal shall also have audio output jacks.
6. Communication Ports: The Operator Interface Terminals shall have an RJ-45 port, and an integral 9-way male SUB-D connector, dedicated to serial communications. The 9- way SUB-D connector shall support RS232/RS485 Communications. The RJ-45 port shall support RS485 communications. A dditionally, two (2) type A host USB connectors shall be provided for applica tion downloading and peripheral use.
Furthermore, the terminal will be supplied with an integral RJ-45 port dedicated to 10BASE-T/100BASE-TX Ethernet TCP/IP communications. Operator Interface Terminals relying on the same port for comm unications and downloading shall not be acceptable.
7. Basis of Design: The basis of design is the General Electric QuickPanel+ terminal series.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas, surfaces, and substrates to recei ve Operator Interface Terminals for compliance with requirements, installation tolerances and other conditions affecting performance.
B. Proceed with installation only after unsatisfactory conditions have been corrected.
City of Abaheim 13502
3.2 APPLICATIONS
A. Select Operator Interface Terminals based upon I/O, memory, communication, expansion, and other criteria. If multiple Operator Interface Terminal-based control panels will be supplied from different vendors, coordinate with othe r vendors to insure that Operator Interface Terminals are of identical brand and are equipped to utilize identical communication networks.
3.3 INSTALLATION
A. Anchor Operator Interface Terminals within enclosures as recommended by the Operator Interface Terminal manufacturer.
B. Provide spacing around Operator Interface Terminals as required by the Operator Interface Terminals manufacturer to insure adequate coo ling. Insure that the air surrounding and penetrating the rear and sides of the Oper ator Interface Terminal has been ambiently conditioned to maintain the required temperatur e and humidity range of the Operator Interface Terminal.
C. Wires entering and exiting Operator Interface Te rminals shall be sized to comply with the manufacturers requirements.
D. During installation, upper ventilati on slots shall be covered to prev ent accidental debris entry.
However, during normal operation ventilation slots sh all not be blocked, or obstructed by any means.
3.4 IDENTIFICATION
A. Identify Operator Interface Terminal components, and wiring according to all applicable codes, standards and contract document sections.
3.5 FIELD QUALITY CONTROL
A. Field Service: The Operator Interface Termin al-based control panel supplier shall provide a qualified service representative to perform the following:
1. Inspect Operator Interface Terminal, wiri ng, components, connections, and equipment installation.
2. Assist in field testing of equipment.
3. Report results in writing.
B. DEMONSTRATION
1. Control panel supplier shall provide a qualif ied service representative to train Owner's maintenance personnel to adjust , operate, and maintain Operat or Interface Terminals.
Manufacturer’s standard training will be sufficient unless specified elsewhere.
END OF SECTION 13502
Electrical: General Requirements
City of Anaheim 16010 - 6 06/27/13
SECTION 16010
ELECTRICAL: GENERAL REQUIREMENTS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Basic requirements for electrical work.
B. Install and wire all equipment, including prepurchased equipment, and perform all tests necessary to assure conformance to the Specifications and ensure that equipment is ready and safe for energization.
C. Related Sections include but are not necessarily limited to:
1. Section 11005 - Equipment: Basic Requirements.
2. Section 16100 – Basic Electrical Materials and Methods.
D. Installation of all systems and equipment is subject to clarification as indicated in reviewed shop drawings and field coordination drawings.
1.2 AREA CLASSIFICATIONS
A. Classification of an area will determine the NEMA rating of the electrical equipment enclosures to be used in that area. Selection of electrical equipment enclosures shall be based on the following criteria:
1. Outdoor locations may be classified as Wet or Corrosive. a. For Wet outdoor locations all equipment enclosures shall be NEMA 4. b. For Corrosive outdoor locations all equipment enclosures shall be NEMA 4X.
1.3 DEFINITIONS
A. Outdoor Areas:
1. Those locations on the Project site where the equipment is normally exposed to wind, dust, rain, snow, etc.
B. Indoor Areas:
1. Those locations on the Project site where the equipment is normally protected from wind, dust, rain, snow, etc.
C. Shop Fabricated:
1. Manufactured or assembled equipment for which a UL test procedure has not been established.
1.4 QUALITY ASSURANCE
A. Referenced Standards:
1. American National Standards Institute (ANSI):
a. C2, National Electrical Safety Code.
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2. ETL Testing Laboratories, Inc (ETL).
3. Factory Mutual System (FM):
a. A Guide to Equipment, Materials and Services.
4. Institute of Electrical and Electronics Engineers (IEEE):
a. 141, Recommended Practice for Electrical Power Distribution for Industrial Plants.
b. 242, Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems.
5. National Electrical Manufacturers Association (NEMA):
a. ICS 6, Enclosures for Industrial Controls and Systems.
6. National Fire Protection Association (NFPA):
a. 70, National Electrical Code (NEC).
7. Underwriters Laboratories, Inc (UL):
a. 508, Safety Industrial Control Equipment.
b. 698, Industrial Control Equipment for Use in Hazardous Locations.
B. In case of conflict or disagreement between codes, standards, laws, ordinances, rules, regulations, specifications, or within either document itself, the more stringent condition shall govern.
C. Miscellaneous:
1. Verify motor horsepower loads, other equipment loads, and controls from approved shop drawings and notify Engineer of any discrepancies.
2. Verify the required control wiring for a complete system and notify Engineer of any discrepancies.
1.5 SYSTEM DESCRIPTION
A. Provide functioning systems in compliance with manufacturer's instructions, performance requirements specified, and modifications resulting from reviewed shop drawings.
1.6 SUBMITTALS
A. Shop Drawings:
1. See Section 11005.
2. Submit shop drawings prior to purchase or fabrication of equipment. See individual Division 16 sections for specific requirements.
3. Prior to submittals of shop drawings, coordinate electrical equipment with all applicable equipment and systems interfacing with that equipment.
4. For each product, clearly identify manufacturer by name.
5. Provide manufacturer's technical information on products to be used, including:
a. Product descriptive bulletin.
b. Electrical data pertinent to the Project and necessary to assure compliance with Specifications.
c. Equipment dimensions, where applicable.
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d. Evidence that the products submitted meet the requirements of the standards referenced.
6. When general data sheets are provided as part of the submittal, specifically identify the products to be used on this Project.
7. Ensure that all submittals clearly indicate the equipment is UL or ETL listed or is constructed utilizing UL or ETL listed or UL recognized components.
Where a UL standard has not been established clearly identify that no UL standard exists for that equipment.
8. For all equipment, provide manufacturer's installation instructions.
B. System Coordination Report:
1. As a minimum it shall include the following:
a. Manufacturer's information.
b. Assumptions.
c. Advise the Engineer of potential coordination problems discovered during and include recommendations to resolve the problem. d. The report shall be submitted for approval 5 days prior to equipment energization.
C. Operation and Maintenance Manuals:
1. See Section 14.
1.7 DELIVERY, STORAGE, AND HANDLING
A. Protect nameplates on electrical equipment to prevent defacing.
B. Repair, restore or replace damaged, corroded and rejected items at no additional cost to the Owner.
PART 2 - PRODUCTS
2.1 ACCEPTABLE MANUFACTURERS
A. Refer to related Division 16 sections.
1. All equipment of a similar type shall be by one manufacturer unless otherwise noted in the Specifications.
2.2 MATERIALS
A. Trade names and catalog numbers may be used in the Specifications to establish quality standards and basics of design.
1. Other listed manufacturers in the applicable specification sections with equal equipment may be acceptable.
2. If no other manufacturer is listed, then manufacturers of equal equipment may be acceptable.
B. Listed:
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1. Where UL test procedures have been established for the product type, electrical equipment shall be approved by UL or ETL and shall be provided with the UL or ETL label.
2.3 FABRICATION
A. When equipment is shop fabricated for the Project, the electrical devices and enclosures utilized shall be UL or ETL listed and labeled or shall be UL recognized.
B. Shop or Factory Finishes:
1. See Section 11005.
PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment shall be installed in accordance with the requirements of the NEC.
B. Enclosures for Use with Electrical Equipment:
1. NEMA 12: Use in unclassified indoor locations.
2. NEMA 4:
a. Use in wet indoor locations.
b. Use in wet outdoor locations.
c. Unless other enclosures are approved and UL listed for the application.
3. Exceptions:
a. As modified in other Division 16 sections.
4. Standards:
a. NEMA ICS-6, Enclosures for Industrial Controls and Systems. b. UL 508, Safety Industrial Control Equipment.
c. UL 698, Industrial Control Equipment for Use in Hazardous Locations.
C. Verify that equipment will fit.
D. Install equipment in accordance with the manufacturer's instructions.
E. Equipment shall be installed plumbed, square and true with the building construction and shall be securely fastened.
F. Equipment shall be provided with corrosion-resistant spacers to maintain 1/4 IN separation between the equipment and the wall.
G. Provide all necessary anchoring devices and supports.
1. Use supports as specified.
a. Where not specified, use supports and anchoring devices rated for the equipment load and as recommended by the manufacturer.
2. Supports and anchoring devices shall be rated and sized based on dimensions and weights verified from approved equipment submittals.
3. Hardware shall be malleable type, corrosion resistant and shall be supported by heavily plated machine screws or brass, bronze or stainless steel bolts.
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H. Material that may cause rusting or streaking on a building surface shall not be used.
3.2 FIELD QUALITY CONTROL
A. System Coordination Study:
1. Perform a system coordination study of all new equipment and the first upstream and downstream protective devices of existing equipment for the electrical distribution system.
a. The electrical distribution system shall include equipment from the point of connection to the last branch circuit protective device. b. The study shall be performed in accordance with ANSI/IEEE Standards 141 and 242, and shall use actual equipment data from the manufacturer supplying the equipment.
B. After installation, all equipment shall be tested as recommended by the manufacturer.
C. Verify all components are operational.
D. Perform ground-fault performance testing as required by NEC Article 230-95(c).
E. Test Equipment Interface:
1. Verify systems coordination and operation.
F. Set all adjustable trip protective devices as required for system protection and coordination.
1. Settings shall be as recommended in the System Coordination Study.
G. Verify all system and equipment ground continuity.
H. Adjust installed equipment for proper operation of all electrical and mechanical components.
I. Replace equipment and systems found inoperative or defective and re-test.
1. If equipment or system fails re-test, replace it with products which conform with Contract Documents.
2. Continue remedial measures and re-tests until satisfactory results are obtained.
3. Remedial measures and re-tests will be done at no cost to the Owner.
J. At Completion of Installation:
1. Test to ensure all equipment is free of short circuits and improper grounds.
2. Test to ensure all equipment is operational.
3.3 CLEANING
A. Clean dirt and debris from all surfaces.
B. Apply touch-up paint as required to repair scratches, etc.
C.
Replace nameplates damaged during installation.
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D. Thoroughly vacuum the interior of all enclosures to remove dirt and debris.
3.4 DEMONSTRATION
A. Demonstrate equipment in accordance with applicable codes and manfacturers’ requirements.
END OF SECTION
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SECTION 16100
BASIC ELECTRICAL MATERIALS AND METHODS
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements specified in Conditions of the Contract, Division 1 a nd Section 160l0 form a part of this section. This Section outlines th e requirements for the basic electrical materials and methods for the electrical work, and forms a part of all other Sections of Division 16 unless otherwise specified.
A. Related Work Included in Other Divi sions or Sections (Related Work not Included in This Section).
1. Earthwork, Division 2.
2. Concrete, Division 3.
3. Painting and Protective Coatings, Section 09900.
4. Instrumentation, Division 13.
5. Induction Motors, Section 16150.
6. Service and Distribution, Section 16400.
7. Electrical Controls, Section 16900.
8. Electrical Equipment Testing, section 16960.
1.02 SUBMITTALS
Submit for the Owner's approval material lists , shop drawings, factory test reports and technical data to the extent required in this Section and Section 16010.
1.03 WIRING
Wiring for furnished equipment shall include the following:
A. Wiring for Furnished Equipment. Th e wiring from electrical panels, control panels and motor control centers to the furnished equipment shall include all the required materials and installations to complete the wiring as shown on the Drawings, specified and required.
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PART 2 - PRODUCTS
2.01 GENERAL
Provide basic materials and all wiring installations as indicated, specified and required.
2.02 METAL CONDUITS
A. Metal conduits shall be steel, hot-dipped galvanized (including threads) and equipped with couplings and thread prot ector caps. The surfaces and threads shall be corrosion-resistant coated. Condu its shall be in ten foot lengths and manufactured in accordance with U.L. 6 by Triangle, Pittsburgh, V.A.W., Wheatland, Allied or equal. Conduits shall be a minimum size of 3/4 inch.
B. PVC Coated Conduit shall have a polyvi nyl chloride coating bonded to the outer surface of rigid steel conduit and couplings . The plastic coating shall have an average thickness of 0.020 inches on 3/4-in ch and 1-inch conduits. For conduits 1-1/4 inch and larger, the PVC coating shall have an average thickness of 0.040 inches. The bonding of the PVC coating to the conduit shall be stronger than the tensile strength of the PVC coating. Th e polyvinyl chloride coating shall be bonded to the galvanized surface of ri gid steel conduit by Youngstown, Kor-Kap, Occidental Coating, Robroy or equal.
2.03 NONMETALLIC CONDUITS
Nonmetallic conduits shall be polyvinyl chlori de, low temperature, corrosion and moisture resistant, Schedule 80, as manufactured by Cert ainteed, Carlon or equal. All the conduit shall be of one type.
2.04 FLEXIBLE CONDUIT
A. Liquid-tight Conduit shall have an inte rlocked, flexible, galvanized steel core, permanently bonded exterior gray polyvinyl chloride jacket and shall be UL listed.
B. Conduits, l-l/4 inch and smaller sha ll have an internal copper bonding conductor wound spirally in the space between each convolution.
C. Manufacturers of liquid-tight flexible conduit shall be Anaconda (by Anamet, Inc.), Type UA, Electri-Flex Type LA, Universal or equal.
2.05 CAST METAL BOXES AND FITTINGS
Cast boxes and fittings shall be finished as specified in Section 16010. The outlet bodies, boxes, fittings, covers and supports shall be cast iron alloy with threaded hubs. The materials shall be manufactured by Crouse-Hinds, Appleton, Pyle-National, Efcor or equal.
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A. Covers and Gaskets shall be provided for all conduit outlet bodies, boxes and fittings. The covers shall be cast iron alloy and equipped with neoprene gaskets.
B. PVC Coated Fittings shall have the same polyvinyl chloride coating that is on the conduit to which they shall be connected. The PVC coating shall have an average thickness of 0.040 inches and the bonding sh all be stronger than the tensile strength of the PVC coating. The PVC co ating shall be bonded to the surfaces of cast outlet bodies, boxes, fittings, supports, etc. by Occidental Coating, Kor-Kap, Robroy, Youngstown, or equal.
C. Plastic Fittings shall be solvent weld type and shall be compatible with the conduit to which they shall be connected.
D. Expansion/Deflection Fittings shall consist of cast metal conduit hubs securely attached to a flexible outer neoprene jacket. A flexible copper grounding strap shall be provided inside the fitting and connected to the two hubs. The linear expansion or contraction shall be a movement up to 3/4 inch. The linear misalignment shall be a movement up to 3/4 inch. The angular misalignment shall be a movement up to 30 degrees. The expansion/deflection fittings shall provide flexible and watertight conduit joints.
E. Thread Lubricant shall inhibit corrosion and maintain grounding continuity, and shall be Crouse-Hinds STL, Thomas and Betts "Koper-Shield" or UL listed equal.
F. Couplings and Elbows. For rigid steel conduits, the couplings and elbows shall be steel, hot dipped galvanized, threaded and one-piece. For plastic conduits, couplings and elbows shall have plain e nds for tight weld fits, which form watertight joints. For joining plastic and rigid steel conduit systems, couplings shall have a plain end and a threaded end.
2.06 STEEL BOXES AND FITTINGS
Pull Boxes. Boxes 24 inches square and smalle r shall have gasketed screw type covers.
Larger boxes shall have bi-parting gasketed hinged doors with latch mechanisms, handles and cylinder locks complete. Provide two keys for each lock. Pull boxes shall be painted as specified in Section 16010. The pull boxes shall be Hoffman, Boss, Circle A-W or equal.
2.07 WATER AND GAS SEAL FITTINGS
A. Water and gas seal fittings shall consist of a thick, synthetic rubber, sealing ring secured between two metal plates by socket head screws. When the conduit water and gas seal fitting is in place and the sc rews are tightened, the synthetic rubber shall become compressed between the meta l plates and be forced against the conduit inside wall and also against the c onductor insulation to form a watertight seal inside the conduit. The synthetic rubber shall resist aging, ozone, sunlight, water, chemicals and extreme temperatur e variations. The water and gas seal fittings shall be O-Z/Gedney Type CSB or equal.
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B. Water and gas wall and floor seals shall consist of a synthetic rubber sealing ring between two pressure rings or a series of synthetic rubber links between pressure plates held together with corrosion resi stant bolts, nuts and washers. When the bolts are tightened, the synthetic rubber expands to provide a watertight seal between the outer surface of the entering conduit, and the inner surface of the wall or floor penetration. The synthetic rubber shall resist aging, ozone, sunlight, water, chemicals and extreme temperat ure variations. The seals shall be Thunderline "Link-Seal", O-Z/Gedney Type CSM, FSK, WSK or equal.
2.08 CONDUIT FITTINGS
Conduit fittings shall be hot dipped galvanized steel and cast iron as required.
A. Liquid-tight Conduit Fittings shall be Types LT, ST, CT as manufactured by Crouse-Hinds, Appleton, Pyle-National or e qual. Fittings 1-1/2 inch and larger shall have provision for a separate equipment ground conductor.
B. Unions shall be type UNY or UNF. R unning threads are not acceptable. Unions shall be Appleton, Crouse-Hinds, Pyle-National or equal.
C. Bushing reducers shall be Appleton, Thomas and Betts, Efcor or equal.
D. Conduit Enlargers shall be Appleton, Thomas and Betts, Efcor or equal.
E. Locknuts shall have notches all around for tightening with a screwdriver.
Locknuts shall be Appleton, O-Z, Thomas and Betts or equal.
F. Metallic Insulated Bushings shall have ground terminals and smooth and well rounded surfaces to protect the conductor insulation. The conduit threads shall be deep, clean and easily attached to the conduits. The bushings shall be O-Z, Efcor, Thomas and Betts or equal.
G. Plugs shall be the recessed type and Appleton, Crouse-Hinds or equal.
H. Interchangeable Hubs shall have an insulated throat, sealing ring and vibration- proof nut. Machined serrations on hub and nut shall bite into the metal enclosure assuring an equipment ground. The hubs shall be Myers "Scru-Tite", Efcor "Space-Saver" or equal.
2.09 CONDUCTORS AND CABLES
Conductors and cables shall be new, single conductor, copper, not smaller than #12 AWG for power and #14 AWG for control unless otherwise indicated, and as shown on the Drawings.
A. Conductors 250 kcmil and larger shall be stranded, 600 volts, flame retardant, ethylene propylene rubber insulation, UL labeled, Type RHW, without outer covering. Insulation other than ethylene propylene rubber shall not be used.
Conductors shall be Rome FR-EPR, O konite-FMR, Houston Wire and Cable FREP or equal.
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B. Conductors Smaller than 250 kcmil shall be stranded (except #10 and #12 for lighting and receptacle circuits which sh all be solid), 600 volt and Type THWN or THHN. Conductors shall be Rome, Caro l Cable, Techbestos, Triangle, Atlas, Northern or equal. Sizes #10 and sma ller shall have colored insulation where indicated.
C. Ground and Neutral Conductors.
1. Insulated ground and neutral conductors shall be the same type as the phase conductors, except for circuits above 600 volts which shall be Type THWN.
2. Bare ground conductors shall be copper, soft drawn, annealed, concentric lay, stranded conforming to ASTM Specifications B3 and B8.
D. Fixture Wires shall be rated 90 o centigrade, #16 AWG stranded, thermoplastic insulated with an outer jacket. The wi re shall be Type TFFN and manufactured by Brand-Rex, Carol Cable or equal.
E. Instrumentation Signal Cables shall be single twisted pair or multi twisted pairs of stranded, copper cables with 600 volt, 15 m il polyvinyl chloride insulation with 4 MIL nylon jacket over each conductor, overall aluminum-mylar tape shield, overall tinned copper drain wire and 45 m il minimum polyvinyl chloride jacket overall, 90° centrigrade dry/75° centrigrade wet rating. Twisted pair cables that are required to be shielded, shall have aluminum-mylar tape shields and tinned copper drain wires over individual twisted pairs of cable. Single twisted pair cables shall be #16 AWG minimum. Cables shall be Okonite "Okoseal-N-type P- OS, type TC", Dekoron type TC or equal.
F. Wire Lubricant shall be Burndy "Slikon", Holub "Hi- Green", Ideal "Yellow 77" or equal.
G. Identifications on the conductors and cables shall be continuous and include the type, voltage, size and name of the manufacturer.
2.10 WIRE CONNECTORS
Connectors shall be provided for splices and terminal connections of all conductors and cables. The connector shall fit the conducto r to which it shall be connected, and the assembly shall have joint contact surfaces not less than 50 percent.
A. Compression Connectors shall be copper lugs for terminal connections, and two- way copper sleeves and taps for splice c onnections. A crimping tool shall be provided to make tight and neat comp ression connections. The connectors and crimping tool shall be Anderson-Square D, Thomas and Betts, Buchanan or equal.
B. Tapered Spring Connectors shall have live springs attached to inner steel housings and enclosed with plastic insulators, and shall be Buchanan B-Cap, 3-M, Scotchlok Type Y, R, G, B, Ideal Wire-Nut or equal.
C. Connectors in all flush with grade pu ll boxes shall be watertight. Connector splice kits for the wire range size for wh ich they apply shall be 3M Type DB-6 and DBR-6, Buchanan B-cap Twist and Seal, or equal.
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D. Electrical Tape shall be plastic, 0.007 inches thick, and resistant to abrasion, alkalies, acids, corrosion, moisture, low and high temperatures. The tape shall be Scotch No. 33 Plus, Plymouth Premium Black No. 4453 or equal.
E. Wire Markers. The individual conductor wire markers shall be adhesive and manufactured by Thomas and Betts, Brady, Scotch 3M or equal. The wire marker to identify groups of conductors shall be nylon cable tie markers as manufactured by Thomas and Betts, Panduit or equal. The marker pads on the cable tie markers shall be large enough to show the moto r or device numbers using minimum 3/16 inch high numbers and letters. Manufacturer shall provide permanent marking pens.
2.11 PANELBOARDS
Panelboards shall be factory assembled, metal enclosed, dead front and equipped with bus, terminals and thermal-magnetic molded case circuit breakers as shown on the drawings.
A. Circuit Breakers shall be molded case, quick-make, quick-break, single and multipole, bolted type, and arranged as shown on the Drawings. Each circuit breaker shall have clear indications fo r "ON", "OFF" and "TRIP" positions. The minimum interrupting capacity shall be 10,000 symmetrical amperes at 240 volts.
As indicated, provide devices to lock the branch circuit breaker in the "ON" and "OFF" positions. Ground fault protecti on, 5 milliampere sensitivity, shall be provided for the indicated branch circuits, which shall be an integral part of the regular branch breaker. A circuit break er with integral ground fault circuit interruption shall require no more pane lboard branch circuit space than the regular circuit breaker. Branch circuits that have exterior convenience outlets, and as indicated shall be equipped with ground fault protection.
B. Copper Bus shall be provided for panel boards. Bus shall be provided for the complete length of the panelboard branch circuit area including circuits indicated as spaces. Bus bars shall be drilled and tapped for the indicated spaces for installation of future circuit breakers.
C. Single Phase Panelboards, three wire, shall be bussed so that any two adjacent single-pole breakers shall be connected to opposite polarities. A single handle two-pole circuit breaker can be installe d in any location, and in place of two adjacent single pole breakers.
D. Three Phase Panelboards, four wire, shall be bussed so that any three adjacent single-pole breakers shall be connected to different phases. A single handle two- pole breaker or three-pole breaker can be installed in any location, and in the same space of two or three adjacent single pole breakers.
E. Terminals and connectors shall be provi ded for all feeder, branch, neutral and ground conductors shown on the Drawings.
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F. Circuit Numbers shall start at the top of the panelboard. Odd numbers shall be assigned in sequence on the left side, a nd even numbers shall be in sequence on the right side of the panelboard.
G. The Cabinet shall enclose the bus a nd breaker assembly, and shall be steel fabricated and coated with corrosion-resistant finish as specified in Section 16010. The front of the panelboard sh all include a trim, hinged door, flush cylinder lock with catch. The lock shall be furnished with two keys, and all locks shall be keyed alike. Fronts shall not be removable when the door is in the locked position.
H. Metal Circuit Directory frame and car d with clear plastic covering shall be provided on the inside of the door. The directory card shall provide a space at least 1/4-inch high and 3 inches long for each branch circuit. The card shall be completely typed to identify each connected circuit, spare and space.
I. Manufacturers for the single phase 120/240 volt and three phase 208Y/120 volt panelboards shall be Square D Type NQOD, Cutler-Hammer POW-R-LINE 1, General Electric Type AQ or equal.
2.12 OVERCURRENT PROTECTION
Circuit breakers, fuses, relays and other protective devices that protect the conductors and equipment against overload currents and short circuit currents shall be provided as indicated, specified and required. The circuit breakers shall be coordinated as specified in this Section.
A. Circuit Breakers shall be molded case type unless otherwise indicated. Breakers shall be quick-make and quick-break on au tomatic operation. The drawings shall indicate the number of poles and ampere trip ratings. The handle mechanism shall be trip-free which prevents holdi ng the contacts against overload or short circuit conditions. Circuit breakers shall be equipped with lugs properly sized to terminate all required conductors as shown on the drawings.
1. The thermal device shall provide time-delay tripping on overloads, and the magnetic device shall provide instantane ous tripping on short circuits. The instantaneous magnetic trip shall be ad justable and accessible from the front of the circuit breaker on frame sizes above 100 amperes. Non-automatic breakers shall have no tripping devi ces, and shall be used for manual switching of circuits. Molded case th ermal-magnetic circuit breakers shall have at least the following interrupting capacities in symmetrical amperes at 480 volts unless otherwise indicated.
100 Ampere Frame - 22,000.
225 Ampere Frame - 22,000.
400 Ampere Frame - 30,000.
600 Ampere Frame - 30,000.
800 Ampere Frame - 30,000.
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2. Solid state circuit breakers shall be equipped with programmers, integral current sensors, logic and trip circ uitry, sensor-powered shunt trips and integral ground fault protection. The programmer shall include silicon transistors, silicon diodes, silicon controlled rectifiers and printed circuit boards to assure the circuit breaker's reliability and stability. Each printed circuit board shall be given a protec tive epoxy coating to prevent moisture absorption, fungus growth and signal leakag e. Gold plated surfaces shall be provided on all electrical connectors a nd adjustment taps. Sensing power and signals shall be derived from th ree current transformers inside the circuit breaker, which shall supply power to the solid state programmer.
The trip shall utilize logic circuitry contained in the programmer. The ampere setting shall be a tap adjustment which selects the continuous current setting of the breaker. These tap adjustments shall be made with knobs on the front of the programmers. Regulated d-c power shall be provided by the full wave rectifiers and filters in the power supply. There shall be individual signals from the pr ogrammer which shall trip the breaker on overloads, short circuits, ground fa ults and high temperatures. The interrupting capacity for the solid state circuit breaker shall be 65,000 symmetrical amperes at 480 volts. It sh all be possible to lock the operator handle in the "off" position with a padl ock. The solid state circuit breaker shall be 100% rated.
3. Motor circuit protectors shall be provi ded as shown on the drawings. They shall be molded case magnetic-trip-only circuit breakers. Each pole shall provide instantaneous protection by m eans of a single adjustable magnetic element that trips all currents equal or above the trip setting. The single adjustment screw shall adjust all pol es simultaneously. Tripping shall be clearly indicated by the handle automatically assuming a position midway between the manual "OFF" and "ON" positions. All poles shall be constructed to open, close and trip simu ltaneously. The contacts shall be of non-welding silver alloy. It shall be possible to lock the operator handle in the "OFF" position with a padlock.
4. The circuit breakers shall be mounted inside low voltage switchgears, motor control centers, switchboards and separate metal enclosures as indicated.
Breakers shall be equipped with indications for the "trip," "on" and "off" positions, and connectors that fit the conductors shown on the Drawings.
The molded case circuit breakers shall be General Electric, Square D, Cutler-Hammer or equal.
B. Overcurrent Protective Device Coordina tion. Properly coordinated automatically operated overcurrent protective devices sh all be provided for this project. The overcurrent protective devices shown on the Drawings shall be coordinated for adequate continuous current and interrupting capacity to assure proper overcurrent protective devices operation under normal and fault conditions in the system.
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All overcurrent protective devices on this project and the first upstream device of the existing electrical system shall be c oordinated so that they will perform as follows:
When two or more overcurrent protec tive devices (including the first upstream protective device of the existing system) in series with each other experience current flow greater than their rated cu rrent, the device with the lowest rated current shall trip and/or open the circuit first and thereby prevent the higher rated devices from operating.
An overcurrent protective device coordi nation study to verify the above stated performance requirements shall be submitted for the Owner’s approval. The study shall be performed, stamped, and signed by a registered professional engineer in the State of California. The documents included in the study shall include but not be limited to the following:
1. A composite drawing or drawings ( on full size, reproducible, log-log paper) showing the entire new electrical sy stem (including the first upstream protective device of the existing syst em) showing all protective device curves (including motor overloads), short circuit duties, motor starting curves and damage curves for motors, equipment and conductors. This drawing or drawings shall show that all protective devices are properly coordinated to perform as stated above.
2. Manufacturer's overcurrent operating cu rves (on full size, reproducible, log- log paper) for each overcurrent device. In the case of fuses, both minimum melt and maximum clearing time curves shall be included.
3. Reproducible copies of all project si ngle line diagrams so marked to show which operating curve applies to each overcurrent device on the diagram (the operating curves shall also be correspondingly marked);
4. A tabulation of the required settings of all of the adjustable overcurrent devices so that the performance requirements are met.
This documented coordination study shall be submitted for review before the overcurrent devices are supplied for the project. Protective devices which have ground fault protection features are specifica lly required to meet this performance requirement.
2.13 WIRING DEVICES
Receptacles and switches shall be specification grade, heavy duty and rated as indicated on the Drawings and these Specifications.
A. Duplex convenience receptacles sha ll be grounding type, polarized, NEMA 5- 20R, rated 20 amperes and 125 volts AC , and shall have double sided screw terminals for copper wire unless otherwis e indicated. The receptacles shall be Hubbell #5362 brown and ivory, or equal by Leviton or Arrow.
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B. Single convenience receptacles shall be grounding type, polarized, NEMA 5-20R, rated 20 amperes and 125 volts AC, and sh all have side screw terminals for copper wire unless otherwise indicated. The receptacles shall be Hubbell #5361 brown, or equal by Leviton or Arrow.
C. Weatherproof receptacle coverplates shall attach to the boxes with corrosion resistant screws. The plug opening in the coverplate shall have a ethylene propylene rubber gasket. Attached to th e coverplate shall be a hinge-spring cover. The convenience outlet shall be weatherproof both when the receptacle is in use and a cord plug is attached and when the receptacle is not in use and the cover is closed. The coverplate for single convenience receptacles shall be Crouse-Hinds type WLRS, Appleton FSK-WR1 or equal. The coverplate for duplex convenience receptacles shall be Crouse-Hinds type WLRD, Appleton FSK-WR2 or equal
D. Local and Weatherproof Switches shall be toggle type, Specification grade, rated 20 amperes and 120-277 volts AC, and equi pped with side screw terminals for copper wire. Single pole switches sha ll be Hubbell #1221, brown or ivory, or equal by Leviton or Arrow. Double pole switches shall be Hubbell #1222, brown or ivory, or equal by Leviton or Arrow. Three way switches shall be Hubbell #1223, brown or ivory, or equal by Leviton or Arrow. Four way switches shall be Hubbell #1224, brown or ivory, or equal by Leviton or Arrow.
2.14 SUPPORTS
A. Channels shall be stainless steel 304. One side of the channel shall have a continuous slot. On both sides of the sl ot, the edges turn inward and forms a guide for the spring nuts. The fittings sha ll be fabricated from stainless steel 304 and attached to the channel with bolts a nd spring nuts. The channel, fittings and hardware shall be stainless steel 304 a nd manufactured by Unistrut, Power-Strut, Kindorf or equal.
B. One-Hole Clamps shall be stainle ss steel 304, for steel conduits and equipped with clamp-backs. The clamps shall be Efcor, Thomas and Betts, Appleton or equal.
C. Beam Clamps shall be stainless steel 304, right angle and parallel types. The clamps shall be manufactured by Efcor, Thomas and Betts, Appleton or equal.
D. Spacers, provided to support underground c onduits in concrete encasements, shall be plastic. The spacers shall be Carlon, Johns-Manville, Underground Products or equal.
E. Steel Anchors shall be stainless steel 304 and shall be sleeve and stud types for securing equipment to concrete foundations, floors and walls. The anchors shall be Phillips "Red Head", Diamond or equal.
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F. Toggle Bolts shall be stainless steel 304, spring wing type for securing equipment to hollow walls and ceilings. Toggle bolts shall be Phillips "Red-Head", Diamond or equal.
G. Stanchions shall be stainless steel 304 as shown on the drawings.
H. Conduit Hangers shall be stianless st eel 304 and equipped with carriage bolts, 1/4-inch rods and nuts. The hangers shall be Efcor, Kindorf, Appleton or equal.
I. U-Bolts shall be stainless steel 304, a nd equipped with two hexagon steel nuts.
The U-bolts shall be Efcor, Kindorf or equal.
J. Fixture Hangers shall be stainless st eel 304, cushion type, equipped with cover, screw terminal blocks, and permits th e pendant to swing 20 degrees from perpendicular in any direction. Hange rs shall be Crouse-Hinds Type ALT, Appleton Type ALT, Pyle-National Type A-2152M or equal.
K. All nuts and bolts shall be stainless steel 304.
2.15 NAMEPLATES
A. The Nameplates shall be engraved, laminated black plastic with minimum 1/4 inch high letters showing through from the white core, NEMA ES-1, 3-ply (Black-White- Black), 1/16-inch thick, beveled and satin fini shed. Nameplate inscriptions shall include the identifications for the equipment and load s and shall identify the controls on control equipment as shown on the Drawings. Nameplates shall be provided on receptacle plates with 1/8 inch high letters.
2.16 TAGS
Tags shall be 1/16 inch thick stainless steel and shall have embossed (raised) lettering.
Lettering shall be a minimum of 3/8 inch hi gh. Provide a 1/8 inch hole at each end for mounting or wire attachment. All corners shall be rounded and edges ground smooth.
2.17 GROUNDING
Provide all the equipment and materials to complete all the grounding installations as indicated, specified and required.
A. Ground Rods shall be sectional coppe r-clad, high strength steel, minimum 3/4 inch diameter, minimum 10 feet long and w ith pointed ends and chamfered tops.
The sectional ground rods shall be equipped with bronze couplings and driving bolts. The ground rods shall be Copperweld, Hubbard, Chance or equal.
B. Ground Clamps shall be copper alloy, heavy duty, corrosion resistant and consist of U-bolts and saddles with bolted cable connections. The ground clamps shall be O-Z, Thomas and Betts, Burndy or equal.
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C. Ground Connectors shall be cast copper a lloy interlocking clamps equipped with silicon bronze bolts, nuts and lock washers or interlocking lugs with allen head set screws and one-hole tongues. Ground conn ectors shall be corrosion resistant and provided for cable to flat surface connecti ons on equipment and structural steel.
The connectors shall be O-Z, Burndy, Thomas & Betts or equal.
D. Direct Buried Ground Connections sha ll be the exothermic method and supplied by Cadweld, Thermoweld or equal. Exothermic welding method produces a super heated flow of molten copper by burning powder in the crucible-mold.
Brazed, soldered, impact and bolted conn ections shall not be used for buried connections.
E. Ground Conductors shall be provided as shown on the Drawings and specified in Section 16100.
F. Ground Well shall consist of a conc rete box, cover, ground rod and ground rod clamp. The box shall be pre-cast concrete, and the inside dimensions shall be at least 10-1/2 inches wide, 17-1/4 inches long and 12 inches high. The cover shall be traffic type, cast iron and marked "GROUND". Concrete box and cover shall be Brooks No. 3-1/2 T, Quikset No. W-17 or equal.
PART 3 - EXECUTION
3.01 GENERAL
Provide the wiring installations and equipm ent installations, including connections and interconnections as indicated, specified and re quired in a neat and workmanlike manner.
Assure proper fits for all equipment and materials in the spaces shown on the Drawings.
A. Excavations and Backfills. Earthw ork shall be performed for equipment foundations, supports and underground conduits as indicated and as specified in Section 02200.
B. Concrete shall be provided for electrical equipment foundations, support foundations and conduit encasements as i ndicated and as specified in Section 03300.
C. Painting. Painting shall be provided fo r installations having unfinished surfaces per requirements of Section 09900. Field damaged factory finishes on equipment shall be touched-up with paint that is e qual in quality and color to the original factory finish. Paint galvanized st anchions in accordance with Section 09900 requirements.
3.02 RACEWAYS
Provide all conduit installations, including the outlet bodies, boxes, gaskets, covers, fittings and supports to complete the raceway systems as shown on the Drawings and as required.
Conduits shall be a minimum size of 3/4 inch. Install ground conductors in all conduits.
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A. Underground Installations – Outside Building.
1. Bottom of trench shall be of select backfill or sand.
2. All underground raceways shall be concrete encased.
a. Nonmetallic conduit may be installed for underground conduit runs which are outside of the buildings and structures and run between buildings and structures.
b. Rigid galvanized steel conduit sha ll be installed under roads and paved parking areas.
1) The rigid galvanized steel conduit shall extend 5 feet passed the edge of the pavement at wh ich point it may transition to nonmetallic conduit.
3. Provide at least 3 inches of concrete between the conduits and the outside of the encasement, and at least 2 inches of concrete between the conduits unless otherwise indicated.
a. Fifteen (15) pounds of red iron oxide No. 188 per cubic yard of concrete shall be used for coloring of the concrete.
b. Couplings shall be staggered at least 6 inches.
c. Install spacers and adapters to support and terminate underground conduits.
1) Horizontal and vertical separation shall be maintained by plastic spacers set sever 5 feet and duct system shall be anchored at least every 4 feet to prevent movement during placement of concrete.
4. Underground conduits shall be installe d so that the top of the concrete encasement is a minimum of 24 inches below grade, with a minimum slope of 4 inches per 100 feet of duct towards pull-boxes, handholes and manholes so that moisture is not allowed to collect in the conduits. a. Horizontal changes in direction, where conditions permit, shall be accomplished with long sweep bends of minimum radius of 24 times conduit diameter.
b. Conduit entrances into manholes, handholes and pull-boxes shall be terminated with flush end bells and grouted smooth.
5. Rigid steel bends and risers shall be used with nonmetallic conduit wherever conduit rises above grade.
a. Provide and connect the adapters between the rigid steel conduit risers and non-metallic conduits.
b. Conduit risers shall be completely concrete encased to finished grade.
6. Each conduit of a completed duct ba nk shall be cleaned by drawing through it a standard flexible mandrel one foot long and ¼ inch less diameter than the conduit.
a. After the passing of the mandrel, a wire brush and swab shall be drawn through.
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b. All spare conduits shall have their ends plugged and contain a 1/8 inch polypropylene pull cord for future use.
1) Pull cord is not required for capped stubouts.
7. Each conduit entering a pullbox shall be identified by conduit number on an embossed tag securely fastened to th e wall above the conduit. Where view of this tag is obscured, a second similar tag shall be added. This tag shall be attached to the conduit or conductors with #18 AWG stainless steel wire.
B. Conduits in Concrete. Rigid galvani zed steel conduits shall be installed in concrete encasements, slabs, foundations, floors and walls as shown on the drawings. The conduits shall be properly positioned in the concrete forms to provide the required clearance space with reinforcing steel.
C. Conduits installed under the concrete fl oor slab of buildings shall be rigid galvanized steel type. When galvanized conduits are installed in concrete slab, they shall be coated with two heavy coats of asphaltum paint. Acceptable coatings are Kopper Inertol No. 49 or Sherwin Williams Coat Tar Epoxy C-200.
D. Exposed Installations. The installations shall be completed with PVC coated hot- dipped galvanized rigid steel conduits with wrench tight connections in a neat and workmanlike manner. A minimum of 5 th reads shall be engaged and the tapered portion of the threads shall be sufficiently engaged to provide electrical continuity. Supports shall be provided for all conduits. Where new conduits may interfere with existing facilities such as li ghting fixtures, control stations, lighting switches, instruments, control panels, etc., consult the Owner or his representative for direction prior to proceeding with installation. Maintain a minimum clearance of 12 inches for conduits installed near hot pipes or surfaces (150 oF or higher).
Exposed conduits shall be installed parallel or perpendicular to buildings and structures. Where two or more conduits ch ange direction at the same location, all bends shall be concentric around a common center point.
E. No run of conduit, between device, e quipment, box or fitting and another device, equipment, box or fitting, shall contain more than the equivalent of three 90 degree bends (270 degrees total), including offset bends located immediately at the device, equipment, box or fitting.
F. Couplings and Elbows shall be of the same type as the conduit to which they shall be connected, except where rigid steel bends and risers are connected to non- metallic conduits where conduits rise above grade or as required by Section 351-9 of the National Electrical Code.
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G. Flexible Conduits. Flexible conduits sh all be liquid-tight with fittings for short tight connections (30 inches maximum) to equipment, except in Class 1, Division 1 areas. A separate ground conductor shall be installed in flexible conduit that does not have the internal c opper bonding conductor included by the manufacturer.
H. Threads. All steel conduit threads sh all be coated with a conductive, corrosion resisting lubricant, and the connections sh all be made watertight. The lubricant shall maintain the grounding continuity.
I. Conduit Connections. Where conduits ar e connected to couplings, fittings, boxes, etc., a minimum of 5 threads shall be e ngaged so that the system is rigid and sturdy. Also, the tapered portion of the th reads shall be sufficiently engaged to provide electrical continuity. The use of lock-nuts, or other gimmicks with threaded fittings to add rigidity, is not acceptable. Unions shall be provided, as required, for conduit connections to thr eaded outlet bodies, boxes and equipment, and for connecting two steel conduits t ogether. Conduit enlargers shall be provided for connecting two conduits of different sizes together.
J. Water and gas seal fittings shall be provided on all conduits that enter or leave corrosive areas. The seal fitting shall prevent corrosive gases from passing from a corrosive area to a non-corrosive area through the conduit system. Ceramic or other non-asbestos fiber material and s ealing compound shall be placed in the fitting to complete the seal.
K. Water and gas seal fittings shall be inst alled on the ends of exterior conduits that terminate at indoor equipment. The fitti ngs shall provide a water and gas tight seal between the wires and cables and the inside of the conduit.
L. Water seal fittings shall be installed to completely water seal the areas around conduits that pass through concrete floors and outside walls, unless concrete is placed after conduit is installed.
M. Penetrations. Penetrations through c oncrete for sleeves and conduits shall be approved by the Owner. Submit the sizes, locations and methods for all penetrations.
N. Expansion/Deflection Fittings. Expansi on/Deflection fittings shall be connected to steel conduits, to permit movement between two conduits without damage to the conduits or conductors, as indicated and required.
O. Stub-ups and Stub-Outs. All steel condu it stub-ups and stub-outs shall be painted per requirements in Section 09900. Conduits shall be painted a minimum of 4 inches each side of concrete slabs and walls. Finish shall be applied before concrete is poured. Where a spare condu it stubs-up below a control panel, motor control center, switchboard or other electri cal equipment, it shall be terminated with a metallic insulated bushing and grounded. Where a spare conduit stubs-up in a floor, it shall terminate flush with the floor using a coupling and recessed plug. Where a spare conduit stubs out thr ough a wall, it shall be capped. Identify City of Anaheim Basic Electrical Materials and Methods
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all spare stub-ups and stub-outs with tags as to the location of the termination of the conduit at the other end.
P. Conduit Terminations. Conduits enteri ng equipment, including control panels, motor control centers, switchboards, etc. shall enter in the same vertical section in which the circuit will terminate. Meta llic bushings with insulating inserts and ground terminals shall be provided on the ends of threaded steel conduits and nipples that terminate through openings in sheet steel enclosures. Locknuts and bushings shall be installed on the thread s of steel conduits that enter through close-fit openings in enclosures. Interc hangeable hubs shall be provided for rigid steel conduit connections to sheet steel enclosures. Bushing reducers shall be provided in conduit fitting hubs for connections to smaller size conduits.
Q. Tool Marks. Conduits and fittings that have tool marks shall be smoothed and finished with paint that matches the original finish.
R. Conduit Through Roof. Provide a water tight seal around the conduit on the roof.
Coordinate the work with the roofing contractor.
S. Furnished Equipment. Provide conduit installations as shown on the Drawings, and specified in other Sections of the Specifications for furnished equipment.
3.03 BOXES AND FITTINGS
Conduit outlet bodies, boxes, fittings, gaskets, covers and supports for lighting outlets, lighting switches, receptacles, control stations, alarm switch and thermostat outlets, etc. in exposed conduit installations, shall be installed as indicated, specified and required, and shall be of sufficient size to provide free space for all conductors that shall be enclosed.
A. PVC Coated. Outlet bodies, boxes, gask eted covers and fittings shall be PVC coated and connected to PVC coated steel conduits.
B. Sheet Steel. Sheet steel boxes shall be of sufficient size to accommodate the connected conduits and enclosed conductors and provided with close-fit holes for steel conduit connections. Weatherp roof boxes shall be provided with interchangeable conduit hubs for steel conduit connections as indicated.
C. Interchangeable Hubs. The hubs shall be installed in steel enclosures for rigid steel conduit connections. Cut a close fitti ng hole in the sheet steel enclosure and place the interchangeable hub in the opening. Connect the hub on the conduit and make a tight connection to the enclosure.
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3.04 CONDUCTORS, CABLES, CONNECTIONS AND WIRE MARKERS
Install all the conductors, cables and connections for the wiring as indicated, specified and required. Recommended pulling tensions shall not be exceeded. Pulleys and/or rollers shall be provided so that conductors do not come in contact with ground, concrete, manhole entrance rings, edges of handholes, edges of boxes, or any other surface likely to damage the outer covering, etc. during pulling operations. Branch circuits that have exterior convenience outlets, and as indicated shall be equipped w ith ground fault protection. Provide separate neutral conductors as required. Ground conducto rs shall be insulated wire unless noted otherwise on the Drawings.
A. Conductors. Conductors shall be complete ly installed and connected. Apply wire lubricant to ease the pulling of conducto rs in conduits. Splice and terminal connections shall be made tight with spring and compression connectors. The connectors shall be crimped with a t ool that provides uniform and tight connections. Connectors shall be sized as outlined in paragraph on Wire Connectors in this Section. Include a ll the required wiring interconnections.
When routing conductors and cables through pull boxes, the longest (not shortest) route from entrance to exit shall be used.
B. Connections.
1. Low Voltage Connectors. Connect ors for conductors No. 8 AWG and larger shall be compression type. Connectors for conductors No. 10 AWG and smaller shall be tapered spring type.
2. Conductor and cable splices shall be located only in pull-boxes, junction boxes, handholes and manholes.
C. Wire Markers shall be provided to identify each conductor at equipment terminals, and in intermediate junction boxes, pull boxes, handholes and manholes. At motor control centers and control panels, identify each motor or other electrical device circuit conductor with the motor or device number shown on the Drawings and with the terminal number of the motor control center or control panel to which the conductor is connected. At motor and device terminals, at control stations, and in junction boxes, pull boxes, handholes and manholes, identify each motor or device circuit conductor with the terminal number of the motor control center or c ontrol panel to which the conductor is connected. In addition to identifying each conductor with the terminal number, in junction boxes, pull boxes, handholes a nd manholes, identify each group of conductors forming a motor or device ci rcuit with the motor or device number shown on the Drawings. The motor or device numbers on the cable tie markers shall be 3/16 inch high minimum and shall be applied to the marker pads using marking pens for the purpose which shall be provided by the manufacturer of the cable tie markers. When a device is not numbered on the Drawings, use a short descriptive title or assign numbers and provide the Owner with a list of the devices and assigned numbers. Electrical devices include items such as solenoid valves, vibrators, horns, heaters, analyzer s, computers, instruments, etc. At City of Anaheim Basic Electrical Materials and Methods
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panelboards, junction boxes, pull boxes, handholes and manholes, identify each panelboard circuit conductor with the panelboard number and circuit number.
D. Insulate. All connections shall be insula ted as required with tight wraps of plastic tape. Apply insulation putty to fill irregularities and voids in splices E. Furnished Equipment. Provide wiring installations as shown on the Drawings, and specified in other Sections of the Specifications for furnished equipment.
3.05 PANELBOARDS
Install and completely connect all the factory assembled panelboards as shown on the Drawings.
A. Panelboard shall be installed in motor control center as shown on the drawings.
B. Locking Devices. Attach locking devices on the handles of branch circuit breakers for the "ON" and/or "OFF" positions as shown on the Drawings.
C. Circuit Directory Card. Completely type the card to identify each connected circuit, spare and space.
D. Tight Connections. Provide tight conn ections for feeder and branch circuit wiring.
3.06 OVERCURRENT PROTECTION
Install all the overcurrent protective equipment as indicated, specified and required.
A. Metal Enclosures. The enclosures for individual equipment shall be constructed to satisfy the condition in the location where they shall be installed.
B. Trip Settings. Circuit breakers shall assu re the required circuit protection with the indicated trip settings.
3.07 WIRING DEVICES
Install the required local switches, and conveni ence outlets complete, in cast iron boxes with covers, including the supports and wiring, as id entified and located on the Drawings. Unless otherwise indicated, the device phenolic color sh all be ivory for all receptacles and local switches. One-hole plates shall be provided on telephone outlets. All surface device outlets shall have cast iron boxes.
3.08 SUPPORTS
Install the required structural channels, brack ets, stanchions, U-bolts, clamps, anchors, hangers, fittings and other hardware to secu rely attach and support all the equipment, materials and conduits, as indicated, specified a nd required. Supports shall be stainless steel 304 for all exposed conduits.
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3.09 NAMEPLATES
Nameplates shall be provided as indicated to identify equipment, and the positions and circuits within the equipment. Also, indi vidually enclosed equipment shall be provided nameplates as indicated. Plastic nameplates shall be positioned and lined-up to provide a neat appearance, and shall be attached to th e cleaned metal surfaces of enclosures with stainless steel screws.
A. Plastic Nameplates. Nameplates sh all be provided on, switchboards, service equipment, motor control centers, panelboards, and individually enclosed circuit breakers, disconnect switches, magnetic starters, manual starters, relays and control stations unless otherwise indicated. Provide lighting switch nameplates as indicated on the Drawings.
B. Nameplates shall be attached to the object, or adjacent to the object, with self taping screws. Adhesive materials shall not be used for attachment. Objects such as explosion proof enclosures, that would have their UL listing nullified by drilling for mounting screws shall have their nameplate mounted on an adjacent wall or plate provided by the constructor.
3.10 GROUNDING
Install all the equipment, materials and wiring to complete the equipment, structural, lightning and system grounding installations as shown on the Drawings, specified and required.
A. Ground Rods, sectional, shall be long enough and driven to reach the permanent moisture level of the soil. The resi stance of any driven ground rod shall not exceed 10 ohms, and additional sections sh all be installed to obtain the required lower resistance. The hand or power driving methods shall produce a force in line with the main axis of the ground rod, and the blow shall drive the rod straight to the required depth in the earth.
B. Ground clamps and Connectors shall be connected tight to ground conductors and securely attached to equipment, struct ural steel, conduits, metal pipes and ground rods with set screws, bolts and nuts.
C. Grounding Bushings shall be installed tight on the ends of metal conduit, and ground jumpers shall be securely attached to the bushings and equipment enclosure or ground bus.
D. Where a ground loop is installed around structures or equipment, it shall be placed, as much as possible, in undisturbed earth.
E. Exothermic Welding Connections shall be provided for buried connections and as indicated. Brazed, soldered, impact and bo lted connections shall not be used for buried connections.
F. Ground Conductors shall be completely installed and connected in conduits, in trenches, in pull-boxes, and on poles as shown on the Drawings. When installing the copper conductor in a trench, allow 5 percent additional length for slack, to City of Anaheim Basic Electrical Materials and Methods
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the conductor length, before backfilli ng the trench. When routing ground conductors through pull boxes, the longest ( not shortest) route from entrance to exit shall be used.
G. Ground Well shall include a precast conc rete box, cover, ground rod and clamp.
The ground rod shall be located in the center of the box and equipped with a ground clamp.
H. Connectors and Clamps shall be insta lled for conductor connections and supports as required.
I. The resistance to earth of the grounding el ectrode system shall be measured by an approved testing service using the three point, fall of potential method. If 10 ohm ground resistance is not achieved, the C ontractor shall provide sufficient additional ground wells, ground rods, gr ound connections and interconnecting wiring, arranged and located in a similar manner as is shown on the Drawings, to achieve the indicated value. The modi fied grounding electrode system shall be tested in the same manner to verify the modification achieved the specified requirements.
3.11 CHECKING, ADJUSTING AND TESTING
Provide the required labor and equipment, and all checking, adjusting and testing operations on the electrical installations.
A. Check. All wire terminals shall be checked to assure tight connections.
B. Tests.
1. Tests shall be per Section 16960.
2. For items not included in Section 16960, tests shall be performed per NETA and IEEE standards, to detect wrong c onnections, short circuits, continuity and ground. Tests shall be made with a hand crank test instrument (meggar) on all motor control center busses, transformer windings, motor windings and all cables and conductors.
NOTE: WARNING. Do not make insulati on tests on any conductors either signal or power, that are connected to semi-conductor type equipment. Remove the conductors from the equipment before insulation testi ng; severe damage may result from meggar- type instruments. Power feeders and branch conductors shall be tested phase to phase and phase to ground. Phase to ground tests on shielded cable shall mean "conductor to shield". Test voltage and application time for the various cables and conductors shall be submitted to the Owner. Correct any defects in the wiring systems.
C. Equipment Tests. Perform equipment tests as indicated and directed by the manufacturer. Refer to Section 16010 fo r Manufacturers' Certified Reports on service equipment and motor control centers.
D. Test Data. Test data for equipment, shielded cables and supply voltage shall be submitted to the Owner.
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E. Supply Voltage. Test the supply voltage while the normal plant loads are operating. If the voltage is not within normal limits (plus or minus one percent), notify the power company and request a voltage correction.
F. Operation Tests. Perform operation te sts and observe that all loads operate satisfactorily. Refer to Section 16010 fo r Demonstration and Final Operation Test Plans and Results.
END OF SECTION 16100
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SECTION 16400
SERVICE AND DISTRIBUTION
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements specified in Conditions of the Contract, Section 16010 and Section 16100 form a part of this Section. This Section outlin es the electrical requirements for the service equipment consisting of the pull section and main circuit breaker section of the main switchboard. The MCC section of the main switchboard shall be covered under Section 16900.
A. Related Work Not Included In This Section.
1. Electrical Controls, Section 16900.
2. Earthwork, Division 2.
3. Concrete, Division 3.
4. Painting, Division 9.
B. Power Service. The underground power service shall be complete and as shown on the Drawings. The service installation shall conform with City of Anaheim’s service requirements.
C. Distribution. The power distribu tion system shall include equipment installations and underground wiring installations as shown on the Drawings.
1.02 SUBMITTALS
Submit for the Owner's approval material lists , shop drawings, factory test reports and technical data to the extent required in Section 16010.
PART 2 - PRODUCTS
2.01 GENERAL
Provide all the equipment and materials, and complete all of the power service and power distribution as indicated, specified and require d. Sizes of equipment shown on the Drawings and space allowed for the equipment are base d on equipment manufactured by only one of the listed acceptable manufacturers. The manufactur ers and models listed in this Section of the Specifications are acceptable providing they conform to the Specifications and that the equipment and materials provided fit properly in the available space. Refer to Section 16100 for conduits, conductors, circuit breakers and nameplates.
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2.02 SERVICE EQUIPMENT
Provide the totally metal enclosed, dead front , service equipment as shown on the Drawings, specified and in accordance with City of Anah eim Public Utility Department requirements.
The equipment shall be completely fabricate d, assembled, wired, checked and tested at the factory in accordance with applicable ANSI, NE MA and UL standards. Shipment shall be made in sections to facilitate field handling and the shipped sections shall be joined together in the field to form a complete unit assemb ly. The service equipment shall be Cutler- Hammer “POW-R-LINE”, Square D "Power Style" or equal. Service equipment shall line up with motor control center to form a single assembled unit as shown on the Drawings.
A. The service equipment shall be totally metal enclosed, dead front, totally front accessible, and shall include an underg round power service pull section for terminating the power company service conductors, power service metering and main circuit breaker section, and any ot her required components to complete the assembly.
B. Pull Section shall be totally metal enclosed, full height, free standing and equipped with copper busses and conn ectors for terminating the underground service conductors and connecting to the Main Circuit Breaker Section.
C. Main Circuit Breaker Section shall be free standing, full height and shall contain power bus, supports, ground bus, fuses, me tering, test equipment, terminals, wiring and main circuit breaker. The section shall be complete, and in accordance with City of An aheim’s utility service requirements. Meter sockets shall be provided for power company meters as required. Bus work shall include provisions for mounting power company current transformers and potential transformers or potential taps as required by City of Anaheim.
D. Main Circuit Breaker shall be rated as shown on the Drawings, and specified in Section 16100. Main Circuit Breaker sha ll be interlocked with the vertical section door such that door cannot be opened when main circuit breaker is on, and the breaker cannot be closed when the door is open. Provide defeater mechanism for use by authorized personnel.
E. Vertical Sections shall be fabricated from standard gauge formed steel with uniform surfaces, shall be 90 inches hi gh, depth and width as indicated and required. The sections shall contain busses, supports, brackets, protective devices, metering, barriers, doors, trims, base channels, provision for lifting, hardware, terminals, wiring and connector s. Front to rear bracing shall not interfere with the conduit entrance areas.
F. Bus Bars shall be provided for power and grounding. The power bus bars shall be copper, and shall be braced to withstand mechanical forces exerted during short circuit conditions, to the rating of the main circuit breaker specified. Verify short circuit duty with the power company. The power bus bars shall be rigidly supported on insulators, and enclosed with non-metallic barriers. At the bottom of each section, provide a 1/4-inch by 2- inch copper ground bus, and splices that City of Anaheim Service and Distribution
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connect the bus in each section for the full length of the main switchboard. The minimum continuous current rating of the power bus bars shall be as shown on the drawings.
G. Provide under-voltage relay as shown in the drawings.
H. Wiring inside the switchboard shall be provided as required. The wiring shall include terminal blocks with numbered terminals, fuse blocks and wire connectors.
I. Nameplates shall be provided on the main switchboard. Refer to Section 16100 for nameplates.
J. Finish shall be as specified in Section 16010.
PART 3 - EXECUTION
3.01 GENERAL
Provide all the equipment installations and wiring installations including connections and interconnections for the power service, distribution and grounding as indicated, specified and required. Assure proper fits for all equipm ent and materials in the spaces shown on the Drawings.
A. Service Equipment. Install the metal enclosed service equipment and wiring as indicated, specified and required.
1. Equipment shall be installed level a nd securely attached to the concrete foundation with anchor bolts. The secti ons shall be joined together with bolts, washers and nuts to form a unit assembly. Provide concrete housekeeping pads as shown on the drawings.
2. Wiring installations shall be comple te and in accordance with City of Anaheim’s utility service requirements.
3. Nameplates shall be attached to clean surfaces of the metal enclosures with stainless steel screws.
END OF SECTION 16400
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SECTION 16900
ELECTRICAL CONTROLS
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements specified in Conditions of the Contract, Division l, Section 16010 and Section 16100 form a part of this Section. This Section outlines the electrical work for motor controls.
A. Related Work Not Included in This Section.
1. Induction Motors, Section 16150.
2. Service and Distri bution, Section 16400.
3. Earthwork, Division 2.
4. Concrete, Division 3.
5. Painting, Division 9.
B. Instruments. Voltmeters, ammeters, meter switches and elapsed-time meters shall be provided as shown on the Drawings and as specified.
C. Controls. Controls shall be provide d as indicated, specified and required.
1. Motor Controls shall include the instal lations for motor control centers, and individual enclosed combination starters , control stations and other controls including complete wiring and all interconnections.
2. Motors shall be provided with the driven equipment, and as specified in Section 16150 and equipment sections of the mechanical specifications.
3. Individual Enclosed Equipment shall be provided as shown on the drawings. The equipment shall be metal enclosed, NE MA 12 and/or NEMA 3R gasketed as indicated.
a. Enclosed control stations shall be pr ovided as indicated and specified in this Section.
b. Enclosed combination starters shall be provided as indicated and as specified in this Section.
1.02 SUBMITTALS
Submit for the Owner's approval material lists, shop drawings, factory test reports, manufacturers' certified reports and technical data to the extent required in this Section and Section 16010.
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A. Shop Drawings. In addition to the inform ation required to be included in the shop drawings as specified in Section 16010, shop drawings shall include the following:
1. Schematic and elementary wiring diag rams, for each control unit, showing numbered terminal points, numbered wi res and numbered interconnections to other equipments and remote devices.
2. Connection wiring diagrams, for each cont rol unit, showing numbered terminal points, numbered wires and numbered inte rconnections to other equipment and remote devices.
3. Numbering of external wiring to othe r equipment and remote devices may be included in the Operation and Maintenance Manuals.
4. Complete catalog inform ation for all components.
5. A complete list of parts, with prices, th at would be necessary to maintain and/or modify the equipment.
PART 2 - PRODUCTS
2.01 GENERAL
Provide all the equipment and ma terials and complete the contro l installations as shown on the Drawings, specified and required. Sizes of equipment shown on the Drawings and space allowed for the equipment are based on equipment manuf actured by only one of the listed acceptable manufacturers. The manufacturers and models lis ted in this Section of the Specification are acceptable providing they conform to the Specificat ions and that the equipment and materials provided fit properly in the available space. Refer to Section 16100 for conduits, conductors, overcurrent protective devices and nameplates.
2.02 MOTORS AND CONTROLS
The motors shall be furnished and installed with the driven equipment as indicated and specified in Division 11 and Section 16150.
A. Motor Wiring shall be provided as shown on the Drawings. Include the wiring interconnections between the motors, motor st arters, control panels and controls as required.
B. Control Power shall be 120 volts, single phase and 60 hertz unless otherwise indicated.
A separate control transformer shall be provided for each motor magnetic starter, contactor and grouped relays as indicated.
C. Control Stations shall be heavy duty, oil- tight and shall consist of operators, contact blocks and legend plates. Control stations shall be included in equipment as shown on the drawings. The pushbutton, selector switc h, cylinder lock and pilot light operators shall include the number of units as indicated and requi red. Operators shall be non-illuminating and black, except the "STOP" button shall be red. Provisions shall be included for locking the "STO P" button in the depressed position, and locking the selector switch in the "OFF" position. Cyli nder lock operators shall be provided as City of Anaheim Electrical Controls
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indicated. Locks shall be keyed alike a nd provide two keys. Pushbutton operators shall have full guards, momentary or maintain ed contacts as indi cated and required.
Legend plates shall indicate the operator func tions. Selector switch operators shall have standard knobs with manual return a nd the indicated positions. Indicating lights shall be transformer type, push-to-test, 60 hertz with 6 volt lamps and color caps as shown on the drawings. The c ontrol stations shal l be Square D Class 9001, Type K, Cutler Hammer Type T, Allen-Bradley Bulletin 800T, General Electric Type CR2940 or equal.
D. Magnetic Contactors shall be electrically held unless otherwise indicated, 600 volt, 60 hertz, industrial duty, and connected to 120 volts AC circuit with remote control device. The Drawings shall indicate the number of poles and ampere ratings or NEMA size for the contactors and the locations, which shall be mounted inside motor control centers, panelboards or separate metal enclos ures as indicated. Contactors shall be NEMA type and NEMA rated; IEC type an d rated contactors are not acceptable.
Enclosures shall be finished as specifie d in Section 16010. The silver alloy power contacts shall be load break within the rating of the contactor without assistance from additional arcing contacts. The magnetic co il shall be continuous duty, encapsulated and easily removable. The magnet shall provide rapid action on pickup or dropout and satisfactory operation without hum. The 120 volt circuit shall be provided by an individual control power transformer for ea ch contactor. The contactors shall be Square D Class 8903, Cutler-Hammer Type C30, Allen-Bradley Bulletin 500L or equal.
E. Magnetic Starters shall consist of a ma gnetic contactor equipped with an ambient compensated overload relay in each phase a nd an external manual reset button. The overload relays shall be thermal bi-metallic types. All relays shall be of the same type.
NEMA sizes for magnetic starters shall be shown on the Drawings. Motor starters shall be NEMA type and NEMA rated; IEC type an d rated starters are not acceptable. The molded magnetic coil shall be connected to the 120 volt, 60 hert z control circuit and shall operate satisfactorily through a range of plus and minus 10 percent of the control circuit voltage. Each motor starter shall be equipped with minimum two normally open and two normally closed auxiliary contacts.
F. Relays shall be provided as specified in this Section and as shown on the Drawings.
G. Manual Motor Starters shall be provided for controlling and protecting single phase motors as shown on the Drawings and as re quired. The starters shall consist of a manually operated toggle switch equipped with proper overload relays, box and cover.
The Drawings shall indicate the number of poles, the loads and the starter locations which shall determine the types of enclosure. The starters snap action shall be obtained by a spring over- center toggle. The contacts shall be opened and closed with positive force. The overload shall opera te on the thermal principle. Indication of an overload condition shall be provided by the toggle operator tripping into the center of the normal "ON" and "OFF" positions. On the front of th e enclosure, attach a plastic, laminated nameplate which identifies the load. The manual motor starters shall be Allen-Bradley Bulletin 600, Cutler-Hammer Type B200, Square D Class 2510 or equal.
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2.03 MOTOR CONTROL CENTERS
Provide the metal enclosed motor control cente rs as indicated, specifi ed and required. The enclosures shall be NEMA 12 indoors and NEMA 3R gasketed outdoors, unless otherwise noted.
The motor control centers shall be completely fabricated, assembled, wired, checked and tested at the factory in compliance with applicable NEMA, ANSI and UL standards, and shall be Cutler-Hammer "Series 2100", General Electric "8000 Line," Allen-Bradley "Centerline," Square D "Model 6", or equal by Klochner Moeller. Shipment shall be made in sections to facilitate field handling, and the shipped sections shall be joined together to form a complete back-to-wall or back-to-back unit assembly as indicated. The equipment shall be finished as specified in Section 16010. The motor control center shall line up with and include the service equipment specified in Section 16400.
A. Vertical Sections shall contain adequate space for connecting the incoming power supply conductors, outgoing branch circuits, motor and control circuits to terminals, horizontal and vertical power bus bars, horizontal gr ound bus, circuit breakers, magnetic starters, contactors, control stations, pilot lights, timers, terminals, transformers, panelboards, relays, and manual transfer switches. The vertical sections shall be fabricated from heavy gauge stee l, in compliance with UL 845, with uniform surfaces, and shall be 90 inches high, 20 inches wide and 20 inches deep as indicated and required. Holes shall be provided in the structural base of each section for anchor bolts. Sections shall contain wireways, br ackets, supports, plat es, trims, barriers, gaskets, doors, base channels, lifting angles and hardware. Each section shall have a maximum of six vertical control units, which can enclose Size 1 and Size 2 full voltage non-reversing combination starters. Hori zontal wireways (top and bottom) shall extend through the width and depth of th e section. Wireway openings shall be provided between sections with closing plates on the end sections. Each vertical section shall contain its own individual full height vertical wireway separated from the vertical bus by a metal barrier, and also se parated from the indi vidual control unit by the side pan of the control unit. Wire ties shall be furnished in the vertical wireways to group and securely hold the conductors in place. A separate cover shall be provided on the vertical wireway. Contro l units shall be isolated fr om one another by horizontal steel barriers. Front to rear bracing shall not interfere with the conduit entrance areas.
Hinged doors shall be equipped with screwd river operated quarter -turn latches that catch automatically when the door is pushed closed. Large doors shall be equipped with additional latches. The door shall be furnished with a removable control device panel. Provision shall be included to add a vertical section on the end of the line up in the future.
B. Power Supply Compartment shall be sized to accommodate the incoming power conductors. The compartment shall be locate d at the top or bottom of the vertical section as shown on the Drawings. The pow er compartment shall be covered by a hinged door and shall be held closed with quarter-turn pawl type latches.
C. Bus Bars shall be provided for the power and ground systems. Bus joints shall be connected with bolts, nuts and spring washers. The main horizontal power bus shall be located in the center or near the top of each section, jo ined together to form a City of Anaheim Electrical Controls
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continuous bus for the full length of the mo tor control center. The horizontal power bus shall be copper and the current rating shall be as shown on the Drawings. The vertical power buses shall be copper full height and rated for the section total load. The minimum current rating for the vertical power buses shall be 300 amperes. The power bus bars shall be braced to withstand short circuit currents of 42,000 RMS symmetrical amperes at 480 volts unless otherwise indica ted. The horizontal and vertical power buses shall be rigidly supported on molded insulators, and enclosed with non-metallic barriers. Small openings in the vertical ba rriers shall permit th e plug-on control unit contacts to pass through and engage with the vertical bus bars. Unused plug-on openings in the vertical barriers shall be equipped with plastic snap-in closing plugs. In the bottom horizontal wireway, provide a 1/ 4 inch by 2 inch copper ground bus, and splices that connect the bus in each secti on for the full length of the motor control center. Each vertical section shall contain a 1/8 inch by 1 inch copper, vertical ground bus connected to the horizontal ground bus.
D. Control Units shall be plug-on type, metal enclosed, with a single door, and contain the equipment indicated and required. The plug-on contacts shall be a high quality two point connection for each phase. The contacts shall be se lf-aligning, copper, silver plated and backed by steel clips to provide high pressure connections. An interlock shall be provided to prevent insertion or removal of the control unit unless the circuit is in the "OFF" position. There shall be a copper ground plug-on contact, in each control unit, that engages the vertical ground bus prior to the phase plug-on contacts engaging the vertical power bus. The unit door shall be equipped with the required control stations, pilot lights, reset pushbutton, hard ware and other indicated devices. An operator handle, with positive handle posi tion indication, shall be provided on the control unit door for each circuit breaker. The handle shall have an up-down motion or equal, and the down position shall be "OFF". It shall be possible to lock the operator handle in the "OFF" position with a padlock. The handle shall be interlocked with the control unit door so that the circuit breaker cannot be placed in the "ON" position when the door is open, nor can the door be opened wh en the circuit breaker is in the "ON" position without by-passing the interlock by us ing a small screwdriver. The highest position of the circuit breaker operator ha ndle shall not exceed 78 inches above the floor with the motor control center installed on a concrete housekeeping pad as shown on the Drawings. The control units shall accommodate the circuit breakers, magnetic starters, reset buttons, contactors, switches, transformers, control circuit fuses, control stations, relays, timers, pilot lights, wiring, terminals and nameplates as indicated.
Each control unit shall be sized to acco mmodate the required relays and other equipment as shown on the Drawings. There shall be a provision to disconnect external 120 volts control circuits inside the control unit when the circuit breaker is opened.
E. Circuit Breakers shall be molded case, 600 volt, three pole and two pole, and shall have the ampere trip ratings as shown on the dr awings, and as specified in Section 16100.
The circuit breakers shall operate satisfact orily in an ambient temperature of 40 degrees centigrade. Each circuit breaker shall have a single operating handle, positive handle indication and proper wire connectors. Circuit breakers shall be equipped with lugs properly sized to terminate all requi red conductors as shown on the Drawings.
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Circuit breakers in combination motor starte rs shall be instantaneous (motor circuit protector) type.
F. Provide solid-state soft start type moto r starter of the size shown on the drawings.
Solid-state starter shall be equipped with fast acting fuses for SCR protection, and surge protection device on the line side of so lid-state starter. Starter motor protection module shall protect the motor. Provide Mu ltilin 269 plus motor protector relay.
Provide current transformers and motor tr ip connection as shown on the drawings.
Solid-state starter shall be G.E. Astat-CD rated for continuous duty with no bypass, with the LCD mounted on the exterior face of the door, 5-feet above finished floor.
G. The pumps’ electric motors shall be equi pped with variable frequency drives (VFDs).
The contractor shall furnish and install two (2) VFDs, each rated at 480 VAC , 60 Hz, 3 phase, variable torque type, and with ampe rage ratings of 30 amps or 125% of the motor full load rating, whichever is greater. The motor cont rol center and VFDs shall be installed outdoors as shown on the drawings. The VFD shall be capable of accepting supply variation of 480 volt plus or minus 10% at 60 hertz pl us or minus 3 hertz. The VFD shall be designed to operate in conjunction with a standard NEMA electric motor, as specified in subsection 6-02.01, and shall attain an efficiency of at least 95% at full load. These drives shall also have the following features:
1. AC line reactor 3 phase
2. DC choke
3. Nema 3R enclosure for mounting outdoors
4. Isolated digital relay out puts (running, fail and ready)
5. Isolated digital inputs (run, stop)
6. Isolated analog input 4-20 mA (speed control)
7. Isolated analog output 4-20 mA (speed indication)
8. Made for centrifugal pump application
9. Motor rating 1800 rpm
10. Keypad 3m extension cable
The VFDs shall be Danfoss VLT® 5000 seri es or Hitachi J300 se ries, or approved equal. Manual constant speed operation of each pump shall be possible in case of failure of its VFD. The control system shall also permit either pump to operate on hand variable speed. Spare parts sufficient to maintain the VFD shall be provided. The Contractor shall provide the required spare parts.
H. Provide two speed full voltage non-reversin g motor starters as shown on the drawings.
I. Provide dry type transformer in motor control center as shown on the drawings.
Transformer shall be 480 volt primary, 120/ 240V secondary, single phase, 3-wire, KVA rating is shown on the drawings. Transformer shall be factory mounted by MCC manufacturer. Transformer shall be equippe d with two 5% full capacity taps below primary voltage. Transformer winding temperature rise shall not exceed 115 oC under
full load condition.
J. Control Stations shall be provided as s hown on the Drawings and specified in this Section.
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K. Panelboards shall be provided as shown on the Drawings and sp ecified in Section 16100.
L. Control Transformers shall be encapsulat ed dry-type, single pha se, 60 hertz, with 120-volt secondary voltage. A separate co ntrol transformer shall be provided for grouped relays, space heaters and each starte r and contactor. Control transformers shall have both primary and secondary fused protection and a grounded secondary.
Transformers shall be provided as shown on the Drawings.
M. Relays shall be open type, and provided in the motor control ce nter as shown on the Drawings and specified in this Section. Th e motor control center plug-in control unit shall have adequate space for the required control and time delay relays and the other indicated equipment.
N. Repeat Cycle Timers shall be open type and provided inside the motor control centers as shown on the drawings, sp ecified and required. The ti mers shall be tork, A.T.C., Eagle or equal. Timer contacts shall be heavy duty, single pole, double throw, rated 20 amperes and 240 volts AC. The timing motor shall be self-starting, synchronous, 120 volts, 60 hertz and rated fo r a temperature range of minus 60 degrees to plus 150 degrees Fahrenheit. The dial shall be approximately 3-1/4 inches in diameter, and shall be adjustable from 2-minute (minimum) cycles to 60-minute (maximum) cycles.
Terminals shall be provided for the required remote wiring.
O. Interval Timers shall be open type and provided inside the motor control centers as shown on the Drawings, specified and required. The interval timers shall be A.T.C., Eagle, Tork or equal. Timer contacts shall be heavy duty, 120 volts, AC, and 40 amperes. The timing motor shall be self- starting, synchronous, 120 volts, 60 hertz and rated for a temperature range of minus 60 degrees to plus 150 degrees Fahrenheit. The large dial shall be adjustable at any select ed hour or hours. The small dial shall be adjustable from 1 to 24 hours. Terminals sh all be provided for the required remote wiring.
P. Wiring shall be NEMA Class II, Type B for the motor control centers, and the control conductors shall be No. 14 AWG minimum. The wire shall be 600 volt, single conductor, 90 degrees centigrade and Type MTW. The wiring shall be provided with pull-apart terminals for power and controls inside each motor control unit. The pull-apart terminals shall be 600 volt, pr operly marked and shall accommodate the conductors shown on the drawings.
2.04 CONTROL RELAYS
Control relays shall be provided for the control and alarm circuits as shown on the Drawings and as required. The relays shall be electrically held, 60 hertz, continuous duty, multipole, connected to 120-volt ac control circuits and mounted inside motor control centers or separate metal enclosures as indicated. Enclosures shall be finished as specified in Section 16010. Control relays shall have convertible contacts with a continuous rating of 10 amperes at 75 percent power factor. The relay base assembly shall accept from 1 through 8 conv ertible poles. Magnetic coil inrush power for relays 2-8 poles shall be approximately 155 volt-amperes, and the operating time shall average 10 milliseconds. Relays shall be attached to pre-spaced mounting channels with captive screws. The City of Anaheim Electrical Controls
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control relays shall be Cutler-Hammer Type D 26, Allen-Bradley Type P, Square D Type X or equal.
PART 3 - EXECUTION
3.01 GENERAL
Provide all the control equipment installations , wiring installations and tests, including connections and interconnections for the electrica l controls as indicated, specified and required.
Assure proper fits for all equipment and materials in the spaces shown on the Drawings.
3.02 CONTROLS
Install the metal enclosed control equipment as indicated, specified and required.
A. Equipment shall be installe d level and securely attached to the concrete foundations and walls with expansion anchor s. The sections shall be joined together with bolts, nuts and washers to form a complete unit assembly. Floor standing equipment shall be installed on concrete housekeeping pads as shown on the Drawings.
B. Wiring installations shall be complete as indicated and specified in Section 16l00.
C. Relays. Provide the control and time delay relays as shown on the drawings and as required. Adjust the time delay relays so motors shall start- up in proper sequence.
D. Nameplates shall be attached to clean su rfaces of the metal encl osures with stainless steel screws. Identify relays, contactors, timers, etc. with typed label, W.H. Brady or equal, in accordance with the tag numbers shown on the Drawings. Install one label on panel adjacent to the device and a second la bel affixed to the device. “Dymo” type labels shall not be used.
E. Grounding shall be provided as shown on th e Drawings and specified in Section 16100.
F.
Checking, Adjusting and Testing operations on equipment and complete installations shall be performed as specified in Sections 16100 and 16960.
3.03 MOTOR CONTROLS
Install all the wiring and control equipment as indicated, specified and required.
A. Motors. Motors shall be provided w ith the driven mechanical equipment.
B. Wiring. The wiring installations shall be complete. Include all the required wiring interconnections between the motor magnetic starters, and between the starters and the instrument control panels. Provide motor frame conduit connection boxes as required.
Be certain that all wiring connections provide the proper motor rotation.
C. Control Stations. Provide the control stat ions near motors as shown on the drawings.
D. Magnetic Starters. The magnetic starters sh all be provided in the motor control centers unless otherwise indicated.
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3.04 PAINTING
A. Field damaged factory finish es shall be touched-up with paint that matches the original equipment finish as specified in Division 9 Section 09900.
END OF SECTION 16900
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SECTION 16960
ELECTRICAL EQUIPMENT TESTING
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements of Conditions of the Contract, Division 1, Section 16010 and Section 16100 form a part of this Section.
A. Work Included in This Section.
1. Testing of electrical equipment.
B. Related Work Included in Other Divisions and Sections.
1. Basic Electrical Materials and Methods, Section 16100.
2. Service and Distribution, Section 16400.
3. Electrical Controls, Section 16900.
1.02 REFERENCES
The inspections and tests shall be in accordance with the following applicable codes and standards except as provided otherwise herein.
A. National Electrical Code - NEC (NFPA 70).
B. National Electrical Manufacturer’s Association - NEMA.
C. American Society for Testing and Materials - ASTM.
D. Institute of Electrical and Electronic Engineers - IEEE.
E. National Electrical Testing Association - NETA.
F. American National Standards Institute - ANSI.
G. State and Local Codes and Ordinances.
H. Insulated Cable Engineers Association - ICEA.
J. Illuminating Engineering Society - IES.
K. OSHA Part 1910; Subpart S, 1910.308.
L. National Fire Protection Association - NFPA.
M. Power Producers Interconnection Handbook - Pacific Gas and Electric Company.
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1.03 SUBMITTALS
A. Prior to the Start of Work
1. Qualifications of Testing Service Comp any. The Owner reserves the right to disqualify any Test Service or te sting personnel based upon qualification submitted.
2. Contractors Test and Report Forms.
B. Upon completion of testing provide formal Test Report to include the following:
1. Summary of project.
2. Description of equipment tested.
3. Description of test.
4. Test results.
a. The following is a list of reports a nd forms that the Contractor or the Testing Service shall use in reporting the results:
(1) Instrument Calibration Test and Data Sheet (2 sheets). (2) Low Voltage Circuit Breaker Test Report.
(3) Switchboard Inspection Report.
(4) Ground Fault System Test Report.
(5) Watthour Meter Calibration Report.
(6) Insulation Resistance Test Report.
(7) DC High Potential Test Report.
(8) Distribution Switchboard Test Report.
(9) Switchboard Metering Test Report.
(10) Motor Control Center Test Report.
b. Contractor may use its standard forms in place of the forms provided if they provide essentially the same information.
1) Submit forms for approval.
c. Where test forms are not provided Contractor may provide its own forms. 1) Submit forms for approval.
5. Conclusions and recommendations.
6. Appendix, including appropriate completed test forms.
7. List of test equipment used and calibration date.
1.04 QUALIFICATIONS
A. The Testing Service shall meet federa l OSHA criteria for accreditation of testing laboratories, Title 29, Part 1907.
B. Testing Services shall submit proof of the above qualifications to the Engineer.
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1.05 SYSTEM DESCRIPTION
A. The Contractor shall engage the services of a recognized Testing Service for the purpose of performing inspections and tests for equipment safety and operability, and functionally verify the control system operates in accordance with the contract documents.
B. The Testing Service shall provide all material, equipment, labor and technical supervision to perform such tests and inspections.
C. The intent of these tests is to assure th at all electrical equipment is operational within industry and manufacturer’s tolerances and to functionally test all electromechanical systems.
D. Upon completion of the tests and inspections noted in these Specifications, a label shall be attached to all devices tested. These labels will indicate date tested and the service company responsible.
E. The tests and inspections shall determine suitability for continuous reliable operation.
F. The Contractor may submit another electrical equipment test procedure in lieu of this Section to the Owner for approval.
G. The Contractor and to facilitate the project start-up and commercial operation.
H. The inspections and tests shall utilize the following references.
1. Project design Specifications.
2. Project design Drawings.
3. Manufacturer’s instruction manuals applicable to each particular apparatus.
4. Contractor generated drawing and documents.
5. Contract Drawings submitted by manufacturers and vendors.
I. All instruments used to evaluate elect rical performance shall meet Specifications for Test Instruments (refer to Part 2 of this Specification).
J. Electrical performance tests shall include the following:
1. Control panels.
2. Motor control centers.
3. Distribution switchboards.
4. Low voltage circuit breakers.
5. 600 volt feeder cables.
6. Current and potential transformers.
7. Grounding systems.
8. System functions tests.
9. Generators.
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K. The Contractor shall perform routine insula tion resistance, continuity and rotation tests for all distribution and utilization equipment prior to and in addition to tests performed by the Testing Service specified herein.
L. The Contractor shall notify the Owner when equipment becomes available for electrical tests. Work shall be coordinated to expedite project scheduling.
M. The Contractor shall supply a set of elect rical plans, specifications and any pertinent change orders to the Testing Service prior to commencement of testing.
N. The Contractor shall notify the Owner prior to commencement of any testing.
O. The Testing Service shall be responsib le for implementing the final settings and adjustments on protective devices and el ectrical equipment in accordance with approved values. Refer to Section 16100 for coordination study requirements.
P. Set points shall be noted on all calibration stickers.
Q. Any system material or workmanshi p which is found defective on the basis of electrical tests shall be replaced and retested at no additional cost to the Owner.
R. The Testing Service shall maintain a writte n record of all tests and upon completion of the project, assemble and certify a final test report.
PART 2 - PRODUCTS
2.01 TEST INSTRUMENT TRACEABILITY
A. The Testing Service shall have a calibrati on program which maintains applicable test instrumentation within rated accuracy.
B. The accuracy shall be traceable to the Na tional Institute for Standards and Technology in an unbroken chain.
C. Instruments shall be calibrated in accordance with the following frequency schedule:
1. Field instruments - 6 months maximum.
2. Laboratory instruments - 12 months.
3. Leased specialty equipment - 12 months . (Where accuracy is guaranteed in writing by the lessor.)
D. Dated calibration labels shall be visible on all test equipment.
E. Records must be kept up to date which show date and results of all instruments calibrated or tested.
F. An up-to-date instrument calibration instru ction and procedure will be maintained for each test instrument.
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PART 3 - EXECUTION
3.01 SAFETY AND PRECAUTIONS
A. Safety practices shall include, but are not limited to, the following requirements:
1. Occupational Safety and Health Act of 1970-OSHA.
2. Accident Prevention Manual for Industr ial Operations, Seventh Edition, National Safety Council, Chapter 4.
3. Applicable State and local safety operating procedures.
4. NETA Safety/Accident Prevention Program.
5. National Fire Protection Association - NFPA 70 (NEC).
6. National Fire Protection Associati on - National Electrical Safety Code.
B. All tests shall be performed with a pparatus de-energized except where otherwise specifically required herein.
C. The Testing Service’s lead test engineer for the project shall be a designated safety representative and shall be present on the project and supervise testing operations and safety requirements.
D. Power circuits shall have conductors shorted to ground by a hotline grounding device approved for the purpose.
E. In all cases, work shall proceed only when the safety representative has determined that it is safe to do so.
F. The Testing Service shall have available sufficient protective barriers and warning signs to conduct specified tests safely, and shall post safety personnel as necessary while dangerous tests are being performed.
G. The Owner’s safety procedures shall be reviewed and understood by the Contractors and Testing Service personnel.
3.02 SPECIAL REQUIREMENTS
Testing of the equipment associated with the inte rconnection to the local utility is required to be tested in strict accordance with the methods and procedures of the “Power Producers Interconnection Handbook.”
A. Where the methods or procedures required under this Section are in conflict with the “Power Producers Interconnection Handbook” the requirements of the “Power Producers Interconnection Handbook” shall govern.
B. The Testing Service is responsible for:
1. Obtaining the latest edition of the “Power Producers Interconnection Handbook.”
2. Coordinating with the local utility in the performance of the required tests.
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3.03 TEST PROCEDURES
A. Metering and Instrumentation
1. Visual and Mechanical Inspection
a. Examine all devices for broken parts, indication of shipping damage and wire connection tightness.
b. Verify meter connections in accordance with single line meter and relay diagram.
2. Electrical Tests
a. Calibrate all meters at mid-scale. Calibration instruments shall have precision no more than fifty percent (50%) of the instrument being tested. b. Calibrate watt-hour meters to one-half percent (1/2%). c. Verify all instrument multipliers.
B. Main Switchboards
1. Visual and Mechanical Inspection
a. Inspect for physical damage, proper anchorage and grounding. b. Compare equipment nameplate data with design plans or starter schedule. c. Check tightness of bolted connections.
2. Electrical Tests
a. Insulation Tests. Measure insulation resistance of each bus section phase to phase and phase to ground for one (1) minute. Test voltage and minimum acceptable values in accordance with Table 16960.2.
3. Test Values
a. Bolt torque levels shall be in accordance with Table 16960.1 unless otherwise specified by manufacturer.
b. Insulation resistance test to be performed in accordance with Table 16960.2.
C. Circuit Breakers - Low Voltage
1. Visual and Mechanical Inspection
a. Inspect for physical damage and nameplate compliance with single line diagram.
b. Mechanical operational tests shall be made in accordance with manufacturer s instruction manual.
c. Cell fit and element alignment shall be checked.
d. Check tightness of connections.
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2. Electrical Tests
a. A contact resistance test shall be performed.
b. An insulation resistance test shall be performed at 1,000 volts DC for one (1) minute from pole to pole and from each pole to ground and across open contacts of each phase.
c. Minimum pickup current shall be determined by primary current injection. d. Long time delay shall be determined by primary injection at three hundred percent (300X) pickup current.
e. Short time pickup and time delay shall be determined by primary injection of current.
f. Instantaneous pickup current shall be determined by primary injection. g. Trip unit reset characteristics shall be verified.
h. Adjustments shall be made for final settings in accordance with prescribed settings.
i. Auxiliary protective devices, such as ground fault or under-voltage shunt trip devices.
3. Test Values
a. Contact resistance shall be determ ined in micro-ohms. values exceeding two hundred (200) micro-ohms or any va lues which deviate from adjacent poles or similar breakers by more th an fifty percent (50%) should be investigated.
b. Insulation resistance shall not be less than fifty (50) megohms. c. Minimum pickup current, trip times and instantaneous pickup values shall be adjusted to approved settings. Test values should fall within manufacturer’s published time-current characteristic tolerance band.
D. Cables - Low Voltage (600 Volt Feeders)
1. Visual and Mechanical Inspections
a. Inspect exposed section for physical damage.
b. Verify cable is supplied and connected in accordance with single line diagram.
c. Inspect for cable support and termination.
d. Visible cable bends shall be check ed against ICEA or manufacturer’s minimum allowable bending radius.
2. Electrical Tests
a. Dielectric absorption (“megger”) test.
(1) Tests shall be phase-to-phase and phase-to-ground.
(2) Test for 5 minutes at voltage given in Table 16960.2.
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3. Test Values
a. Dielectric absorption test results.
(1) Minimum acceptable values of insulation resistance shall be as recommended by the cable manufacturer.
(2) Test should show no evidence of cable damage.
E. Instrument Transformers
1. Visual and Mechanical Inspection
a. Inspect for physical damage and compliance with design drawings. b. Check mechanical clearances and proper operations of all disconnecting and grounding devices associated with potential transformers. c. Verify proper operation of grounding or shorting devices.
2. Electrical Tests
a. Confirm transformer polarity electrically.
b. Verify connection at secondary CT leads by driving a low current through the leads and checking for this current at applicable devices. c. Confirm transformer ratio.
d. Measure insulation resistance of transformer secondary and leads with five hundred (500) volt megohm meter.
e. Measure transformer primary insulation with applicable overpotential tests. f. Verify connection of secondary PT leads by applying a low voltage to the leads and checking for this voltage at applicable devices. g. Check for PT secondary load with secondary voltage and current measurements. Make sure load is less than VA of PT.
F. Grounding Systems
1. Visual and Mechanical Inspection. In spect ground system for compliance with plans and specifications.
2. Electrical Tests
a. Perform fall of potential test per IEEE Standard No. 81, Section 9.04 on the main grounding electrode or system.
b. Perform the two (2) point method test per IEEE No. 8, Section 9.03 to determine the ground resistance between the main grounding system and all major electrical equipment frames, syst em neutral and/or derived neutral points.
3. Test Values. The main ground electrode system resistance to ground should be ten (10) ohms or less unless otherwise specified.
Electrical Equipment Testing
City of Anaheim 16960 ‐ 9 06/27/13
G. Generators
1. The following tests shall be done in the presence of the Owner, and the generator manufacturer’s representative.
a. Phase rotation to be the same as the utility.
b. Phase relation to be the same as the utility.
c. Polarity.
d. Equality of voltage before connecting to the utility.
2. The tests shall be performed by the Tes ting Service with the appropriate test devices including a phase rotation meter.
3. Scheduling of these tests and notifying the parties to attend is the responsibility of the Contractor.
4. The tests shall be done in accordance with IEEE Std. 115.
H. Motor Control Centers
1. Visual and Mechanical Inspection
a. Inspect for physical damage, proper anchorage and grounding. b. Compare equipment nameplate data with design plans or starter schedule. c. Compare overload heaters with motor full load current for proper size.
Adjust size for service factor, temper ature differences and time delay in accordance with the NEC Article 430 C and with the starter manufacturer’s recommendations.
d. Check tightness of bolted connections.
2. Electrical Tests
a. Insulation Tests
(1) Measure insulation resistance of each bus section phase to phase and phase to ground for one (1) minute. Test voltage and minimum acceptable values in accordance with Table 16960.2.
(2) Measure insulation resistance of each starter section phase to phase and phase to ground with the starter contacts closed and the protective device open. Test voltage and minimum acceptable values in accordance with Table 16960.2.
(3) Measure insulation resistance of each control circuit with respect to ground.
(4) Motor overload units shall be tested by injecting primary current through overload unit and monitoring trip time.
b. Perform operational tests by initiating control devices to affect proper operation.
c. Check and verify callibration of motor winding RTDs, and vibration switch.
d. Check and verify the operation of the motor protective relay (MPR).
Electrical Equipment Testing
City of Anaheim 16960 ‐ 10 06/27/13
3. Test Values
a. Bolt torque levels shall be in accordance with Table 16960.1 unless otherwise specified by manufacturer.
b. Insulation resistance test to be performed in accordance with Table 16960.2.
c. Control wiring insulation test volta ge shall be 500V DC. Manufacturer shall be consulted for test voltage where solid state control devices are utilized.
d. Overload tests shall be made at th ree hundred percent (300%) of motor full load current. Trip times shall be in accordance with manufacturer’s tolerances. Values in excess of one hundred twenty (120) seconds shall be investigated.
Electrical Equipment Testing
City of Anaheim 16960 ‐ 11 06/27/13
3.04 TABLES
TABLE 16960.1
US Standard
BOLT TORQUE’S FOR BUS CONNECTIONS
Heat Treated Steel Silicon Bronze Fasteners*
Grade SAE
1 & 2
SAE
5 SAE
6 SAE
8 Minimum
Tensile
(PSI)
64K
105K
133K
150K
Bolt
Diameter
Torque
(Foot Pounds)
Bolt
Diameter
Torque (Foot Pounds) Non-Lubric
ated
Lubricated
¼ 5 7 10 10.5 5/16 15 10
5/16 9 14 19 22 3/8 20 14
3/8 15 25 34 37 1/2 40 25
7/16 24 40 55 60 5/8 55 40
½ 37 60 85 92 3/4 70 60
9/16 53 88 120 132 Aluminum Alloy Fasteners**
5/8 74 120 167 180 Bolt Torque (Foot Pounds)
¾ 120 200 280 296 Diameter Lubricated
7/8 190 302 440 473 5/16 8.0
1.0 282 466 660 714 3/8 11.2
Note: Reduce torque by 20% when 1/2 20.0
Cadmium plated bolts are used. 5/8 32.0
3/4 48.0
* Bronze alloy bolts shall have a minim
tensile strength of 70,000 pounds
square
inch.
**Aluminum alloy bolts shall have a
Minimum tensile strength of 55,000
pounds per square inch.
Electrical Equipment Testing
City of Anaheim 16960 ‐ 12 06/27/13
Grade SAE
1 & 2
SAE
5 SAE
6 SAE
8 Minimum
Tensile
(PSI)
64K
105K
133K
150K
Bolt
Diameter
Torque
(Foot Pounds)
Bolt
Diameter
Torque (Foot Pounds) Non-Lubric
ated
Lubricated
Electrical Equipment Testing
City of Anaheim 16960 ‐ 13 06/27/13
TABLE 16960.2
INSULATION RESISTANCE TEST VOLTAGE
Maximum Voltage
Rating of
Equipment
Minimum Test
Voltage, DC
Minimum Insulation
Resistance in
Megohms
250 500 25
600 1,000 100
5,000 2,500 1,000
8,000 2,500 2,000
15,000 2,500 5,000
Values of insulation resistance less than manufacturer’s minimum or kV + 1 in megohms should be investigated. Overpotential tests should not proceed until insulation resistan ce levels are raised to said minimum.
TABLE 16960.3
AC/DC OVERPOTENTIAL TEST VOLTAGES
Rated kV
AC Test
Voltage (kV)
DC Test
Voltage (kV)
15 27.0 37.5
69 115.0 Consult Manufacturer
Electrical Equipment Testing
City of Anaheim 16960 ‐ 14 06/27/13
TABLE 16960.4
INSULATION RESISTANCE CONVERSION FACTORS
FOR CONVERSION OF TEST TEMPERATURE TO 20C
TEMPERATURE TRANSFORMER
C F OIL DRY
0 32 .25 .40
5 41 .36 .45
10 50 .50 .50
15 59 .75 .75
20 68 1.00 1.00
25 77 1.40 1.30
30 86 1.98 1.60
35 95 2.80 2.05
40 104 3.95 2.50
45 113 5.60 3.25
50 122 7.85 4.00
55 131 11.20 5.20
60 140 15.85 6.40
65 149 22.40 8.70
70 158 31.75 10.00
75 167 44.70 13.00
80 176 63.50 16.00
Electrical Equipment Testing
City of Anaheim 16960 ‐ 15 06/27/13
TABLE 16960.5
HIGH VOLTAGE TEST
FOR RUBBER - THERMOPLASTIC - XLPE - EPR INSULATIONS
Rated circuit
Phase to Phase,
Volts
Conductor Size
AWG or KCMIL
Test Voltage, kV
100 Percent
Insulation Level
133 Percent
Insulation Level
2,001-5,000 8-1,000 25 25
5,001-8,000 6-1,000 35 35
8,001-15,000 2-1,000 55 65
TEST MAXIMUM DC VOLTAGE REFERENCES
Cable Type Standard
Rubber ICEA S-19-81 Table 6-17
Varnish Cambric ICEA S-65-375 Table 3-4*
Thermoplastic ICEA S-61-402 Table 6-10
Cross Linked Polyethylene ICEA S-66-524 Table 6-9
Ethylene Propylene (EPR) ICEA S-68-516 Table 6-9
Armored Cable ICEA S-67-401 80% of factory
* For DC tests multiply table values by 2.
** Consult manufacturer.
END OF SECTION 16960
City of Anaheim
1 6/27/13
CITY OF ANAHEIM
APPENDIX F
CIVIL WORK SPECIFICATION
Table of Contents
City of Anaheim 6/27/13
CIVIL WORK SPECIFICATION
TABLE OF CONTENTS
APPENDIX F
DIVISION 2 - SITEWORK
02200 Earthwork
02221 Trenching, Backfilling and Compacting for Utilities
DIVISION 3 - CONCRETE
03200 Reinforcing
03300 Cast-In-Place Concrete
DIVISION 5 - METALS
05990 Structural and Miscellaneous Metals
DIVISION 7 - SEALANTS AND CAULKING
07920 Joint Sealants
DIVISION 9 - FINISHES
09900 Painting and Protective Coatings
Earthwork
City of Anaheim 02200-1 06/27/13
SECTION 02200
EARTHWORK
PART 1 - GENERAL
1.01 QUALITY ASSURANCE
A. Referenced Standards:
1. American Society for Testing and Materials (ASTM):
a. C33, Standard Specification for Concrete Aggregates. b. D1557, Tests for Moisture Density Relations of Soils and Soil Aggregate Mixtures Using a 10 LB Rammer and a 18 IN Drop. c. D2487, Classification of Soils for Engineering Purposes. d. D4253, Test Methods for Maximum Index Density of Soils Using a Vibratory Table.
e. D4254, Test Methods for Minimu m Index Density of Soils and Calculation of Relative Density.
1.02 SUBMITTALS
A. Shop Drawings:
1. Product technical data including:
a. Acknowledgment that products submitted meet requirements of standards referenced.
2. Certifications.
3. Test reports:
a. Soils inspection and testing results.
B. Samples:
1. Submit samples and source of fill and backfill materials proposed for use.
2. Submit samples and source of borrow materials proposed for use.
PART 2 - PRODUCTS
2.01 MATERIALS
A. Fill and Backfill: Selected material approved by Soils Engineer from site excavation or from off site borrow.
B. Granular Fill Under Building Slabs: Select material approved by Soils Engineer.
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C. Granular Fill Under outdoor Slab-O n-Grade: Clean, crushed, nonporous rock, crushed or uncrushed gravel complying with ASTM C33 gradation size No.67, 3/4-inch to No.4.
PART 3 - EXECUTION
3.01 PROTECTION
A. Protect existing surface and subsurface features on-site and adjacent to site as follows:
1. Provide barricades, coverings, or other types of protection necessary to prevent damage to existing items indicated to remain in place.
2. Protect and maintain bench marks, monuments or other established reference points and property corners. If disturbed or destroyed, replace at own expense to full satisfaction of Owner and controlling agency.
3. Verify location of utilities. Omission or inclusion of utility items does not constitute non-existence or definite location. Secure and examine local utility records for location data.
a. Take necessary precautions to protect existing utilities from damage due to any construction activity.
b. Repair damages to utility items at own expense.
c. In case of damage, notify Engineer at once so required protective measures may be taken.
4. Maintain free of damage, existing sidewalks, structures, and pavement, not indicated to be removed. Any item known or unknown or not properly located that is inadvertently damaged shall be repaired to original condition. All repairs to be made and paid for by Contractor.
5. Provide full access to public and private premises, fire hydrants, street crossings, sidewalks and other points as designated by Owner to prevent serious interruption of travel.
6. Maintain stockpiles and excavations in such a manner to prevent inconvenience or damage to structures on-site or on adjoining property.
7. Avoid surcharge or excavation pro cedures which can result in heaving, caving, or slides.
B. Salvageable Items: Carefully remove items to be salvaged, and store on Owner's premises unless otherwise directed.
C. Dispose of waste materials, legally, off site. Burning, as a means of waste disposal, is not permitted.
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D. During all earthmoving operations the Contractor shall be in compliance with applicable sections of the South Coast Air Quality Management District Rule 403, Fugitive Dust.
3.02 SITE EXCAVATION AND GRADING
A. The work includes all operations in connection with excavation, borrow, construction of fills, rough grading, and disposal of excess materials in connection with the preparation of the site(s) for construction of the proposed facilities.
B. Excavation and Grading: Perform as required by the Contract Drawings.
1. Contract Drawings may indicate both existing grade
and finished grade required for construction of Project. Stake all slabs-on-grade, driveways, piping, parking areas and sidewalks and establish their elevations. Perform other layout work required.
Record, protect, restore, and file record surveys on all property corners, per the WSSS.
2. Preparation of ground surface for fills: Before fill is started, scarify to a minimum depth of 6 inches in all proposed embankment and fill areas.
3. Protection of finish grade: Du ring construction, shape and drain excavations. Maintain ditches and drains to provide drainage at all times. Protect graded areas against action of elements prior to acceptance of work. Reestablish grade where settlement or erosion occurs.
C. Construct fills as required by the Contract Drawings:
1. Construct fills at locations and to lines of grade indicated. Completed fill shall correspond to shape of typical cross section indicated regardless of method used to show shape, size, and extent of line and grade of completed work.
2. Provide approved fill material which is free from roots, organic matter, trash, frozen material, and stones having maximum dimension greater than 6 IN.
Ensure that stones larger than 4 IN are not placed in upper 6 IN of fill or embankment. Do not place material in layers greater than 8 IN loose thickness. Place layers horizontally and compact each layer prior to placing additional fill.
3. Compact by sheepsfoot, pneumatic rollers, vibrators, or by other equipment as required to obtain specified density. Control moisture for each layer necessary to meet requirements of compaction.
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3.03 FIELD QUALITY CONTROL
A. Moisture density relations, to be established by the Soils Engineer required for all materials to be compacted.
B. Extent of compaction testing will be as necessary to assure compliance with Specifications.
C. Give minimum of 24 HR advance notice to Soils Engineer when ready for compaction or subgrade testing and inspection.
D. Should any compaction density test or subgrade inspection fail to meet Specification requirements, perform corrective work as necessary.
E. Pay for all costs associated with corrective work and retesting resulting from failing compaction density tests.
3.04 COMPACTION DENSITY REQUIREMENTS
A. Obtain approval from Soils Engineer with regard to suitability of soils and acceptable subgrade prior to subsequent operations.
B. Remove loose, wet, or soft material a nd replace with approved material as directed by Soils Engineer.
C. Stabilize subgrade with well graded granular materials as directed by Soils Engineer.
D. Assure by results of testing that compaction densities comply with the following requirements:
1. SITEWORK COMPACTION DENSITY
Under Paved Areas, Sidewalks
and Piping: 95 percent, ASTM D1557
Unpaved Areas 90 percent, ASTM D1557
2. STRUCTURES
Under structure footings and foundations,
under equipment support pads, under
slabs-on-grade 95 percent, ASTM D1557
Outside structures and pipe trench backfill 90 percent, ASTM D1557
3.05 EXCAVATION, FILLING, AND B ACKFILLING FOR STRUCTURES A. General:
1. In general, work includes, but is not necessarily limited to, excavation for walls, removal of underground obstructions and undesirable material, backfilling, filling, and fill, backfill, and subgrade compaction.
Earthwork
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2. Obtain fill and backfill material necessary to produce grades required.
Materials and source to be approved by Engineer. Excavated material approved by Engineer may also be used for fill and backfill.
3. In this Section of the Specifications, the word "foundations" includes footings, base slabs, foundation walls, mat foundations, grade beams and any other support placed directly on soil.
4. In the paragraphs of this Section of the Specifications, the word "soil" also includes any type of rock subgrade that may be present at or below existing subgrade levels.
B. Excavation Requirements for Structures:
1. General. Do not commence excavation for foundations for structures until:
a. Engineer approves:
1) The removal of topsoil and other unsuitable and
undesirable material from existing subgrade.
2) Density and moisture content of site area compacted fill material meets requirements of specifications.
3) Site surcharge or mass fill material can be removed
from entire construction site or portion thereof.
4) Surcharge or mass fill material has been removed from construction area or portions thereof.
b. Engineer grants approval to begin excavations.
2. Dimensions:
a. Excavate to elevations and dimensions indicated on plans or as directed by geotechnical engineer.
b. Allow additional space as required for construction operations and inspection of foundations.
3. Removal of obstructions and undesirable materials in excavation includes, but is not necessarily limited to, removal of old foundations, existing construction, unsuitable subgrade soils, expansive type soils, and any other materials which may be concealed beneath present grade, as required to execute work indicated on Contract Drawings. If undesirable material and obstructions are encountered during excavation, remove material and replace as directed by Engineer.
4. Level off bottoms of excavations to receive foundations, floor slabs, equipment support pads, or compacted fill. Remove loose materials and bring excavations into approved condition to receive concrete or fill material. Where compacted fill material must be placed to bring subgrade elevation up to underside of construction, scarify existing subgrade upon which fill material is to be placed to a depth of 6 IN Earthwork
City of Anaheim 02200-6 06/27/13
and then compact to density stated in this Section of Specifications before fill material can be placed thereon. Do not carry excavations lower than shown for foundations except as directed by Engineer. If any part of excavations is carried below required depth without authorization, maintain excavation and start foundation from excavated level with concrete of same strength as required for superimposed foundation, and no extra compensation will be made to Contractor.
5. Make excavations large enough for working space, forms and inspection.
6. Notify Engineer as soon as excavation is completed in order that subgrades may be inspected. Do not commence further construction until subgrade under compacted fill material, under foundations, under slabs-on-grade, under equipment support pads, and under wall footings has been inspected and approved by the Engineer as being free of undesirable material, being of compaction density required by this specification, and being capable of supporting the allowable foundation design bearing pressures and superimposed foundation and fill loads to be placed thereon. Engineer shall be given the opportunity to inspect subgrade below fill material both prior to and after subgrade compaction.
a. Place fill material, foundations, wall footings, floor slabs-on- grade, and equipment support pads as soon as weather
conditions permit after excavation is completed, inspected, and approved and after forms and reinforcing are inspected and approved. Before concrete or fill material is placed, protect approved subgrade from becoming loose, wet or soft due to weather, construction operations, or other reasons.
7. Subgrade stabilization: If subgrade under foundations, fill material, floor slabs-on-grade, or equipment support pads is in a loose, wet, or soft condition before construction is placed thereon, remove loose, wet, or soft material and replace with approved compacted material as directed by Engineer. Provide compaction density of replacement material as stated in this specification section. Loose, wet, or soft materials, when approved by Engineer, may be stabilized by a compacted working mat of well graded crushed stone. Compact stone mat thoroughly into subgrade to avoid future migration of fines into the stone voids. Method of stabilization shall be performed as directed by Engineer. Do not place further construction on the repaired subgrades, until the subgrades have been approved by the Engineer.
8. Do not place floor slabs-on-grade including equipment support pads until subgrade below has been approved, piping has been tested and Earthwork
City of Anaheim 02200-7 06/27/13
approved, reinforcement placement has been approved, and Contractor receives approval to commence slab construction. Do not place building floor slabs-on-grade including equipment support pads when temperature of air surrounding the slab and pads is or is expected to be below 40 DegF before structure is completed and heated to a temperature of at least 50 DegF.
9. Protection of structures: Prevent new and existing structures from becoming damaged due to construction operations or other reasons.
Prevent subgrade under new and existing foundations from becoming wet and undermined during construction due to presence of surface or subsurface water or due to construction operations.
10. Drainage: Control grading around structures so that ground is pitched to prevent water from running into excavated areas or damaging structures. Maintain excavations where foundations, floor slabs, equipment support pads or fill material are to be placed free of water.
Provide pumping required to keep excavated spaces clear of water during construction. Should any water be encountered in the excavation, notify Engineer. Provide free discharge of water by trenches, pumps, wells, well points, or other means as necessary and drain to point of disposal that will not damage existing or new construction or interfere with construction operations.
C. Fill and Backfill Below Foundations, Base Slabs, Floor Slabs, Equipment Support Pads and Piping:
1. General: Subgrade to receive fill or backfill shall be free of undesirable material as determined by Engineer and scarified to a depth of 6 IN and compacted to density specified herein. Surface may be stepped by at not more than 12 IN per step or may be sloped at not more than 2 percent. Do not place any fill or backfill material until subgrade under fill or backfill has been inspected and approved by Engineer as being free of undesirable material and compacted to specified density.
2. Obtain approval of fill and backfill material and source from Engineer prior to placing the material.
3. Granular fill under floor slabs-on-gr ade: Place all floor slabs-on-grade on a minimum of 6 IN of granular fill unless otherwise indicated.
4. Fill and backfill placement: Prior to placing fill and backfill material, optimum moisture and maximum density properties for proposed material shall be obtained from Soils Engineer. Place fill and backfill material in thin lifts as necessary to obtain required compaction density. Compact material by means of equipment of sufficient size and proper type to obtain specified density. Use hand operated equipment for filling and backfilling next to walls. Do not place fill Earthwork
City of Anaheim 02200-8 06/27/13
and backfill when the temperature is less than 40 DegF and when subgrade to receive fill and backfill material is wet, loose, or soft. Use vibratory equipment to compact granular material; do not use water.
5. Where fill material is required below foundations, place fill material, conforming to the required density and moisture content, outside the exterior limits of foundations located around perimeter of structure the following horizontal distance whichever is greater:
a. As required to provide fill material to indicated finished grade. b. 5 FT.
c. Distance equal to depth of compacted fill below bottom of foundations.
d. As directed by Engineer.
D. Filling and Backfilling Outside of Structures. This paragraph of these specifications apply to fill and backfill placed outside of structures above bottom level of both foundations and piping but not under paving. Provide material as approved by Engineer for filling and backfilling outside of structures.
1. Fill and backfill placement: Prior to placing fill and backfill material, obtain optimum moisture and maximum density properties for proposed material from Engineer. Place fill and backfill material in thin lifts as necessary to obtain required compaction density. Compact material with equipment of proper type and size to obtain density specified. Use only hand operated equipment for filling and backfilling next to walls and retaining walls. Do not place fill or backfill material when temperature is less than 40 DegF and when subgrade to receive material is wet, loose, or soft. Use vibratory equipment for compacting granular material; do not use water.
E. Backfilling Outside of Structures Under Piping or Paving: When backfilling outside of structures requires placing backfill material under piping or paving, the material shall be placed from bottom of excavation to underside of piping or paving at the density required for fill under piping or paving as indicated in this Section. This compacted material shall extend transversely to the centerline of piping or paving a horizontal distance each side of the exterior edges of piping or paving equal to the depth of backfill measured from bottom of excavation to underside of piping-or paving. Provide special compacted bedding or compacted subgrade material under piping or paving as required by other sections of these Specifications.
Earthwork
City of Anaheim 02200-9 06/27/13
3.08 SPECIAL REQUIREMENTS
A. Erosion Control: Conduct work to minimize erosion of site. Construct stilling areas to settle and detain eroded material. Remove eroded material washed off site. Clean streets daily of any spillage of dirt, rocks or debris from equipment entering or leaving site.
END OF SECTION 02200
Trenching, Backfilling, and Compacting for Utilities
City of Anaheim 02221-1 06/27/13
SECTION 02221
TRENCHING, BACKFILLING, AND COMPACTING FOR UTILITIES
PART 1 - GENERAL
1.01 SUMMARY
A. Section Includes:
1. Excavation, trenching, backfilling and compacting for all underground utilities.
2. All related utility and process appurtenances.
B. Related Sections include but are not necessarily limited to:
1. Section 02200 - Earthwork.
1.02 QUALITY ASSURANCE
A. Referenced Standards:
1. American Association of State Highway & Transportation Officials (AASHTO):
a. T99, The Moisture-Density Relations of Soils Using a 5.5 LB Rammer and a 12-inch Drop.
b. T180, Moisture-Density Relations of Soils Using a 10 LB Rammer and an 18-inch Drop.
2. American Society for Testing and Materials (ASTM):
a. C33, Concrete Aggregates.
b. D1557, The Moisture-Density Relation of Soils Using a 10 LB Rammer and an 18-inch Drop. D1557 is "Modified Proctor." c. D2487, Classification of Soils for Engineering Purposes. d. D4253, Maximum Index Density of Soils Using a Vibratory Table. e. D4254, Minimum Index Density of Soils and Calculation of Relative Density.
1.03 DEFINITIONS
A. Excavation:
1. All excavation will be defined as unclassified.
Trenching, Backfilling, and Compacting for Utilities
City of Anaheim 02221-2 06/27/13
1.04 SUBMITTALS
A. Submit test reports and fully document each with specific location or stationing information, date, and other pertinent information.
B. Submit respective pipe or conduit manufacturer's data regarding methods of installation and general recommendations.
C. Submit sieve analysis reports on all granular materials.
1.05 SITE CONDITIONS
A. Avoid overloading or surcharge a sufficient distance back from edge of excavation to prevent slides or caving. Maintain and trim excavated materials in such manner to be as little inconvenience as possible to public and adjoining property owners.
B. Provide full access to public and private premises and fire hydrants, at street crossings, sidewalks and other points as designated by Owner to prevent serious interruption of travel.
C. Protect and maintain bench marks, monuments or other established points and reference points and if disturbed or destroyed, replace items to full satisfaction of Owner and controlling agency.
D. Verify location of existing underground utilities.
PART 2 - PRODUCTS
2.01 MATERIALS
A. Backfill Material:
1. As approved by Engineer.
a Free of rock cobbles, roots, sod or other organic matter. b. Moisture content at time of placement: 3 percent
plus/minus of optimum moisture content as specified in accordance with ASTM D1557.
c. Free drainage material having a sand equivalent (SE) of not less than 30 all buried valves and fittings are to be backfilled with clean sand. The sand shall be installed in such a manner that after compaction, no earth or other backfill will be less than 6-inches from any part of the valve, fitting, flanges, bolts, or nuts.
B. Embedment Materials:
1. As approved by the Soils Engineer.
2. Granular bedding materials:
Trenching, Backfilling, and Compacting for Utilities
City of Anaheim 02221-3 06/27/13
ASTM C33, gradation 67 (3/4-inch to No.4 sieve) defined below:
Sieve Size 1 IN 3/4 IN 3/8 IN No.4 No.20
Percent Passing 100 90-100 20-55 0-10 0
by Weight
1) Well-graded crushed stone.
2) Well graded crushed gravel.
3) Well graded gravel.
PART 3 - EXECUTION
3.01 GENERAL
A. Remove and dispose of unsuitable materials as directed by Soils Engineer to site provided by Contractor.
3.02 EXCAVATION
A. Unclassified Excavation:
1. Remove rock excavation, clay, silt, gravel, hard pan, loose shale, and loose stone as directed by Soils Engineer.
B. Excavation for Appurtenances:
1. 12 inches (minimum) clear distance between outer surface and embankment.
2. See Section 02200 for applicable requirements.
C. Trench Excavation:
1. Excavate trenches by open cut method to depth shown on Drawings and necessary to accommodate work.
2. Open trench outside buildings, units, and structures:
a. No more than the 600 LF. For street work, maximum length of open trench shall be 500 feet or the distance of pipe installed in one day, whichever is greater.
b. Field adjust limitations as weather conditions dictate.
3. Trenching within buildings, units, or structures:
a. No more than 100 LF at any one time.
4. Any trench or portion of trench, which is opened and remains idle for seven calendar days, or longer, as determined by the Owner, may be directed to be immediately refilled, without completion of work, at no additional cost to Owner. Said trench may not be reopened until Owner is satisfied that work associated with trench will be prosecuted with dispatch.
5. Observe following trenching criteria:
Trenching, Backfilling, and Compacting for Utilities
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a. Trench size.
1) Excavate width to accommodate free working space.
2) Maximum width of the trench at the bottom of the excavation shall not exceed 10-inches on either side of the pipe.
3) Cut trench walls vertically from bottom of trench to 1 FT above top of pipe, conduit, or utility service.
4) Keep trenches free of water. Include cost of dewatering in original proposal.
D. Trenching for Electrical Installations:
1. Observe paragraph 3.02 C "Trench Excavation"
2. Modify for electrical installations as follows:
a. Open no more than 600 LF of trench in exterior locations for trenches more than 12 IN but not more than 30 IN wide.
b. Any length of trench may be opened in exterior locations for trenches which are 12 IN wide or less.
c. Do not over excavate trench.
d. Cut trenches for electrical runs with minimum 30 IN cover, unless otherwise specified.
e. See Division 16 for additional requirements.
3.03 PREPARATION OF FOUNDATION FOR PIPE LAYING
A. Over-Excavation:
1. Backfill and compact to 95 percent of maximum dry density per ASTM D698.
2. Backfill with granular bedding material as option.
B. Rock Excavation:
1. Excavate minimum of 6 inches below bottom exterior surface of the pipe or conduit.
2. Backfill to grade with suitable earth or granular material.
3. Form bell holes in trench bottom.
C. Subgrade Stabilization:
1. Stabilize the subgrade when directed by the Owner.
2. Observe the following requirements when unstable trench bottom materials are encountered.
a. Notify Owner when unstable materials are-encountered. 1) Define by drawing station locations and limits.
b. Remove unstable trench bottom caused by Contractor failure to dewater, rainfall, or Contractor operations.
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1) Replace with subgrade stabilization with no additional compensation.
3.04 BACKFILLING METHODS
A. Do not backfill until tests to be performed on system show system is in full compliance to specified requirements.
B. Carefully Compacted Backfill:
1. Furnish where indicated on drawings, specified for trench embedment conditions and for compacted backfill conditions up to 12 IN above top of pipe or conduit.
2. Comply with the following:
a. Place backfill in lifts not exceeding 8 IN (loose thickness). b. Hand place, shovel slice, and pneumatically tamp all carefully compacted backfill.
c. Observe specific manufacturer's recommendations regarding backfilling and compaction.
d. Compact each lift to specified requirements.
C. Common Trench Backfill:
1. Perform in accordance with the following:
a. Place backfill in lift thicknesses capable of being compacted to densities specified.
b. Observe specific manufacturer's recommendations regarding backfilling and compaction.
c. Avoid displacing joints and appurtenances or causing any horizontal or vertical misalignment, separation, or distortion.
D. Water flushing for consolidation is not permitted.
E. Backfilling for Electrical Installations:
1. Observe paragraph 3.04 C or D "Backfilling Methods."
2. Modify for electrical installation as follows:
a. Observe notes and details on electrical drawings for fill in immediate vicinity of direct burial cables.
3.05 COMPACTION
A. General:
1. Place and assure backfill and fill materials to achieve an equal or "higher" degree of compaction than undisturbed materials adjacent to the work.
2. In no case shall degree of compaction below "Minimum Compaction" specified be accepted.
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B. Compaction Requirements: Unless noted otherwise on Drawings or more stringently by other sections of these Specifications, comply with following trench compaction criteria:
1. Carefully compacted backfill:
MINIMUM COMPACTIONS
LOCATION SOIL TYPE DENSITY
All applicable areas All soils 95 percent of max dry
density by ASTM D1557
3.06 FIELD QUALITY CONTROL
A. Testing:
1. In-place moisture-density tests will be performed by the Owner.
2. Costs of "Passing" tests will be paid by Owner.
3. Cost associated with "Failing" tests shall be paid by the Contractor.
4. Reference to Engineer in this section will imply Soils Engineer when employed by Owner and directed by Engineer to undertake necessary inspections as approvals as necessary.
5. Assure Owner has immediate access for testing of all soils related work.
6. Ensure excavations are safe for testing personnel.
END OF SECTION 02221
Reinforcing
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SECTION 03200
REINFORCING
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements specified in the Conditions of the Contract and Division 1 form a part of this Section. Provide reinforcing work, complete as indicated, specified and required.
A. Work Included in This S ection. Principal items are:
1. Furnishing and placing bar and mesh re inforcing for cast-in-place concrete.
B. Related Work Specified Elsewhere.
1. Section 03300, Cast-In-Place Concrete.
1.02 QUALITY ASSURANCE
A. Code Requirements. Unless otherwise sp ecified all work specified herein and as shown on the drawings shall conform to the applicable requirements of the 2001 California Building Code.
B. Testing. Materials shall be tested as hereinafter specified, and unless specified otherwise, all sampling and testing shal l be performed by a Testing Laboratory responsible to the Owner and with cost borne by the Contractor.
1. Test Samples. Bars, ties, and stirrups shall be selected by Testing Laboratory representative from material at the site or from place of distribution. Selection shall include at least 2 pieces, each 18 inches long, of each sampling.
2. Required Tests.
a. Identified Bars. Testing will not be required if reinforcement is taken from bundles as delivered from the mill, identified as to heat number and accompanied by certified mill analyses and mill test reports, and is properly tagged with Identification Ce rtificate so as to be readily identified, unless otherwise directed by the Owner.
b. Unidentified Bars. When positive iden tification cannot be made or when random samples are taken, tests shall be made from each 2 tons or fraction thereof for each size. One tensile a nd one bend test shall be made from specimens of each size of reinforcement. Contractor shall bear costs and delays caused by testing unidentified bars.
C. Standard. Reinforcing steel installa tions shall conform to the specification requirements of the Concrete Reinforci ng Steel Institute "M anual of Standard Practice" (herein referred to as the CRSI Manual) except as otherwise indicated or specified.
D. Field Quality Control. All continuous inspections shall be performed by "Special Inspectors' qualified and approved by G overning Building C ode Authority or Reinforcing
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inspector as otherwise qualified and appr oved by the Owner. Prepare and submit to Owner reports as required by Code.
1. Inspection of Reinforcing. Provide 24- hour advance notice to permit inspection of in-place reinforcement prior to closing forms, and refer to applicable requirements of Section 03300 "Cast-In-Place Concrete".
2. Concreting Operations. During concrete placing, a ssign construction personnel to inspect reinforcement and maintain bars in correct po sitions at each pour location.
1.03 SUBMITTALS
Submit the following in advance of fabrication in conformance with applicable requirements of General Conditions.
A. Shop Drawings. Submit shop drawings for reinforcing steel prepared in accordance with ACI 315, "Manual of St andard Practice for Detail ing Reinforced Concrete Structures". Show layouts, bending diagrams, assembly diagrams, dimensioned types and locations of all bar laps and splices, and shapes, dimensions, and details of bar reinforcing and accessories. Include layout plans for bar supports and chairs, with typical details. Dimensions and quanti ties shown on the shop drawings are the responsibility of the Contractor and Own er approval of shop drawings shall not constitute approval of dimensions and quantities thereon.
B. Samples. Submit two 12-inch long samp les of each bar support and two samples of each individual type chair, with catalog data.
PART 2 - PRODUCTS
2.01 REINFORCING
Use deformed bars conforming to ASTM A615, Grade 60 Marked "S".
2.02 WELDED WIRE MESH
Conform to ASTM A185.
2.03 ACCESSORIES
A. Tie Wire: Annealed steel, 16 gage minimum.
B. Coupler Splice Devices. Reinforcing ba r coupler/splice devices which bear current I.C.B.O. Research Recommendation Appr oval, and which develop at least 125 percent of bar yield strength in tension may be used in lieu of lapped bar type splices.
Submit sample for Owner approval in each instance.
C. Supports And Accessories. Do not use aluminum, galvanized steel, plastic or stainless steel supports or acc essories. Supports as herein specified shall conform to CRSI Manual of Standard Practice, Chapte r 3, for Types SB, BB, BC, JC, HC, CHC, and others of standard types as required. Use precast concrete block supports with embedded wire ties or dowels for placement on grade or on membranes. Use Class Reinforcing
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"1" plastic coated chairs and spacers at wa terbearing surfaces, roofs of waterbearing structures, and at all interior or exterior surfaces exposed to view or weather in the completed structure.
2.04 DOWELS
Where and as designated on Struct ural Drawings, provide reinfo rcing bar dowels in new work and for anchorage to existing concrete. For anchorage where shown or required to existing construction use non-shrink epoxy type grout or deferred bolting devices as approved in each instance and conforming to requirements of Part 2, Products of Section titled "Cast-In-Place Concrete" in Division 3.
2.05 FABRICATION AND DELIVERY
Conform to CRSI Manual Chapters 6 and 7 except as otherwise indicated or specified. Bundle reinforcement and tag with suitab le identification to facilitate sorting and placi ng, and transport and store at site so as not to damage material . Keep a sufficient supply of tested, approved, and proper reinforcement at site to avoid delays.
A. Bending and Forming. Fabricate bars of i ndicated size and accurately form to shapes and lengths indicated and required by methods not injurious to materials. Do not heat reinforcement for bending. Bars with kinks or bends not scheduled will be rejected.
Do not field bend bars that are partially embedded in concrete, except as shown on the plans or specifically approved by the Owner.
B. Reinforcing Bars for Masonry. Detail and fabricate bars at the shop, ready for installation by masons.
PART 3 - EXECUTION
3.01 PLACING
Unless otherwise indicated or specified, conform to CRSI Manual Chapter 8 including placement tolerances, except no reduction of concrete cover is allowable fo r bars at concrete surfaces exposed in liquid or water-containing structures.
A. Cleaning. Before placing reinforcing, a nd again before concrete is placed, clean reinforcement of loose mill scale, oil, or other coating that might destroy or reduce bond. Do not allow form coatings, releas e agents, bond breaker, or curing compound to contact reinforcement.
Reinforcing
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B. Concrete Coverage over reinforcing bars shal l be as indicated. The coverage shall be to the outer edge of ties, stirrups, ba r spacers, hangers, and like items, and the reinforcing shall be detailed and fabricated accordingly. Refer to Structural General Note requirements.
C. Securing in Place. Accurate ly place reinforcement and s ecurely wire tie in precise position at all points where bars cross. Tie stirrups to bars at both top and bottom.
Bend ends of binding wires inward allowing no encroachment on the concrete cover; exercise special care at surfaces to rema in exposed and unpainted. Support bars in accordance with CRSI Manual Chapter 3, Sp ecifications for Placing Bar Supports, using approved chairs and supports.
D. Splices shall be wired contact lap splic es unless otherwise indicated or approved.
Splices shall conform to ACI 318, (Class B). Lap lengths shall be as indicated on the Drawings.
1. Vertical Bars. Except as specifically de tailed or otherwise indicated, splicing of vertical bars in concrete is not permitted except at the indicated or approved horizontal construction joints or as otherwise specifically detailed.
2. Horizontal Bars. Unless otherwise show n, make lap splices with at least one continuous bar between adjacent splices. Splices in any one run of bar shall be spaced at least 20 feet apart with splices in adjacent bars offset at least 10 feet.
Where double mats of bars occur in walls, lap splices in opposite mats shall be offset at least 5 feet.
E. Welding of reinforcing bars is not permitted unless approved in each case.
F. Additional Reinforcing. Provide additional reinforcing bars at sleeves and openings as indicated or required.
G. Welded Wire Mesh. Install necessary supports and chairs to hold in place during concrete pours. Straighten mesh to lay in flat plane and bend mesh as shown or required to fit work. Laps shall be no le ss than one complete mesh unless otherwise detailed. Tie every other wire at laps.
H. Do not displace or damage vapor barrier.
I. Accommodate placement of formed openings.
END OF SECTION 03200
Cast-In-Place Concrete
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SECTION 03300
CAST-IN-PLACE CONCRETE
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements specified in the Conditions of the Contract and Division 1 form a part of this Section. Provide cast-in-place concrete work, complete as indicated, specified and required.
A. Work Included in This S ection. Principal items are:
1. All cast-in-place concrete including bases for mechanical and electrical equipment and encasement for underground conduits.
2. Concrete finishing, patchi ng, grouting, and crack repair.
3. Embedded waterstops for cast-in-place concrete.
4. Concrete curing.
B. Related Work Specified Elsewhere.
1. Section 03200, Reinforcing.
2. Section 02200, Earthwork.
1.02 REFERENCE STANDARDS
Except as herein modified, concrete work shall conform to requirements of ACI 301, Specifications for Structural Concrete for Buildings, and to requirements of ACI 350R, Concrete Sanitary Structures, and to re quirements of ACI Standards and ACI Recommended Practices as contained therein.
1.03 SOURCE QUALITY CONTROL
A. Code Requirements. Unless more stringent requirements are specified herein or shown on the Drawings all work shall conform to the applicable requirements of the 2007 California Building Code (CBC).
B. Testing. Materials shall be tested as hereinafter specifie d and unless specified otherwise all sampling and testing shall be performed by Owner approved Testing Laboratory with cost borne by the Owner, ex cept costs of retesting and reinspection because of faulty materials or methods shall be borne by the Contractor.
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1. Cementitious Materials. Provide the follo wing as applicable when material is to be used in performance of the Work.
a. Portland Cement. Submit notarized Mill Certificates, provided by the cement manufacturer, including full compliance with requirements specified. In the absence of certific ates, Testing Laboratory shall perform sampling of cement in conformance with ASTM Designation: C 183 and testing of cement in accordance wi th ASTM Designati on: C 150, all at Contractor's expense. Cement shall be tagged for identification at location of sampling.
b. Fly Ash. Submit notarized certificate of compliance to standard specifications of ASTM Designation: C 618, Class F or C, and as further qualified hereinafter Article 2.01. In addition, provide notarized test reports for compliance with ASTM Designation: C 618.
2. Stone Aggregate for Concrete. Test aggr egate before concrete mix is established and whenever character or source of material is changed. Include a sieve analysis to determine conformity with limits of gradation. In accordance with ASTM D75, take samples of aggregates at source of supply or at the ready-mix concrete plant and conduct the following tests:
a. Sieve Analysis. ASTM Designation: C 136.
b. Organic Impurities. ASTM Designation: C 40. Fine aggregate shall develop a color not darker than reference standard color. c. Soundness. ASTM Designation: C 88. Loss resulting therefrom, after 5 cycles, shall not exceed: 8% of coarse aggregate, 10% for fine aggregate when using sodium sulfate solutions ; or 11% and 14% respectively, when using magnesium sulfate solution.
d. Abrasion of Concrete Aggregate. ASTM Designation: C 131; loss shall not exceed 10-1/2% after 100 revolutions, 42% after 500 revolutions. e. Deleterious Materials. ASTM Designation: C 33.
f. Material Finer Than 200 Sieve. ASTM Designation: C 117; not to exceed 1% for gravel, 1.5% for crushed aggregate per ASTM Designation: C 33. g. Reactivity Potential. Aggregates shall be considered innocuous in accordance with Figure 2 of ASTM Designation C 289.
h. Cleanliness and Sand Equivalent. For all aggregate, not less than 75 for average of 3 samples tested according to Test Method No. California 217E (Materials Manual, Testing and C ontrol Procedures - Materials and Research Department, State of California).
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1.04 CONCRETE MIX DESIGNS AND PRELIMINARY TESTS
At Contractor's expense, Testing Laboratory sh all prepare mix designs for all cast-in-place concrete and shall perform preliminary testing in accordance with the following requirements.
Submit test results to Owner. With Owner's prio r approval, structural concrete mix designs may be based upon field experience with materials to be employed when certified test results, and criteria meet or exceed herein specified requirements, and when supplier certifies that materials to be supplied are those represented by such tests. During job progress, verification of such results shall be by Independent Testing Laboratory.
A. Mix Designs
1. Basis for Mix Designs. Design conc rete mixes for workability of mix and durability of concrete. Concrete mixes sh all be rigidly controlled in accordance with laboratory trial batch method or co mbinations of materials previously evaluated as required by Sections 5.4 and 5.3, respect ively, Standard Building Code Requirements for Reinforced C oncrete (ACI 318), of the American Concrete Institute and to satisfy herein specified concrete strength requirements.
When necessary, increase the cement content to achieve the required strength, at no extra cost to Owner.
2. Compressive Strength Requirements. Un less otherwise shown on the Structural Drawings or otherwise specified herein, normal weight aggregate concrete mixes shall provide the following minimum comp ressive strength for use in various locations:
a. Class 1, 4,000 psi Concrete shall be used for all water bearing structures including top slab of water bearing structures.
b. Class 2, 3,000 psi Concrete shall be used for structural concrete such as concrete fill for steel deck, on-grade walks, paving, curbs, gutters, structural footings, slabs on-grade, and other st ructural concrete not occurring in water bearing structures.
c. Class 3, 2,000 psi Concrete shall be us ed for non-structural concrete such as encasement of pipe or conduit, fi lls for over-excavations, fence post footings, thrust blocks, and other locations requiring similar non-structural concrete.
3. Water/Cement Ratios. Unless otherwis e specified or shown on Structural Drawings, prepare mix designs in confor mance with methods No. 1 or No. 2 as outlined in Section 3.8 of ACI Std. 301 with Contractor having option of selecting water/cement ratio which assures a compatibility with strength and workability requirements, but not greater than 0.53.
4. Admixtures. Add to concrete mixes, upon approval prior to use, and modify mix design proportions accordingly. Fly ash may be used at Contractor's option, except where prohibited herein.
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B. Preliminary Strength Tests. In laborato ry, prepare 6 compressive test cylinders for each concrete mix design (unless more tests are required for an earlier age). Fabricate and cure cylinders in accordance with ASTM Designation: C 31. Use cement, aggregates and admixtures proposed for the concrete work. In accordance with ASTM Designation: C 39, test three sets of two cy linders at 28-day age. For each mix, no individual strength test result shall fall below the required f'c.
C. Reports. File 3 copies of each mix design and preliminary strength test report, with the Owner for review and approval. Submit a letter of certification that the concrete materials, mixes, properties, and work conform to the require ments indicated and specified.
1.05 PRODUCT DELIVERY, STORAGE, AND HANDLING
Deliver materials in a timely manner to insure uninterrupted progress of work. Store materials in a manner that will preclude damage and permit ready access for inspection and identification.
PART 2 - PRODUCT
2.01 MATERIALS
A. Cementitious Materials
1. Portland Cement. Standard bra nd of domestic Portland cement, ASTM Designation: C 150, Type I. Do not cha nge brand of cement during progress of Work without written approval of the Owner.
2. Fly Ash. Except for instances requiring hi gh early strength, the use of Class F or Class C fly ash meeting ASTM Designatio n: C 618 with ignition loss limited to
1.5 percent may be used in lieu of Portland cement to the limits of not less than 10 percent nor more than 20 percent by weight. This substitution or any changes in brand or type of cement shall not be made without advanced written approval of the Owner.
B. Normal Weight (Stone) Aggregates. Furn ish natural aggregates from approved pits, free from opaline, feldspar, mica (fools gold), siliceous magnesium limestone or other deleterious or reactive substances. Aggregate shall conform to ASTM Designation: C 33 except as modified herein. Fine aggregates shall pass a #4 sieve. Do not use pozzolan or other additives to compensate for aggregate-alkali reactivity.
1. Coarse Aggregates. Clean, hard, fine-grained sound crushed rock or washed gravel which does not contain in excess of 5% in weight of flat, chip-like, thin and elongated, friable or laminated pieces, or more than 2% by weight of total amount of cherty material and soft particle s, or more than 1% of chert as soft material as defined on Table 3 of ASTM Designation: C 33. Consider any piece having a major dimension in
excess of 5 times its thickest dimension perpendicular to the major dimension to be flat or elongated.
a. Maximum Sizes. As indicated on Dr awings, except for concrete in water Cast-In-Place Concrete
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bearing structures where coarse aggregate sizes per Table 2 of ASTM Designation: C 33 shall be No. 467 (1-1/2 in.), No. 57 (1 in.), or No. 67 (3/4 in.) as otherwise required by design, specifications and ASTM Designation:
C 33, and except that coarse aggreg ate nominal maximum size shall not exceed one-fifth the narrowest dimension between sides of forms and reinforcing steel, one-third the depth of slabs, or three-fourths of minimum clear spacing between reinforcing bars.
b. Quality. All aggregates shall meet th e test requirements of Article "Source Quality Control" hereinbefore.
C. Admixtures. Use one ma nufacturer's products throughout. Upon Owner's approval of use and of a particular brand or type, assure that use is reflected in mix designs.
1. General. Use no admixture that ha s chlorides added during manufacture.
Admixtures used in combination shall be physically and chemically compatible and shall be so certified by each ad mixture manufacturer and by Testing Laboratory that prepared respective mix designs.
2. Admixture. At Contractor's opti on in Class "2" concrete in amounts recommended by manufacturer, as a pproved by Owner, use water-reducing, retarding chemical admixture conforming to ASTM Designation: C 494, Type A or Type D. The admixture shall provi de the following, and Contractor shall provide proof thereof at time of request for approval:
a. Decrease drying shrinkage.
b. Increase compressive strength at all ages up to and including five years. c. Increase flexural strength, modulus of elasticity, and abrasive resistance. d. The water-cement ratio and required strengths shall be maintained as scheduled (cement factor for a cubic yard of concrete, reduced proportionately).
e. There shall be no loss of workability resulting from reduction in slump. If the admixture is of liquid type, it must be considered in proportioning water.
3. Air Entrainment. Use air entrai nment additive conforming to ASTM Designation: C 260 as approved by the Owner.
a. For normal weight aggregate concrete subject, after cu ring, to freezing temperature while wet shall contain air entrainment within limits of Table
4.5.1 of ACI 318 and Table 3.4.1 of ACI 301.
D. Water. From a domestic potable source.
E. Preformed Plastic Adhesive Waterstops. In horizontal construction joints of vertical walls, use preformed plastic adhesive waterstops in lieu of PVC waterstops. Preformed plastic adhesive waterstops shall be the product of Synko-Flex Products Inc. or approved equal.
F. Concrete Joint Sealants. For sealing joints in concrete surfaces, use materials conforming with requirements specified in Section 07920, "Sealants and Caulking".
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1. Primer. Use primer produced and/or recommended by sealant manufacturer.
2. Back-up Preformed Joint Filler. Use cl osed cell polyethylene foam or equal impervious, compatible, compressible foam material recommended for retaining sealant depth in expansion joints while curing. Use no bitumen or oil saturated material.
3. Bond Breakers, where required, shall be polyethylene tape or equal as recommended by sealant manufacturer to prevent adherence of sealant to back-up material.
G. Nonshrink Grout. Use "Mas terflow 713" manufactured by Master Builders or Five Star grout manufactured by U.S. Grout , or an approved equal nonmetallic, nonshrinking, nonstaining, premixed, water and oil resistant, high-strength grout.
H. Deferred Bolting Devices (DBD).
1. Deferred bolting devices may be used in lieu of anchor bolts and expansion bolts in interior and exterior dry locations. The anchor shall be Hilti HD1 304 SS or approved equal. Installati on shall be in accordance w ith current International Conference of Building Officials (ICBO) Research Report recommendations.
2. Deferred bolting devices will not be permitted:
a. In wet or submerged locations.
b. For anchorage of vibrating machinery or equipment.
I. Epoxy. Epoxies for grouting, crack repair, patching, bonding or other uses shall be as follows as manufactured by Master Buil ders, Sika Chemical Company, Select Products, or equal by other manufactur er. Throughout use products of single manufacturer, except as approved by Owner.
1. All epoxy mixing, surface preparation a nd application shall be made in conformance with manufacturer's prin ted specifications, as approved by the Owner.
2. For bonding new concrete to old conc rete, grouting metal anchors, and for overhead and vertical b onding and embedment, use "Sikadur 31 Hi-Mod Gel", Select Products GP-3000 or approved e qual. All epoxies shall be used as recommended by manufacturer to satisfy entailed project temperature and surface moisture variations at time of application.
3. For pressure injection or gravity-feed grouting, use; Sika's "Sikadur 35 Hi-Mod LV", Select Products GP-2000, or approved equal.
J. Liquid Curing Compound. Use white pi gmented Burke "Rez-X" or equal white pigmented compound conforming to ASTM Designation: C 309 a nd providing no detrimental effects with deferred finishes. On surfaces within reservoirs or other concrete structures containing potable water, use nontoxic materials which are free of odor and taste. Provide supporting technical data. Floor hardener treated floors shall use curing materials only as recommended in writing by hardener manufacturer.
K. Sheet Curing Materials. ASTM Designa tion: C 171, waterproof paper, polyethylene film or white burlap-polyethylene sheet, non-staining.
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L. Vapor Barrier Membrane. Under interior on-grade slabs indicated on the Drawings provide lapped and sealed vapor barrier membrane using Fortiber "Moistop-2", Damproof xx" by Nicolet of California, Inc., or equal with manufacturer's recommended pressure sensitive tape seal ant used continuously at lapped joints, penetrations and at perimeter walls or f ooting surfaces. Use products and system of single manufacturer throughout.
2.02 CONCRETE MIXES
A. 28-Day Compressive Strengt h. Concrete used on the job shall be of 150 lb/cu. ft. nominal density and shall attain the compressi ve strength at 28 da ys as designated on Structural Drawings for use in various locations.
B. Maximum Aggregate Size. Conform to Article 2.01 B.1. For Class "2". a. Use 1-1/2 in. max. size aggregate typical and
b. 3/4" maximum for concrete fill roof deck, unless otherwise designated. In no case shall the size of the coarse aggregate exceed 75% of the horizontal space between reinforcing bars or between reinforcing bars and forms.
C. Mix Designs. Conform w ith requirements of Article 1.04 "Concrete Mix Designs and Preliminary Tests". At least 30 days before any Class concrete is to be placed, the Contractor shall submit for approval, mix designs for each proposed mix prepared and supervised by a Testing Laboratory approved by the Owner.
2.03 CONCRETE MIXING
Concrete shall be ready-mixed, supplied from an off-site commercial ready-mix plant approved by Owner, each load accompanied by a bonded weightmaster's certificate listing the quantity of each concrete ingredient, admixture quantity, water content and slump, and time of loading and departure from ready-mix plant. Also include notations to indicate equipment was checked and found to be free of contaminants prior to batching.
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A. Ready-Mixed Concrete. Unless approve d otherwise in advanc e of batching all concrete of a single design mix for any one day's pour shall be from a single batch plant of a single supplier. Conform to ASTM Designation: C 94, except materials, testing and mix design shall be as specified here in. Use transit mixers equipped with automatic devices for recording number of revolutions of drum.
B. Mixing Water Limitations. If water is added at the batching plant, do not hold ready-mixed concrete in the mixer for more than one hour from the time the water is added. Do not deliver ready-mixed concrete to job with the total specified amount of water incorporated therein. Withhold 2-1/2 U.S. gal. of water per cubic yard, then incorporate in mix before concrete is discharged from mixer truck. If no water is added at the batching plant, add measured quantities of water at the site and rotate mixer at 70 to 100 revolutions in accordance with re quirements of ASTM Designation: C 94 to achieve uniformity of mix without segreg ation and without ex ceeding water/cement ratio or slump. Adding of water shall be under observation of Inspector. Each mixer truck shall arrive at the job site with its water container full. In event container is not full or concrete tests to a greater slump than specified, the load is subject to rejection.
C. Job Mixed Concrete. Obtain the approval of the Owner for equipment and procedures proposed for job mixed concrete.
D. Consistency. Adjust quantity of water so concrete does not exceed maximum slumps specified when placed or specified wate r cement ratio; use minimum necessary for workability required by the pa rt of the structure being ca st. Measure consistency of concrete in accordance with ASTM Designation: C 143. Concrete exceeding maximum slump will be rejected.
Part of Structure Slump
Footings and mass concrete not reinforced 3 inches maximum Slabs and floors 4 inches maximum
Columns, walls 4 inches maximum
Equipment bases 3 inches maximum
PART 3 - EXECUTION
3.01 PREPARATION BEFORE PLACING
Remove excess water from forms before concrete is deposited. Do not a llow water to flow over freshly deposited concrete. Remove hardened concrete, debris, and foreign materials from interior of forms and from inner surfaces of mixing and conveying equipment.
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A. Secure reinforcement as sp ecified in Section 03200, and ob tain Engineer's approval.
Embedded metal shall be free of old mortar, oils, mill scale, and other encrustations or coatings that might reduce bond. Wheeled c oncrete-handling equipment shall not be wheeled over reinforcing nor shall runways be supported on reinforcing.
B. Wetting. Wet wood forms sufficiently to tighten up cracks. Wet other materials sufficiently to reduce suction and maintain concrete workability.
C. Earth Subgrade. Fine grade subgrades smooth and level and lightly dampen 24 hours in advance of concrete placing. Remove all loose materials.
D. Vapor Barrier Membrane. Roll finish gr ade surfaces free of protrusions that may perforate membrane sheet. Use maximum feas ible sheet width, make 6 in. laps with top lap in direction of concrete spreadi ng, and seal membrane laps with minimum 2 inch wide pressure-sensitive tape or membrane manufacturer's recommended adhesive. Closely cut around penetrations and seal with tape. Terminate membrane at walls, footings and other vertical surfaces and tape seal. Remove and replace torn, punctured, or damaged vapor barrier membrane as directed prior to placement of sand cushion or drainage fill.
1. Sand Cushion. Prior to pl acing reinforcing or concre te, place a uniform 2-inch minimum thickness of clean sand on the intact membrane. Moisten sand immediately prior to pouring concrete.
3.02 JOINTS IN CONCRETE
Locate joints in concrete where indicated unless otherwise approved. Obtain approval of points of stoppage of any pour.
A. Construction Joints. Unless otherwise s hown, provide all cons truction joints with suitable keyways or other keying methods. Clean and roughen contact surfaces of construction joints by removing entire su rface and exposing clean aggregate solidly embedded in mortar matrix. Use mechanical chipping, sandblasting, or application of surface mortar retarder followed by washing and scrubbing with stiff broom. Cover and protect waterstops and other inserts from damage. The hardened concrete shall be watered and kept wet for at least 24 hours before placing ne w concrete. Just prior to placing adjoining concrete, slush face of construction joints with 1:2 mix of cement and sand mixed to paint consistency. At construction joints not containing water-stops, the coarseness amplitude of the prepared surface shall be 1/4 inch minimum in accordance with ACI 318, Section 11. 7.9.
3.03 CONVEYING AND PL ACING CONCRETE
Do not pour concrete until rein forcing steel and forms have b een inspected and approved as specified in Section 03200. Notify Owner not le ss than one full working day in advance of readiness for inspection of forms and reinforcing. Do not use al uminum equipment to handle or pump concrete.
A. Weather. Do not place concrete duri ng rain or freezing w eather unless approved measures are taken to prevent damage to c oncrete. Concrete placed during periods of Cast-In-Place Concrete
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dry winds, low humidity, high temperatures, and other conditions causing rapid drying shall be initially cured with a fine fog spray of water applied immediately after finishing and maintained until final curi ng operations are star ted. Also under hot weather conditions, steps shall be taken to reduce concrete temperature and water evaporation by proper attention to ingredients, production methods, handling, placing, protection, and curing. Subject to Owner's a pproval, applicable preventive measures shall be taken for placing concrete during hot and cold weather in conformance with ACI Reports 305R and 306R respectively en titled, "Hot Weather Concreting", and "Cold Weather Concreting".
B. Conveying. Do not drop conc rete from its point of release at mixer, hoppers, tremies, or conveyances more than 3 feet, nor through reinforcing bars in a manner that causes segregation. Provide form windows, tremies, elephant trunks, and equivalent devices as required. The use of chutes for conve ying or depositing concrete is not allowed except for small isolated portions of the work and only with prior approval of Owner.
Deposit concrete directly into conveyances and from conveyances to final points of repose. Deposit concrete so that the surface is kept level throughout, a minimum being permitted to flow from one portion to another.
C. Placing Concrete. Place and compact concre te within 90 minutes after water is first added to the mix; no concrete shall be placed after there is eviden ce of initial set.
Retempering of concrete is not allowed.
1. Lifts. Pour concrete into forms imme diately after mixing in a manner that will prevent separation of ingredients. Ex cept as interrupted by joints, place all formed concrete in continuous, approxima tely horizontal layers, not generally exceeding 18 inches in depth. The Owner may require lesser depths where necessary to insure each new layer being pl aced while the previous layer is still soft and so the two layers can be made monolithic by penetration of the vibrators.
All construction joints which will be exposed to view shall be made straight and level or plumb.
a. Walls. Pour walls of water-contai ning structures incl uding tank exterior walls, as one continuous operation from footing to top of wall between indicated construction joints at the specified pour rate. Each section of wall shall be in place at least 7 days before the adjoining wall section is cast.
Shear walls and columns within tanks and other walls may have horizontal construction joints at approved locations.
b. Slabs. Pour slabs as one contin uous operation between indicated or approved construction joints. Cure in place slabs not less than 7 days prior to pouring alternate slabs. Then continue to cure until required curing time is attained.
c. Monolithic Elements. Pouring of all beams and slabs must be continuous and monolithic with the floor system where so shown on the Drawings. At least two hours must elapse after depositing concrete in walls or columns before pouring beams, etc. supported thereon.
2. Pumping Concrete. No increase in th e specified slumps will be allowed and Cast-In-Place Concrete
City of Anaheim 03300 - 11 6/27/2013
required water/cement ratios shall be ma intained for concrete pumping. Do not use aluminum tubes to convey concrete. Equipment shall be capable of maintaining the specified pour rates. Conform with guide lines of ACI 304, except where more stringent requiremen ts are specified herein. Minimum conduit (tube) diameter shall be 4 inches. Submit special mix designs to Engineer and obtain his approval for all concrete to be pumped.
3. Pouring Openings. Pouring of walls may be done only through pouring openings on one of the wall sides, and may not be pumped or poured from the top through the use of “elephant trunks” or tremies. The horizontal ce nterline distance between such openings shall not exceed 96 inches nor shall the distance between the nearest opening and the bulkhead for the vertical joint exceed 36 inches. The vertical centerline distance between horizontal rows of openings shall not exceed 96 inches. The minimum pouring opening size shall be 18” x 18”. The bottom of the lower opening shall be no more than 48 inches from the top of the wall footing. Under no circumstances shall forming be such that the drop of concrete in the forms will exceed 8 feet in any one place.
4. Pour Rates.
a. Vertical Elements. Place concrete in lif ts as specified at a rate that does not overstress forms nor allows the top of a lift to begin to harden before the next lift is placed.
b. Slabs. Place concrete at a rate th at ensures all deposits are joined to concrete that is still plastic.
c. Do not place concrete adjoining a construction joint until the adjoining concrete has cured for at least seven days unless approved by the Owner.
D. Compaction. Obtain effective compacti on by vibration, ag itation, spading, and rodding until the concrete is free from voids, or rock poc kets. Do not use vibrators to move concrete within the forms. During pours, maintain at least one spare vibrator in good condition for each two vibrators in use. Assign one experienced workman exclusively to the operation of each vibrator during the placing operation. Immediately correct operations not deemed to be satisfactory by the Owner.
1. Vibration. Compact all concrete, with th e exception of concrete slabs 4 in. or less in depth, with high frequency, intern al mechanical vibrating equipment supplemented by hand spading. Concrete sl abs 4 in. or less in depth shall be consolidated by wood or metal grid tamp ers, spading and settling with a heavy leveling straight edge. Carefully vibrat e concrete around waterstops and ensure the waterstops are not bent or damaged.
a. Vibrators shall be designed to opera te with vibratory element submerged in the concrete, and shall have a frequency of not less than 7,000 impulses per minute when submerged. The vibrating equipment shall be adequate at all times in number of units and power of each unit to consolidate the concrete to the maximum practicable density so that it is free from air pockets, honeycomb, entrapped air and so it cl oses snugly against all surfaces of forms and embedded items.
Cast-In-Place Concrete
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b. Operation of Vibrators. Do not allow vibrators to contact forms or reinforcing. When vibrating a freshly placed layer of concrete, insert the vibrator vertically through the preceding layers that are still completely plastic and withdrawn slowly, produc ing the maximum obtainable density in the concrete without creating voids. Do not permit the vibrator to enter or disturb concrete that has stiffened or partially set. The interval of vibrator placing shall not exceed 2/3 the effectiv e visible vibration diameter of the submerged vibrator. Avoid excessive vibration that causes concrete segregation or causes an inordinate amount of entrained air to move to the face of the forms.
c. Revibration of Retarded Concrete . Place concrete containing retarding admixture for structural walls and co lumns on a schedule that allows each layer of concrete to be in place and compacted for at least 30 minutes before the next layer of concrete is placed. Remove bleed water on the surface of the concrete before additional concrete is placed and revibrate the concrete in place before the next lift is placed. Remove concrete containing excess water or fine aggregate caused by vibration from tops of walls and columns while plastic, fill the spaces with co mpacted concrete of the correct proportions, and vibrate in place.
E. Slabs. Set screeds at maximum centers, as approved and verify correct elevations and consideration for any camber in the form. Compact and tamp concrete to bring 3/8 inch mortar to surface, and wood float to straightedges and screeds. Make finished surfaces level or sloped as detailed, with maximu m deviation of 1/4 inch from 10 feet straightedge for exposed finishes, and ther e shall be no low spots to impound water.
Do not use steel or plastic floats of any kind for initia l floating operations. Unless otherwise specified, do not apply hereinaf ter specified finishes until surface water disappears and surface is sufficiently hardened. Remove all bleed water and laitance as it appears.
3.04 CURING FORMED CONCRETE
Maintain forms containing concrete in a thoroug hly wet condition until removal. Maintain all concrete in a continuously moist condition for not less than 7 consecutive days after pouring.
Keep concrete moist with fine fog spray until pr otected by curing material s. Use water curing method, specified liquid membrane-forming compound, or concrete curing paper or mats. Obtain Engineer's approval for each specific use.
3.05 FINISHING FORMED CONCRETE
A. Immediately remove projections and offsets. Saturate form tie holes with water and fill voids with mortar of same mix as concrete (less coarse aggregate), cure, and dry. Cut out all surface holes 1/4 inch and larger, a ll rock pockets and damaged surfaces to sound concrete, edges square to surface a nd back beveled. Apply approved epoxy concrete adhesive and fill patched area with mortar as specified for the holes; allow Cast-In-Place Concrete
City of Anaheim 03300 - 13 6/27/2013
mortar to temper 1/2 hour before placing. Finish patches flush with adjoining surfaces and cure the same as the concrete. No other finishing operat ions are required for permanently concealed concrete.
B. All exposed interior and exterior formed concrete shall have gr out cleaned finish in conformance with applicable requirements of Section 10.3.2 of ACI Standard 301 to produce reasonably smooth surfaces suitable for painting, waterproofing and protective coating work. Provide similar finish on formed concrete surfaces of tank interiors and other waterbearing surfaces.
3.06 FINISHING SLABS AND FLATWORK
As specified in the preceding Article, initially co mpact, bring 3/8 in. mortar to surface, and float surfaces. Finished surfaces shall be "puddle-free" and level or sloped as indicated to above specified maximum deviation limits. Remove and replace surfaces which are not within these limits at no additional cost to Owner. Patching is not acceptable. Keep surface moist with monomolecular film or fine fog spray of water to prevent drying until curing media is applied, except that no sprinkling of water shall be done wh ile mechanically finishing concrete. Do not dust with cement or sand during finishing operations.
A. Precautions. Slabs have not been designed for heavy construction loads. Repair or replace as directed by Engineer, at no extra cost to Owner, all slabs damaged by use of heavy equipment at loadings.
B. Rough Slabs. Broom surfaces of slab afte r initial set of conc rete leaving coarse aggregate slightly exposed. Apply on following areas and surfaces:
1. Concrete to receive deferre d concrete, grout or mortar.
2. Tops of footings for masonry.
3. Chemical and Ammonia Rooms ~ Ramp entrances provide non-slip/non-skid rough finish.
C. Monolithic Trowel Finish. For all floor , slab, and flatwork surfaces not otherwise indicated or specified. After surface water disappears and floated surface is sufficiently hardened, steel trowel and retrowel to smooth surface. After concrete has set enough to ring trowel, retrowel to a smooth uniform finish free of trowel marks or other blemishes. Avoid excessive troweling that produces burnished areas.
D. Steel Float Finish. Same as monolithic tr owel finish, except omit second retroweling.
Apply on following area and surfaces:
1. Apply on floor slab surfaces in water-bearing structures.
E. Wood Float Finish. Float to screeds. When ready, finish with wood floats to a uniformly textured surface. Apply on following areas and surfaces:
1. Exterior walking surfaces exceeding 1:10 slope.
3.07 CURING SLABS AND FLATWORK
Apply curing media as soon as feasible after finishing operations without marring surfaces, and in Cast-In-Place Concrete
City of Anaheim 03300 - 14 6/27/2013
any case on same day. Keep surfaces moist unt il curing is applied. Ap ply liquid compounds in strict accordance with material manufacturer's pub lished application rates; apply 2 spray coats, second coat sprayed at right angle direction from first coat. Carefully mask and protect adjoining surfaces where compound is used.
A. Curing Period and Protection. Maintain cu ring materials in proper sealed condition for minimum of 14 days after application. K eep traffic on curing surfaces to minimum possible, and completely off liquid compound cured surfaces. Immediately restore any damaged or defective curing media.
B. Restriction. Do not use liquid memb rane-forming curing compound within water bearing structures, or on surfaces to r eceive deferred concrete or masonry, or on surfaces to receive fluid-applied protective coatings or waterproofing.
C. Liquid Membrane-Forming Curing Compound. Ex cept as restricted above, use liquid curing compound for all slabs, floors, and flat work. Cure slabs having floor hardener treatment in strict conformance with pr inted recommendations of floor hardener manufacturer.
D. Sheet Curing. Use concrete curing sh eet material, all joints sealed with pressure-sensitive tape; immediately repair any tears during curing period. Verify that surfaces remain damp for full curing period; if necessary or directed, lift sheeting and wet surfaces with clean water, and repl ace sheeting. Use on surfaces where liquid curing is not permitted.
E. Water Curing. Alternate to either li quid curing compound or sheet curing method.
Keep concrete continuously wet by ponding, sprinklers, or equivalent for entire curing period.
3.08 CHAMFERS AND FILLETS
Unless otherwise shown on the drawings or dire cted by the Owner, exposed edges of formed concrete structure shall be provided with a 3/4 in. x 3/4 in. chamfer. Where fillets are shown on the drawings they shall be formed with a 3/4 in. x 3/4 in. form chamfer.
3.09 JOINTS WITH SEALANT
Prepare surfaces and joints, mix and apply sealant in strict accordance with Section 07920 of these Specifications.
A. Manufacturer's Supervision. Arrange for a technical representa tive of the sealant manufacturer at the time sealant operati ons are started to s upervise and approve preparation, sealant mixing, and sealant applications procedures and applicators. The representative shall make frequent visits to the site to ensure the sealant installations conform to the manufacturer's instructions, and shall issue a written report to Owner covering each visit. Include the technical representative's expenses in the bid price.
B. Crack Sealing. Before and after backfilli ng of the tanks cut out all cracks over 0.01" wide in concrete surfaces of tanks and other water-containing structures as detailed and Cast-In-Place Concrete
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fill the groove with backing, primer, and sealant.
3.10 INSTALLATION OF PIPELINE S THROUGH CONCRETE STRUCTURES A. Whenever a pipeline or any material termin ates at or extends through a structural wall or sump, install the fitting or special cas ting required for the particular installation before pouring the concrete. Otherwise, submit shop drawings of alternate installation methods and obtain Owner's approval before concreting.
B. Whenever any run of pipe is installed pe r approved shop/erection drawings subsequent to placing of concrete, accurately positi on the opening in the concrete for such pipelines. Unless otherwise required, all pipes penetratin g fluid containing or earth supporting portions of the structure shall be ring flanged.
1. Opening shall be of sufficient size to pe rmit a perfect final alignment of pipelines and fittings without deflection of any pa rt and to allow adequate space for satisfactory packing where pipe passes through wall to insure water tightness around openings so formed.
2. The boxes or cores shall be provided with continuous keyways to hold the filling material in place and to insure a watertight joint.
3. Boxes or cores shall be fi lled with nonshrink grout.
3.11 FIELD QUALITY CONTROL
A. Continuous Inspection. Place all Class "1" and Class "2" concrete under the continuous inspection of Owner's Inspector.
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B. Concrete Tests. Owner's selected Testing Laboratory shall perform the following concrete tests:
1. Compressive Strength Tests. Make one set of at least four standard test cylinders from each day's placing and each l00 cubic yards, or fraction thereof, each class of concrete. Date cylinder, number and tag, indicating location in structure from which sample was taken. Indicate slump test result of sample. Do not make more than one set of test cylinders from any one location or batch of concrete.
2. Test Cylinders. Provide for testing by Owner or Testing Laboratory to take test cylinders at the job in accordance with ASTM Designation: C 31. Test specimens in accordance with ASTM Designation: C 39 at the age of 7 and 28 days. Furnish labor and assistance for casting test cylinders, and furnish moist curing cabinets, as required, conforming to ASTM Designation: C 31 at the site.
3. Core Tests. Should strength of concrete , as indicated by tests, fall below required minimum, then additional tests of conc rete (which the unsatisfactory samples represent) may be required by Owner. Testing Laboratory will make such tests in accordance with ASTM Designation: C 42. C ontractor shall fill the holes made by cutting cores with dry pack concrete. Tests for below-strength concrete shall be paid for by the Contractor even though such tests indicate the concrete has obtained the required minimum compressive strength.
4. Air Content. At time the compressive test cylinders are cast, test a sample of the concrete for air content in accordance with ASTM Designation: C 231.
3.12 ALTERATIONS AND REWORK
Heavily sandblast existing concrete surfaces to r eceive new concrete to expose coarse aggregate and produce a clean coarse textured surface. Coat the prepared surfaces with epoxy bonding compound immediately prior to placing concre te. The compound shall be Sika Chemical Company's "Sikastix Adhesive", Hunt Proce ss Company's "HB Series Epoxy Mortar", or approved equal. Use products of single manuf acturer throughout. Mix and apply in strict accordance with manufacturer's printed recommendations and directions for various conditions, as approved.
3.13 QUALITY OF WORK
If so ordered by the Owner, remove and replace all concrete which is defective or not within the permissible tolerances, at no extra cost to Owner.
END OF SECTION 03300
Structural and Miscellaneous Metals
City of Anaheim 05990-1 06/27/13
SECTION 05990
STRUCTURAL AND MISCELLANEOUS METALS
PART I - GENERAL
1.01 SUMMARY
A. Section Includes:
1. Custom fabricated metal items and certain manufactured units not otherwise indicated to be supplied under work of other sections.
B. Related Sections include but are not necessarily limited to:
1. Section 09900 - Painting.
1.02 QUALITY ASSURANCE
A. Referenced Standards:
1. Aluminum Association (AA):
a. 30-86, Specifications for Aluminum Structures.
2. American Society for Testing and Materials (ASTM):
a. A36, Standard Specification for Structural Steel.
b. A47, Standard Specification for Ferritic Malleable Iron Castings. c. A48, Standard Specification for Gray Iron Castings.
d. A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless.
e. A108, Standard Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality.
f. A123, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
g. A307, Standard Specification Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength.
h. A325, Standard Specification for High-Strength Bolts for Structural Steel Joints.
i. A496, Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.
j. A500, Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes.
k. A536, Standard Specification for Ductile Iron Castings. l. A563, Standard Specification for Carbon and Alloy Steel Nuts. m. A668, Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use.
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City of Anaheim 05990-2 06/27/13
n. A780, Standard Practice for Repair of Damaged Hot-Dipped Galvanized Coatings.
o. B221, Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes.
p. B308, Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Shapes.
q. B632, Standard Specification for Aluminum-Alloy Rolled Tread Plate. r. F467, Standard Specification for Non-Ferrous Nuts for General Use. s. F468, Standard Specification for Non-Ferrous Bolts, Hex Cap Screws, and Studs for General Use.
t. F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.
3. American Welding Society (AWS):
a. AS.1, Specification for Covered Carbon Steel Arc Welding Electrodes.
b. D1.1, Structural Welding Code Steel.
c. D1.2, Structural Welding Code Aluminum.
4. National Association of Corrosion Engineers (NACE).
5. U.S.Department of Labor, occupational Safety and Health Administration (OSHA):
a. 29 CFR 1910, OSHA Safety and Health Standards for General Industry (referred to herein as OSHA standards).
6. Provide all fabricated items complying with 1991 Uniform Building Code and OSHA Regulations.
B. Qualifications:
1. NACE certified inspector shall have minimum of 2 years experience performing inspections as indicated.
1.03 DEFINITIONS
A. Installer or Applicator: Installer or applicator is the person actually installing or applying the product in the field at the Project site.
1. Installer or applicator are synonymous.
1.04 SUBMITTALS
A. Shop Drawings:
1. Fabrication and/or layout drawings:
a. Submit shop drawings for all fabrications and assemblies.
Structural and Miscellaneous Metals
City of Anaheim 05990-3 06/27/13
2. Product technical data including:
a. Acknowledgement that products submitted meet requirements of standards referenced.
b. Manufacturer's installation instructions.
c. For grating, include manufacturer's standard allowable load tables.
B. Miscellaneous Submittals:
1. NACE inspector qualifications.
2. Certification of surface preparation.
3. Certification of paint application.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable:
1. Headed studs and deformed bar anchors:
a. Nelson Stud Welding Div., TRW Inc.
b. KSM Division Omark Industries.
c. Eric/Jones Stud Welding Div.
2. Expansion anchors:
a. Hilti Inc.
b. Phillips Drill Co., Inc.
c. Wej-it.
3. Adhesive anchors:
a. Hilti Inc.
b. Emhart Corp., Molly Div.
4. Castings, trench covers and accessories:
a. Neenah Foundry Co.
b. Deeter Foundry Co.
c. Barry Craft Construction Casting Co.
d. McKinley Iron Works.
5. All purpose metal framing:
a. Unistrut Building Systems.
b. B-Line Systems.
c. Allied Tube and Conduit.
B. Submit requests for substitution in accordance with Specification Section 01640.
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City of Anaheim 05990-4 06/27/13
2.02 MATERIALS
A. Steel:
1. Structural steel: ASTM A36.
2. Steel pipe: ASTM A53, Types E or S, Grade B.
3. Structural tubing: ASTM A500, Grade B.
4. Bolts, nuts and washers, high strength: ASTM A325.
a. Provide washers with all nuts.
5. Bolts and nuts unfinished: ASTM A307, Grade A.
a. Provide washers with all nuts.
6. Anchor bolts: ASTM A36.
7. Electrodes for welding steel: AWS AS.1, E70 Series.
8. Steel forgings: ASTM A668.
B. Iron:
1. Ductile iron: ASTM A536.
2. Gray cast iron: ASTM A48.
3. Malleable iron: ASTM A47, A197.
C. Stainless Steel:
1. Stainless steel: ASTM A666, Type 302, Grade A.
2. Stainless steel bolts and nuts: ASTM F593, Type 303 or 304 with minimum yield strength of 30,000 psi and minimum tensile strength of 70,000 psi.
D. Aluminum:
1. Rolled shapes and extrusions: ASTM B308 or B221.
2. Castings: ASTM B26.
3. Alloys 6061-T6 or 6063-T6 unless specified otherwise in this Section.
4. Aluminum angles, beams, pipes, plates and channels: Alloy 6061-T6.
5. Aluminum weir plates and baffles: Alloy 6061-T6.
6. Aluminum bolts: ASTM F468, alloy 2024 T4.
7. Aluminum nuts: ASTM F467, alloy 2024 T4.
8. Electrodes for welding aluminum: AWS Di.2, filler alloy 4043 or 5356.
E. Washers: Same material and alloy as found in accompanying bolts and nuts.
F. Expansion Anchors:
1. Kwik-Bolt by Hilti, Red Head by Phillips Drill Co., or approved equal.
G.
Adhesive Anchors:
1. Parabond capsule anchors by Molly; HVA anchors by Hilti; or approved equal.
Structural and Miscellaneous Metals
City of Anaheim 05990-5 06/27/13
2.03 FABRICATION
A. Verify field conditions and dimensions prior to fabrication.
B. Form materials to shapes indicated with straight lines, sharp angles, and smooth curves.
C. Drill or punch holes with smooth edges.
D. Weld Permanent Shop Connections:
1. Welds to be continuous fillet type unless indicated otherwise.
2. Weld structural steel in accordance with AWS DI.1 using Series E70 electrodes conforming to AWS AS-1.
3. Weld aluminum in accordance with AWS Dl.2.
4. Grind smooth welds that will be exposed.
E. Conceal fastenings where practicable.
F. Punch or drill for field connections and for attachment of work by other trades.
G. Fabricate work in shop in as large assemblies as is practicable.
H. Finishes:
1. Aluminum: Mill finished unless scheduled or otherwise specified or, if approved, finished in manufacturer's standard.
a. Coat surfaces in contact with dissimilar materials. See Section 09900.
2. See Section 09900 for preparation and painting of ferrous metals and other surfaces.
I. Fabricate grating, checkered plate and accessories using steel unless shown otherwise on Drawings.
2.04 SOURCE QUALITY CONTROL
A. Surface Preparation:
1. All miscellaneous metal fabrication item surfaces shall be inspected and approved by NACE certified coatings inspector prior to application of shop-applied paint coating.
a. Inspection shall be performed to determine depth of blast profile and cleanliness of surface.
b. Refer to Section 09900 for surface preparation requirements. c. Fabricator shall reblast and or re-clean surfaces as required until acceptable.
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City of Anaheim 05990-6 06/27/13
B. Paint Coating Application:
1. After surface has been accepted in writing by NACE certified coatings inspector, fabricator may proceed with application of paint coatings.
2. Application of paint coatings shall be observed and certified by NACE certified coatings inspector.
3. Refer to Section 09900 for painting requirements.
PART 3 - EXECUTION
3.01 PREPARATION
A. Prior to installation, inspect and verify condition of substrate. Installation of product constitutes installer's acceptance of substrate condition for product compatibility.
B. Correct surface defects or conditions which may interfere with or prevent a satisfactory installation.
3.02 INSTALLATION
A. Set metal work level, true to line, plumb.
B. Shim and grout as necessary.
C. Bolt Field Connections: Where practicable, conceal fastenings. Grind welds smooth where field welding is required.
D. Unless noted or specified otherwise:
1. Connect steel members to steel members with 3/4 IN DIA high strength bolts.
2. Connect aluminum to aluminum with 3/4 IN DIA aluminum bolts.
3. Connect aluminum to structural steel using 3/4 IN DIA stainless steel bolts.
Provide dissimilar metals protection.
4. Connect aluminum and steel members to concrete and masonry using 3/4 IN DIA stainless steel expansion bolts unless shown otherwise. Provide dissimilar materials protection.
a. Expansion bolts to have a minimum embedment of 4 IN into concrete and masonry unless indicated otherwise on Drawings.
E. Tighten ASTM A325 high-strength bolts in accordance with Section 11005.
1. Provide hardened washers for all ASTM A325 bolts. Provide the hardened washer under the element (nut or bolt head) turned in tightening.
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City of Anaheim 05990-7 06/27/13
F. Do not field splice fabricated items unless said items exceed standard shipping length or change of direction requires splicing. Provide full penetration welded splices where continuity is required.
G. Provide each fabricated item complete with attachment devices as indicated or required to install.
H. Anchor aluminum and metal work so that work will not be distorted nor fasteners overstressed from expansion and contraction.
I. Tie anchor bolts in position to embedded reinforcing steel with wire. Tack welding prohibited. Coat bolt threads and nuts with heavy coat of clean grease. Anchor bolt location tolerance: 1/16 IN. Provide steel templates for all column anchor bolts.
J. Accurately locate and place frames for openings before casting into floor slab so top of plate is flush with surface of finished floor. Keep screw holes clean and ready to receive screws.
K. Prepare and paint ferrous metals in accordance with Section 09900.
L. Coat aluminum surfaces in contact with dissimilar materials in accordance with Section 09900.
END OF SECTION
11-07 07920 - Joint Sealants - 1 of 5
SECTION 07920
JOINT SEALANTS
PART 1 - GENERAL
1.1 Work Included
A. This section includes materials, testing, and installation of joint sealants.
1.2 Related Work
A. Section 09900: Paints and Coatings
1.3 System Description
A. Where required throughout Work to provide a positive barrier against passage of moisture and air, furnish and install complete operating joint sealant system in conformance with manufacturer’s installation requirements and compliance with applicable building codes and standards.
B. Caulking, if noted shall be synonymous with sealant.
1.4 References
A. ASTM C834 Latex Sealants
B. ASTM C920 Elastomeric Joint Sealants
C. Fed Spec TT-S-01543A
1.5 Submittals
A. Furnish the following submittals.
SUBMITTAL DESCRIPTION
Catalog Data Required per catalog data requirements.
Installation
Instructions
Required per installation or application instruction
requirements. Include manufacturer’s recommendations for primer, joint cleaner and bond breaker.
Certificate of
Compliance
Submit sealant system certification per certificate of
compliance requirements.
Manufacturer’s
Statement of
Responsibility
Required per manufacturer’s statement of responsibility requirements.
Material and Color
Samples
Required.
Color Charts Submit Manufacturer’s standard color charts to allow owner to select color to match adjacent work.
Warranty Furnish 1-year warranty from date of final acceptance
1.6 Delivery, Storage and Handling
11-07 07920 - Joint Sealants - 2 of 5
A. Manufacturer’s instruction and warranty require ments for delivery, storage and handling of joint sealants shall be strictly followed.
B. Do not retain at the job site any material which has exceeded the shelf life recommended by the manufacturer.
C. Do not retain at the job site any mixed s ealant material which has exceeded the pot life recommended by the manufacturer.
1.7 Unit Prices
A. Payment for the Work in this section shall be included as part of the lump-sum or unit-price bid amount for which such Work is appurtenant thereto.
PART 2 - PRODUCTS
2.1 Acceptable Manufacturers
A. Acceptable manufacturers include the following:
ITEM MANUFACTURER MANUFACTURER
LOCATION
Sealant Type A
Self Leveling for
Horizontal
Surfaces
AEP Span
Atas International. Inc. Monarch
Approved equal
Sealant Type B
Non Sag for
Vertical Surfaces
AEP Span
Atas International. Inc. Monarch
Approved equal
Sealant Type C
Silicone
AEP Span
Atas International. Inc. Monarch
Approved equal
Sealant Type D
Acrylic Latex
AEP Span
Atas International. Inc. Monarch
Approved equal
2.2 Materials
A. Joint sealants shall be constructed of the following materials:
11-07 07920 - Joint Sealants - 3 of 5
ITEM MATERIAL SPECIFICATION
Sealant Type A Self
Leveling for Horizontal
Surfaces
Pour Grade
Urethane
ASTM C920 Grade P Class 25
Sealant Type B Non
Sag for Vertical
Surfaces
Single Component ASTM C920 Type S Grade NS Class 25
Sealant Type C
Silicone
Silicone Fed Spec TT-S-01543A Class A
Sealant Type D Acrylic
Latex
Acrylic Latex ASTM C834
Mastic Joint Sealant for
Buried Manholes and
Vaults
Mortar One part Portland cement to two parts well-
graded sand passing No. 8 sieve per
Specifications Section 03300.
Plastic sealing
compound
Federal Specification SS-S-00210
Primer
Nonstaining type recommended by sealant
manufacturer
Joint cleaner
Noncorrosive and nonstaining type
recommended by sealant manufacturer,
compatible with joint compounds
Bond Breaker Pressure sensitive
tape
Recommended by sealant manufacturer to
suit application.
Rope Yarn Rope fiber or
cotton wicking
Use raveled strands.
B. The following product design criteria, options and accessories are required:
ITEM DESCRIPTION
Color
Owner will select from standard colors available from
manufacturer
C. Do not use non-elastic putty-type compounds.
D. Sealant compounds shall be of proper consistency to be readily worked and not be affected by vibration or by long exposure to outside climate and temperature.
E. Sealant compounds shall form a thin, tough, elas tic film on surface, but remain permanently plastic underneath.
F. Sealant compounds shall contain no acid nor ingredients which will stain stone, corrode metal or have an injurious effect on painting.
G. Sealant compounds shall be colored to match adjacent work.
H. Special sealants called for elsewhere shall be provided and installed as directed by the manufacturer.
11-07 07920 - Joint Sealants - 4 of 5
PART 3 - EXECUTION
3.1 Preparation
A. Make field measurements needed to install jo int sealants before submitting catalog data or ordering. Make minor changes in dimensions a nd alignments as needed to avoid utilities or structural conflicts.
B. Verify that surfaces are ready to receive wo rk and that joint measurements and surface conditions are as recommended by sealant manufacturer.
C. Remove loose materials and foreign matter which may affect adhesion of sealant.
D. Joints and spaces to be sealed shall be clean, free from dust, and dry.
E. Joints more than ¾-inch deep and joints where suitable backstop has not been provided shall be packed with rope yarn to within ½-inch of surface before applying and sealing.
3.2 Application
A. Install joint sealants at the location shown on the Plans and Submittals.
B. Clean joints and install joint sealants accord ing to manufacturer’s installation and warranty requirements. Manufacturer’s requirements for installation, application, connection, erection, maintenance, operating, cleaning, conditioning and startup of products shall be strictly followed.
C. Install joint sealants to tolerances and within temperature ranges recommended by manufacturer.
D. Tool joints concave unless otherwise shown.
E. Joints in stone and precast work shall be slightly convex.
F. Seal joints before final coat of paint is applied to adjacent work.
G. Apply compound with a pressure gun having proper size nozzle or with knife as required.
H. Use sufficient pressure to fill all voids and joints solid. Superficial painting of joints with a skin head will not be accepted.
I. Remove excessive sealant and leave surfaces neat and clean. Upon completion, sealant shall have a smooth, even finish.
J. All sealed joints shall be watertight.
K. Refer variances between manufacturer’s installation instructions and Contract Documents to Owner’s Representative.
3.3 Field Quality Control
A. Field testing shall include the following:
11-07 07920 - Joint Sealants - 5 of 5
ITEM TEST FOR
TEST STANDARD
(ASTM OR
OTHER TEST
STANDARD)
FREQUENC
Y
FIRST
TEST
PAID
FOR BY
RETEST
S PAID
FOR BY
Joint
Sealants
Installation
& Leakage
Visual inspection of
finished installation
and water test at
Owner’s discretion
1 inspection Owner Owner
Field
Performance
Demonstrate
compliance to
Contract Documents
and Manufacturers’
printed Literature
1 test Contractor Contractor
11 month
Warranty
Inspection
Demonstrate
compliance to
Contract Documents
and Manufacturers
printed Literature
1 test Owner Contractor
s
END OF SECTION
Painting and Protective Coatings
City of Anaheim 09900 - 1 6/27/2013
SECTION 09900
PAINTING AND PROTECTIVE COATINGS
PART 1 - GENERAL
1.01 SCOPE
Requirements of the Conditions of the Contract apply to this Section. Provide all labor, materials, apparatus, scaffolding, and all appur tenant work in connection with painting and protective coatings, complete as indicated, specified and required.
A. Work Included in This Section. Principal items to be painted include:
1. All exposed piping, conduits, ducts and other metal surfaces, interior and exterior, except as hereinafter specifically excluded.
2. All submerged and intermittently submerged metal surfaces, except stainless steel.
3. The interior of manholes, junction structures, and similar structures.
4. Equipment furnished with and without factory finished surfaces, except as hereinafter specified otherwise.
5. Equipment on which factory applied finishes have been marred, abraded, scratched, nicked, or otherwise damaged.
B. Related Work Specified Elsewhere. Th e following surfaces, in general, shall not be painted:
1. Plastic surfaces and fiberglass reinforced plastic (FRP) surfaces unless otherwise noted or indicated.
2. Nonferrous metals and stainless steel unless otherwise noted or indicated.
Galvanized metal shall not be considered a nonferrous metal.
3. Mechanical and electrical equipmen t with approved factory finish as specified herein.
4. Waterproofing, dampproofing and roof covering work.
5. Pavement striping and marking specified in other sections.
C. In no case shall any ferrous metal su rfaces, except stainless steel, be left unpainted or uncoated even though not speci fically indicated herein or on the Drawings.
D. Contractor shall provide extra paint for touch up by the Owner.
1.02 GUARANTEE
Provide a three (3) year guarantee which co mmences on the date of acceptance against failure of all coatings. Failure of any coa ting during the guarantee period shall be repaired by the Contractor who shall absorb all costs related to the repair of the coating.
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1.03 REFERENCE SPECIFICATIONS AND STANDARDS
A. Without limiting the generality of other requirements of these Specifications, all cleaning, surface preparation, and coating shall conform to the applicable requirements of the referenced portions of the standards specified herein to the extent that the requirements therein sp ecified are not in conflict with the provisions of this Section.
B. Unless otherwise specified, all work and materials for the preparation and coating of all metal surfaces shall c onform to the applicable requirements specified in the Steel Structures Painting Manual, Volume 2, Systems and Specifications 1967, published by the Steel Structures Painting Council.
C. The surface preparation specifications of the Steel Structures Painting Council (SSPC) referenced herein, shall form a part of this Section.
D. Quality Evaluation. Evaluation of surface preparation for ferrous metals will be based upon SSPC-Vis 1 ASTM Designati on D 2200 and "Standard Methods of Evaluating Degree of Rusting on Painte d Steel Surfaces", SSPC-Vis 2 ASTM Designation D 610.
E. South Coast Air Quality Management District's Requirements. The Volatile Organic Compounds (VOC) levels of all coatings shall comply with the requirements of the South Coast Air Qu ality Management District (SCAQMD) for shop and field applications, current at the time of application.
1.04 SUBMITTALS
A. Schedule. The Contractor shall s ubmit his proposed schedule of painting and coating to the Engineer for approval not less than 30 working days prior to the start of painting work.
B. Materials List. The Contractor sha ll submit to the Engineer for approval 6 copies of a list describing the materials he proposes to use. The materials list shall indicate the brand names and the surf aces to which the material is to be applied. Contractor shall also furnish the VOC level of each proposed coating to verify compliance with SCAQMD's requirements.
C. Color Samples. Submit to the Owner /Engineer for approval 2 samples of all selected colors. Painting shall not be st arted until samples of colors have been approved. For colors to be applied on smooth surfaces, the sample shall be prepared on a flat sheet of metal, temper ed hardboard, or other sheet material.
The minimum size of sample shall be 8-1/2 by 11 inches. The sample shall show the color of primer, undercoat, and finish co ats. The finish coat shall be applied in a band not less than 3 inches wide. The color of the undercoat shall be slightly different from the finish coat so as to be distinguishable in artificial or Painting and Protective Coatings
City of Anaheim 09900 - 3 6/27/2013
natural illumination. The approved colors of the undercoat and finish coats shall be uniform throughout the work.
1.05 PROTECTION OF WORK
A. Place drop cloths where required as a protection from spatter and droppings.
Drip and spatter, spots and stains, shall be removed from all surfaces.
B. Provide surfaces not required to be coated, but which are adjacent to surfaces to be cleaned and coated, from stains a nd damage during the cleaning and coating operations.
C. Handle items of metalwork which have been coated with care and protect their coatings from damage. Repair and rest ore coatings which have been damaged by handling, shipping, welding, cleaning, pa inting, or other operations to their original condition. Items of metalwork which have been coated shall not be welded unless damaged coatings are repairable and unless the damaged coatings and repairs can be inspected by the Engineer.
D. Protect from damage all work including the work of others during the time work specified in this Section is in progress.
1.06 MANUFACTURER'S RECOMMENDATIONS
Unless otherwise specified herein, strictly observe the paint and coating manufacturer's printed recommendations and instructions for thinning, mixing, handling, applying, and protection of his coating materials; for prepara tion of surfaces for coating; and for all other procedures relative to coating. No substitutions or other deviations will be permitted without written permission of the Owner.
1.07 DELIVERY AND STORAGE
A. Delivery. Deliver materials in the or iginal unbroken packages or containers bearing the brand name and manufacturer 's name. Do not change or thin materials except as indicated by the manuf acturer's printed directions, or as specified herein. When requested, submit complete specifications and samples of materials to the Engineer for approval.
B. Storage. Store and mix materials onl y in areas designated by the Engineer for that purpose. Keep storage and mixing ar eas clean and free of rags, waste, and scrapings.
1.08 SAFETY
In accordance with the requirement s of the latest revision of the Safety Construction Safety orders of the California Division of Occupati onal Health and applicable OSHA Regulations for Construction provide and require the use of personal protective lifesaving equipment for all persons working in or about the project site.
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A. Respirators shall be worn by all pers ons engaged in, and assisting in, spray painting. In addition, workers engaged in or near the work during sandblasting shall wear eye and face protection devices meeting the requirements of ANSI Z87.1 latest revision, and approved OSHA Regulations for sandblasting operations and approved air-purifying, half -mask or mouthpiece respirator with appropriate filter.
B. Ventilation. Where ventilation is used to control potential exposure to workers as set forth in Section 1910.94 of th e OSHA Regulations for Construction, ventilation shall be adequate to reduce th e concentration of the air contaminant to the degree that a hazard to the worker does not exist. Methods of ventilation shall meet the requirements set forth in ANSI-Z9.2, latest revision.
C. Sound Levels. In accordance w ith Sections 1926.52 and 1926.101 of OSHA Regulations For Construction, whenever the occupational noise exposure exceeds maximum sound levels as set fort h in Table D-2 therein during blast cleaning, ear protective devices shall be fitted and determined individually and used, and a continuing, effective hearing safety program shall be administered.
1.09 RIGHT OF REJECTION
The Owner shall have the right to reject all material or work that is unsatisfactory, and require replacement at the expense of the Contractor.
1.10 JOB CONFERENCE
Prior to commencing work a pre-job conference shall be held for the purpose of reviewing and clarifying the painting and coating requirements of the project. The Owner's Representative, Contractor, Applicator, and Coatings and Paint Manufacturers, shall be present. A schedule of work to be accomplished will be established.
PART 2 - PRODUCTS
2.01 GENERAL
Surfaces to receive paint protective coating materi als as herein specified in this Section shall be coated in conformance with the applicable coating systems specified herein. All materials specified by name and/or manufacturer or sel ected for use under these Specifications, shall be delivered unopened at the job site in their original containers and shall not be opened until inspected by the Owner. Whenever a manufacturer 's brand name is specified, it is intended to define the general type and quality of paint or coating desired. Other coatings or paints of equal quality may be used. All paint, and coa tings shall be produced and applied as herein called for or, if not specifically called for, it shall be applied in accordance with the manufacturer's printed recommendations as approved by Owner. As far as possible, all paint and coating materials shall be provided by a single source supplier.
2.02 PAINTING AND COATING REQUIREMENTS
Painting and Protective Coatings
City of Anaheim 09900 - 5 6/27/2013
A. General.
1. Except when specifically or otherwise exempted herein or on the Drawings, all exposed interior and exterior unmachined metal surfaces of piping, valves, equipment, structural steel, including galvanized surfaces, doors and window frames, and other metal work, except nonferrous or stainless steel surfaces, shall be painted in accordan ce with the requirements hereinafter specified, and as shown on the Drawings. Other pipe coatings are specified in Division 15. Before procuring or fabricating equipment to be finish- coated, submit for approval, by the Engineer, the finished color of each item of equipment.
2. The following listed surfaces shall not be painted:
a. Concrete surfaces not specified under this Section.
b. Polyvinyl chloride piping except non- pressure PVC pipe specified or required under another section.
c. Surfaces having an approved, factory-applied finish, if it matches the Owner color code or requirement.
d. Concealed electrical conduits.
e. Concealed galvanized steel, except as otherwise indicated.
3. The finish coats shall be omitted for the exterior surfaces of valves, fittings, and piping in structures with manhol e or right-of-way type covers for access. However, except where surfaces are to be top-coated with high solids epoxy, the valve, fittings, and bare metal surfaces of piping shall receive 2 coats of zinc-rich polyamide epoxy primer to achieve a total of 6 mils minimum dry film thickness.
4. Electrical pullboxes shall be hot-dip galvanized. Electrical pullboxes shown on the Drawings to be installed in corrosive environments shall be coated on the interior and exterior with high solids epoxy. The epoxy shall be applied in multiple coats. The finished dry film thickness shall be 30 mils. Except for the pullboxes to be coated with high solids epoxy, galvanized electrical pullboxes as shown on the drawings sha ll be pretreated with manufacturer's recommended vinyl wash after surface preparation, 1 coat of polyamide epoxy primer and 2 finish-coats of exterior acrylic polyurethane enamel.
5. Except as otherwise specified, galvanized surfaces required to be painted shall be given a vinyl wash pretreatme nt and prime coat prior to painting.
Vinyl wash and prime coat shall conf orm to the printed recommendations of the finish-coating material manufacturer.
6. Portions of structural steel and surf aces of other metalwork to be wholly embedded in concrete need not be painted; provided, that they shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar, and other foreign substances immediat ely before the concrete is placed.
Bottoms of baseplates to be placed on drypack or grout, which have not been galvanized, shall be prime coat ed with minimum 6 mils dry film Painting and Protective Coatings
City of Anaheim 09900 - 6 6/27/2013
thickness of zinc-rich primer. Bottom of handrail posts shall be coated with zinc-rich primer prior to grouting.
7. Surfaces of stainless steel; electrical outlets, fixtures and switch plates; fiberglass; and fiber-reinforced plastic (FRP) are not required to be painted.
8. Unless otherwise shown on the Draw ings, surfaces which will not be accessible after assembly or after inst allation, except surfaces specified to receive zinc-rich primer, shall be given a second shop coat of primer.
9. Channels, struts, supports, clamps, and miscellaneous metalwork which cannot be adequately or completely painted in place shall be painted prior to installation and the accessible visibl e portions thereof touched up, if required, after installation.
10. Concrete block masonry surfaces require d to be painted shall be given 1 full coat of concrete block and masonr y primer and 2 coats of 100 percent acrylic emulsion masonry paint by Dunn-Edwards Corporation, Sherwin- Williams, or an approved equal. If a uniform finish is not obtained with 2 coats, additional coats shall be applied at no additional cost to the Owner.
11. Unless otherwise shown, portions of pi pe which extend into the concrete wall of a structure, and are not coated, shall be coated with zinc-rich primer for that portion of the pipe which w ill be embedded in the wall, and this coating shall extend not less than 3 inches inside and outside the structure.
The zinc-rich material shall be applied in multiple coats to produce a dry film thickness of not less than 6 mils.
12. Continuously submerged and intermittently submerged machinery, equipment and piping of carbon steel, including galvanized surfaces, shall be painted with high solid epoxy whether or not it is shown on the drawings.
13. All coatings in contact with water sh all be approved for use in potable water systems.
14. After installation of metalwork thoroughl y clean all surfaces to be painted and repair all damaged areas in the ex isting paint film prior to placing of succeeding coats. Repair work shall meet the Engineer's approval. Color paint shall be applied in accordan ce with the manufacturer's printed directions.
2.03 QUALITY ASSURANCE
A. Definitions. The term "coating materials, " as used herein, shall include enamels, paints, sealers, epoxy resins, stains, and all other paints and protective coatings, excepting galvanizing, whether used as a pretreatment, primer, intermediate coat, or finish coat.
Painting and Protective Coatings
City of Anaheim 09900 - 7 6/27/2013
B. Product Qualifications.
1. Paint product names and numbers used in these specifications identify materials which are approved for the use specified. Any change in the formulation or quality control tole rances of an approved product will necessitate fresh approval. Other pr oducts will be approved if sufficient proof is submitted to demonstrate th at they are equal to the products specified. The Owner's decision in this respect shall be final.
2. All specified coating systems shall ha ve compatible products of the same manufacturer which includes primers and finish coats.
C. Compatibility. Only compatible materials shall be used in the work. Particular attention shall be directed to compatib ility of primers, intermediate coat, and finish coats. If necessary, subject to approval of the Owner, a compatible barrier coat shall be applied between all existi ng prime coat and subsequent field coats to insure compatibility.
D. Colors. All colors and shades of colo rs of all coats of paints and protective coating material shall be as selected by the Owner. Each coat shall be of a slightly different shade, as directed by the Owner to facilitate inspection of surface coverage of each coat.
Finish-paint for metalwork shall matc h the Federal Standard 595a(68) color listed below, as applicable. The numbers define the required color but do not necessarily indicate the required degree of luster, which shall be full gloss in each case.
1. Light grey to be selected by Owner, fo r interior and exterior metal surfaces including structural steel, miscellaneous metalwork platforms, and handrails (except for handrails selected to be painted yellow). In general, the above roof equipment (antenna, vents, exhaus t fans, etc.) should be the same color as the roofing
2. Tan, color No. 20372, for hatch covers and operating handles of valves and equipment;
3. Exterior finishes for hydrants, tr affic and protective posts, doors and louvres, and other metal work shall be painted, in addition to prime coat, of a color to be selected by the Owner.
2.04 PAINTING AND COATING SYSTEMS AND MATERIALS
Materials shall include those listed in the following paragraphs:
A. Ferrous metals other than stainless steel, including architectural steel, doors and window frames, louvres and vents, expos ed to normal atmospheric conditions such as valves, pumps, motors, handrails, etc. will require the following coating systems.
Painting and Protective Coatings
City of Anaheim 09900 - 8 6/27/2013
Ameron Amershield Polyurethane topcoat
Amerlock 400 Epoxy primer
Devoe/Napko Prufthane 359 High Build Polyurethane topcoat Chemfast 547 Thixomastic primer
Porter 8610 Hi Build Hi Solids Polyurethane topcoat
7500 Magna Prime primer
Valspar 54-Y-12 V-Thane Polyurethane topcoat
75-W-9 High Solids Epoxy Mastic primer
Sherwin-Williams Hi-Solids Polyurethane B65W300 top coat Epoxy Mastic Aluminum B62S10 primer
Primers shall be applied to achieve a minimum of 6 mils DFT (those listed can achieve this in one coat). Topcoats sh all be applied to achieve a minimum of 4 mils DFT (those listed can achieve this in one coat). If maximum mil thickness or hiding is not accomplished in one coat th en subsequent coats shall be applied.
Polyurethane topcoats used on this pr oject shall be acrylic types containing pigments that are ground into the coa ting at the time of manufacturing. All colors shall conform to Federal Specification 595a.
B. Submerged carbon steel items or intermittently submerged carbon steel items such as valves etc. will require coating with the following materials:
Ameron 395 High Solids Epoxy (self priming)
3-M Company Scotchkote 306 Epoxy (self priming)
Tnemec 104 Hi Build Pota-Pox Epoxy (self priming)
Sherwin-Williams Hi-Solids Catalyzed Epoxy, B62W201
(self priming)
Materials shall be applied in multiple coats to produce a minimum DFT of 30 mils.
C. Ductile iron and carbon steel contained in vaults and structures such as piping, etc. will require two coats of the following materials; Ameron 400 Epoxy Mastic
Carboline Carbomastic 15 Epoxy Mastic
Devoe/Napko Chemfast 547 Thixomastic
Glidden 5475/5476 Glid Guard Metallic High
Build Epoxy
Sherwin-Williams B62S10 Aluminum Epoxy Mastic
Valspar 75-A-1 Alumapoxy
Materials shall be applied to produce a minimum DFT of 12 mils.
Painting and Protective Coatings
City of Anaheim 09900 - 9 6/27/2013
D. Zinc-rich primers applied in 2 coats to achieve 6 mils D.F.T. and not topcoated shall be as follows:
Ameron-Amercoat 68 H.S. Epoxy Zinc Rich
Devoe/Hapko #14730 Epoxy Zinc Rich
Porter #308 Zinc Lock Epoxy Zinc Rich
R.R.G. #UC46079 Aquapon Zinc Rich Epoxy
Sherwin-Williams Zinc Clad 8
Zinc-rich primers are not to be applied on any items which will receive topcoats consisting of self-priming, high solids epoxy materials.
E. Heat Fusion Epoxy Coating.
1. Surface Preparation - Metal shall be ab rasive blasted to achieve a "white metal" finish in accordance with th e requirements of SSPC-5. The blast media selected shall be of such size as to achieve an anchor pattern profile of not less than 1.5 mils nor more than 2.5 mils. Prior to blast cleaning, all oil, grease, and other deposits sha ll be removed by solvent cleaning in accordance with the requirements of SSPC-1.
2. Heating.
a. Metal parts to be coated shall be preheated to the temperature and for the length of time recommended by the coating manufacturer. b. Post heat curing of fusion-bonded epoxies shall also be done to the temperature and for the length of time recommended by the coating manufacturer.
3. Coating Application.
a. After parts have been preheated, the temperature shall be tested using a calibrated pyrometer. Oxidation of steel prior to coating in the form of "blueing" or any other apparent oxi de formation will not be accepted.
Whenever such oxidation occurs, said part shall be cooled to room temperature and recleaned.
b. Heat fusion bonded materials shall be applied using an electrostatic spray apparatus or fluidized bed.
c. Finished dry mil thickness shall be a minimum of 12 mils to maximum 16 mils to produce a completely holiday-free and uniform surface.
After cooling, the entire coated surface shall be tested for porosity using a 67-1/2-volt Tinker and Raso r Model M-1 non-destructive type holiday detector. Random dry film thickness testing will be done using an acceptable calibrated gauge.
d. During the coating and curing operati ons, metal parts shall be hand-led with care to avoid damage to the co ating. Any damages to the coatings shall be repaired in a manner and with materials recommended by the coating manufacturer.
e. Areas not required to be coated like bolt holes shall be protected using an approved heat resistant tape.
Painting and Protective Coatings
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4. Materials. Materials shall include the following:
3 M Scotchkote No. 203
Dexter Corp Hysol DK 18
5. Storing and shipping. Sufficient spacer s and padding shall be used during storing and shipping of coated metal part s to prevent damage to the coating.
Chains or steel bands shall not be used without the proper padding.
F. Secondary Containment Coating
1. Product.
a. Concrete surface protection for secondary containment shall be 35 to 45 mils DFT of a flake filled vinyl ester, Plasite Protective Coatings #4100 or equal.
b. Concrete surface imperfections (bug hol es, etc.) shall be filled and/or sealed with a 100% solids Epoxy fille r, Plasite Protective Coatings #9028 or equal.
2. Application.
a. Concrete shall be abrasive blast cleaned to remove laitance and to provide a hard, firm, clean and neutral fully-c ured concrete surface for coating.
After blasting, concrete surface sha ll be clean, rough, and similar in appearance to medium grade sandpaper.
b. All surface imperfections shall be f illed and sealed in accordance with manufacturers instructions.
c. Two or more coats of flake filled vinyl ester shall be applied in strict accordance with manufacturer’s recommendations.
d. Visual inspection shall be performed. All coated surfaces shall be free from pinholes, sags, runs, embedded debris, etc.
2.05 SHOP PAINTING OF VALVES, METERS, PUMPS AND OTHER FACTORY
PAINTED EQUIPMENT
A. Unless otherwise specified, interior ferrous metal surfaces of all valves, meters, pumps, and other factory painted equipmen t shall be shop painted as follows:
Surface preparation and cleaning shall be as specified for painting these surfaces with not less than 30 mils of high solids e poxy as specified in coating system B.
An NSF approved heat fusion epoxy coati ng as specified in coating system E will be an acceptable alternative.
2.06 FILM THICKNESS
A. Unless otherwise specified, the complete d paint coatings shall have the following minimum dry film thicknesses; however, in all cases, paint films shall be sufficiently thick to provide complete c oncealment of the surfaces to which they are applied:
1. All metal specified to be painted sh all have film thicknesses in accordance with Article 2.04 hereof.
Painting and Protective Coatings
City of Anaheim 09900 - 11 6/27/2013
2. Masonry, concrete, or plaster:
a. Polyvinyl acetate: 3 mils
b. Enamel: 5 mils
B. Dry film thicknesses shall include shop applied primers, field applied primers, undercoats, and topcoats, but shall not include surface fillers or galvanizing.
2.07 PROTECTION OF SHOP COATED SURFACES
Protect surfaces of all shop prime or finish coated products from solar exposure at all times.
Handle with care during transport and st orage in accordance with manufacturer's recommendations to avoid damage to the shop coated surfaces.
PART 3 - EXECUTION
3.01 STORAGE, MIXING, AND THINNING
Protect paint and coating materials from expos ure to cold weather. Materials shall be thoroughly stirred, strained, and kept at a unifo rm consistency during application. Do not mix materials of different manufacturers togeth er. Thin packaged materials immediately prior to application in accordance with the manufacturer's directions.
3.02 EXAMINATION OF SURFACES BEFORE SURFACE PREPARATION Examine all surfaces to be coated, and corr ect all surface defects before sandblasting or application of any coating material. Beginni ng the work of this Section without reporting unsuitable conditions to the Owner constitutes acceptance of conditions by the Contractor.
Any required removal, repair, or replacement of this work caused by unsuitable conditions shall be done at no additional cost to the Owner. All marred or abraded spots on shop- primed and factory-finished surfaces shall r eceive touch-up restoration prior to any other coating application.
3.03 PROTECTION OF ITEMS NOT TO BE COATED
Remove or mask prior to surface preparation and painting operations all hardware, hardware accessories, name plate data tags, machined surf aces and similar items in contact with coated surfaces not to be coated. Following completion of coating of each piece, reinstall removed items. Such removal and installation shall be done by workmen skilled in the trades involved.
3.04 SURFACE PREPARATION
A. Clean and dry all surfaces and shall a pply protective coatings to surfaces as herein specified. All defects shall be scraped, cleaned, and repaired as required by the Engineer to produce first-class workmanship.
B. On metal surfaces, weld spatter, burns, weld smoke stains and other irregularities shall be carefully removed or repair ed, and all welds shall be ground smooth, Painting and Protective Coatings
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burrs shall be removed, and all sharp edges and corners shall be ground to a curve before cleaning the surfaces.
C. Sandblast metal surfaces, except galvanized steel, to be coated with dry sand to "white" metal in accordance with the requirements of Specifications SSPC-SP5.
D. Perform blasting with dry compressed air, compressed-air blast nozzles, and a dry silica sand of a particle size not larger than that which will pass through a 16- mesh screen, U.S. Sieve series. Any dry abrasives used on this Project shall be certified by the California Air Resources Board (CARB) for unconfined blasting pursuant to Section 92520 of Subchapter 6, Title 17, California Administration Code. In sandblasting to "white" metal, re move all mill scale, rust, loose scale, paint, and other foreign matter. After blasting, remove all traces of sandblasting products from the surfaces by cleaning with a vacuum, by brushing with clean brushes made of hair, bristle, or fiber, or by blowing with compressed air from which all oil and water have been removed.
E. The height of the surface profile afte r blasting shall not exceed 3 mils and the surface shall be a uniform, gray-white me tallic color. Apply the first of the protective coatings to the surface within 2 hours after completion of blasting. Do not touch the surfaces between the time of blasting and the time that the coating is applied.
F. Metal surfaces which have been previously sandblasted and given the required shop coats of primer will not be require d to be recleaned by sandblasting if the original coat is intact. Clean th ese surfaces by approved means which will properly prepare them for repriming and fi nish paint. Wherever any previously primed or painted surfaces have become corroded or damaged, clean the surface to "white" metal by sandblasting before a ny paint is applied. Clean and repair abraded and bare spots in shop-prime coats with the appropriate metal primer.
G. Galvanized metal shall be clean, dry, and free of dust, dirt, oil, grease, and other deleterious matter. All galvanized su rfaces shall be power-tool-cleaned in accordance with the requirements of Specification SSPC-SP3.
H. Remove all grease, dust, bond-breaking materials, and efflorescence from concrete and concrete block surfaces. If efflorescence is present, neutralize the surfaces with 15 percent solution of phosphor ic acid. Use a stiff bristle broom or brush to spread the acid solution evenly over the surface. After the foaming action stops, in 3 to 5 minutes, flush the surface thoroughly with water and re- scrub with stiff bristles to remove salts formed by the acid solution. Rinse surfaces again and allow to dry before applying coatings Painting and Protective Coatings
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3.05 APPLICATION OF PROTECTIVE COATINGS
A. General.
1. Perform painting in a skillful and workmanlike manner. Apply paint only on thoroughly dry surfaces, during periods of favorable weather. Allow each coat of paint to dry properly before the succeeding coat is applied.
Replace newly applied coatings which are damaged by the elements at no additional cost to the Owner.
2. Do not paint or coat during rainy weat her, or when the temperature of the surface to be coated is below 50 oF, or is anticipated to be below 50 oF within 24 hours. Unless otherwis e directed by the Engineer or recommended in the manufacturer's prin ted instructions, surface, ambient, and paint temperatures shall be between 50oF and 100oF.
3. Use oil and water separators in a ll compressed-air lines used in spray painting and sandblasting operations, to re move oil or moisture from the air before it is used. Place separators as cl ose as practicable to the equipment.
Application equipment shall conform to the requirements and recommendations contained in the paint manufacturer's printed instructions.
4. Do not apply paint or other coating before the Engineer has approved the surface preparation. If paint or other coating has been applied without such approval and the Engineer so direct s, remove it by sandblasting or other approved means and recoat the surface in accordance with these specifications, at no extra cost.
5. Place drop cloths where required as a protection from spatter and droppings.
Remove drip and spatter, spots and stains, from all surfaces.
6. Items of metal work which have been coated shall be handled with care and their coatings shall be protected from damage. Repair and restore coatings which have been damaged by ha ndling, shipping, welding, cleaning, painting, or other operations to their original condition. Items of metal work which have been coated shall not be welded unless damaged coatings are repairable and unless the damaged coatings and repairs can be inspected by the Engineer.
7. Assembled parts shall be disassemb led sufficiently before painting or coating to insure complete coverage by the required coatings. If approved by the Engineer, paint may be applied by brushing, rolling, dipping or spraying; provided, these methods of application are recommended and shown on the coating manufacturer's data sheet; and provided further; that spraying shall not be used where th e paint could be deposited on surfaces other than those intended to receive it. Roller or spray applied paint shall have the same dry film thickness as brush-applied.
8. Apply paint evenly without sags or runs. Thoroughly coat rivets, welds, edges, crevices, and other irregularities. If necessary, apply an extra coat to Painting and Protective Coatings
City of Anaheim 09900 - 14 6/27/2013
provide the same resistance to moistu re penetration prevailing on adjacent smooth surfaces which have been coated to the required dry thickness.
9. Remove canopies of lighting fixtures a nd cover and protect the fixtures from damage. Remove electrical switch and outlet plates before painting adjacent surfaces and replace plates on comple tion of the work. Provide the necessary protection to prevent damage to the painted surfaces and repair all painted surfaces of equipment scratched or damaged. Keep equipment name and description plates free of paint. Remove all paint and thoroughly clean glass surfaces.
B. Application.
1. Apply primers, finish-paints and coatings, and linings in accordance with the printed instructions of the manuf acturers of the materials and these specifications. All prime, intermediate, and finish coating materials applied to given surfaces shall be compatible products of the same manufacturer.
2. Apply all zinc-rich prime coatings for piping, valves, equipment, and miscellaneous metal surfaces by brush or spray methods to a minimum dry film thickness of not less than 3 mils.
3. Where coal-tar epoxy is shown on the Drawings, apply the coal-tar epoxy in multiple applications to produce a minimum overall dry film thickness of 20 mils in addition to primer coats. I ndividual coats shall not be applied in thicknesses which could cause runs. Th e finished coating shall be uniform in thickness and holiday free.
4. Clean all surfaces of all carbon steel flanges, including the bolt holes, by approved methods and paint with zinc-ri ch primer sufficient to attain a uniform dry film thickness of 3 mils.
5. Apply intermediate and finished coats to all surfaces primed with zinc-rich primer except the contact faces of fl anges, flange bolt-hole surfaces, and contact faces of webs and tap plates.
6. Coat concrete surfaces as specified. Apply the coating in accordance with the manufacturer's printed instructions for such surfaces. Apply coats as recommended by the manufacturer's time intervals.
C. Galvanizing.
1. Steel designated on the drawings, shall be hot-dip galvanized after fabrication.
2. Fabricated steelwork required to be ga lvanized shall, after the steel surfaces have been thoroughly cleaned of rust a nd scale, be galvanized in accordance with ASTM Standard A 123-78, except that galvanizing shall withstand seven 1-minute immersions when tested in accordance with the requirements of ASTM Standard A 239-73 (1983).
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3.06 TESTING AND INSPECTION
A. Inspection Devices. Furnish, until final acceptance of coating and painting, inspection devices in good working condition for detection of holidays and measurement of dry-film thickness of coa tings and paints. Also furnish U.S.
Department of Commerce, National Bu reau of Standards certified thickness calibration plates to test accuracy of dry-film thickness gauge and certified instrumentation to test accuracy. Dry-film thickness gauges shall be made available for the Inspector's use at all times until final acceptance of application.
Operate holiday detection devices in th e presence of the Inspector. Operate inspection devices in accordance with th e manufacturer's instructions at the direction of the Engineer.
B. Conduct film thickness measurements and electrical inspection of the coated surfaces with equipment furnished and recoat and repair as necessary for compliance with the Specifications.
C. After repaired and recoated ferrous meta ls areas have cured, final inspection tests will be conducted by the Engineer. Coa ting thicknesses specified in mils on ferrous substrates will be measured with a nondestructive magnetic type dry-film thickness gage such as the Elcometer, manufactured by Gardner Laboratories, Inc. Discontinuities, voids and pinholes in the coatings will be determined with a nondestructive type electrical holiday det ector. Epoxy coatings and other thin film coatings will be checked for disc ontinuities and voids with a low voltage detector of the wet-sponge type, such as Model M1 as manufactured by Tinker and Rasor. Use a non-sudsing type we tting agent, such as Kodak Photo-Flo, which shall be added to the water prio r to wetting the sponge. A high voltage, low current, spark type detector such as Model EP, manufactured by Tinker and Rasor, will be used for electrical inspection of only coal tar enamel. Tape type coatings will be inspected for holiday s using a device designed for use in detecting such flaws. All holiday de tection devices shall be approved by the Engineer. Mark all pinholes, repair in accordance with the manufacturer's printed recommendations, and retest. No pinholes or other irregularities will be permitted. Measure and verify wide film thickness discrepancies with a micrometer or other approved measur ing instrument. Coatings not in compliance with the Specifications will not be acceptable and shall be replaced, and reinspected until the Specifications are met, at no extra cost to Owner.
D. On non-ferrous surfaces, dry film thic kness readings shall be taken at random locations with a Tooke Gauge at the rate of approximately five readings per 100 square feet of surface. Repair groove cu t into coating by application of all coats of paint or coating film being tested. The average of all readings for a given area or surface shall be within required dr y film thickness range and no individual reading shall be more than 20 per cent below the recommended dry film Painting and Protective Coatings
City of Anaheim 09900 - 16 6/27/2013
thickness. Any areas that are found to be below standard shall be marked and recoated to obtain proper film thickness.
E. Warranty Inspection. Warranty insp ection shall be conducted during the eleventh month following completion of all coating and painting work. All personnel present at the pre-job conferen ce shall attend this inspection. Repair all defective work in accord ance with this specification and to the satisfaction of the Owner.
3.07 CLEANUP
A. At the end of each work day place a ll cloths and cotton waste that might constitute an environmental hazard in en closed metal containers. Dispose of containers regularly at an approved location.
B. Upon completion of the work, staging, scaffolding, and containers shall be removed from the site or destroy in an approved manner. Remove paint spots, oil, or stains upon adjacent surfaces shall be removed.
3.08 PIPE PAINTING AND IDENTIFICATION
A. General. Exterior surfaces of burie d piping shall be painted or coated in accordance with the requirements specifi ed in the City of Anaheim Water Services Standard Specifications. Exte rior surfaces of exposed piping shall conform to the requirements specified in Article 2.04 of this Section.
B. Piping Systems. Identification of piping systems shall conform to the requirements of ANSI A13.1, "Scheme for th e Identification of Piping System," unless otherwise specified herein.
C. Process Piping Color Identification C ode. All exposed pipe, including steel, copper and brass tubing, galvanized st eel, and polyvinyl chloride, shall be identified by color and labeling to show its function as selected by the Owner.
D. Process Valve Identification. Conform to the requirements as selected by the Owner.
END OF SECTION 09900
City of Anaheim 1 6/27/13
CITY OF ANAHEIM
APPENDIX G
MECHANICAL SPECIFICATION
Table of Contents
City of Anaheim 6/27/13
MECHANICAL SPECIFICATION
TABLE OF CONTENTS
APPENDIX G
DIVISION 15 - MECHANICAL
15010 Mechanical: General Requirements
15060 Piping and Appurtenances
15100 Valves: General Requirements
15103 Ball Valves
15106 Check Valves
15114 Miscellaneous Valves
Mechanical: General Requirements
City of Anaheim 15010-1 06/26/13
SECTION 15010
MECHANICAL: GENERAL REQUIREMENTS
PART 1 - GENERAL
1.01 SUMMARY
A. Section Includes:
1. Mechanical equipment.
B. Related Sections include but are not necessarily limited to:
1. Section 09900 - Painting.
2. Section 11005 - General Mechanical and Equipment Provisions.
3. Section 13440 - Instrumentation for Process Control: General Requirements.
4. Division 16 - Electrical.
1.02 QUALITY ASSURANCE
A. Comply with requirements of Section 11005.
B. Perform work in strict accordance with rules, regulations, codes, ordinances, or laws of Local, State, and Federal governments, or of other authorities having lawful jurisdiction. Such rules, regulations, codes, ordinances, or laws include but are not necessarily limited to the following:
1. State building and fire codes.
2. State plumbing and mechanical codes.
3. City building and fire codes.
4. City plumbing and mechanical codes.
5. American Gas Association (AGA).
6. National Electric Code (NEC).
7. National Fire Protection Association (NFPA).
8. Occupational Safety and Health Act (OSHA).
C. Referenced Standards:
1. Air Moving and Conditioning Association (AMCA).
2. American National Standards Institute (ANSI):
a. B40.1, Gauges-Pressure Indicating Dial Type Elastic Element.
3. American Society of Heating, Refr igeration and Air-Conditioning Engineer (ASHRAE).
4. American Society of Mechanical Engineers (ASME).
5. American Society for Testing and Materials (ASTM):
Mechanical: General Requirements
City of Anaheim 15010-2 06/26/13
a. A36, Specification for Structural Steel.
6. Factory Mutual Association (FM).
7. Instrument Society of America (ISA):
a. S20, Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves.
8. National Electric Manufacturers Association (NEMA).
9. Sheet Metal and Air-Conditioning National Contractors Association (SMACNA).
1.03 DEFINITIONS
A. Installer or Applicator: Installer or applicator is the person actually installing or applying the product in the field at the Project site.
1. Installer or applicator are synonymous.
1.04 SUBMITTALS
A. See Special Provisions Section 2-13.
B. Verify sheet metal shop drawing dimensions, transverse joints, reinforcement, seams, seals, fittings, hangers and miscellaneous appurtenances. Include on fabrication drawings location and connection details of jointed sections to permit access and maintenance of connected equipment, dampers, and controls and to permit removal of connected equipment without disturbing main duct system.
C. Submit copies of any manufacturer's written directions regarding shipment and material handling, installation, operation and maintenance.
D. Detail coordinations, connections, offsets and crossovers in work.
E. Locate and dimension equipment items with reference to other items of work accurately.
F. Operation and Maintenance Manuals:
1. See Special Provisions Section 1-09.09.
1.05 PERMITS
A. Permits, Fees, Licenses, and Inspections:
1. Make arrangements for, obtain, and pay for necessary permits, licenses, and inspections. Pay necessary fees in conjunction with mechanical work.
Mechanical: General Requirements
City of Anaheim 15010-3 06/26/13
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. See narrow scope sections for acceptable manufacturers.
B. Submit request for substitution in accordance with Specification Section 1-06.02.
2.02 MATERIALS
A. Unions:
1. Provide union between valves and connection to each item as required to make up or disconnect piping. Install unions to facilitate removal of parts, equipment of fixtures, for inspection or cleaning. Install in position which will permit device, fixture or part to be removed without disconnecting piping except unions.
2. Use unions of type and material specified under each piping specification.
3. Where mechanical type couplings are used, they may serve as unions.
Make connections between couplings and flanged equipment with flanges and flexible couplings.
4. At flanged connections additional fl ange unions are not required. Make connections to flanged valves and equipment using ANSI type flanges.
Use flanges, rated 125 psi. In no case shall flange pressure ratings be less than equipment served or system operating pressure. Where 150 LB steel flanges mate with 125 LB cast-iron flat face flanges, use flat face steel flanges with full face gaskets.
B. Drains:
1. Install drains on plumbing, process or other piping, either as indicated or as required to permit complete drainage of systems. Use drain consisting of 3/4 inch globe valve with hose adapter. Where additional drains are required to drain low points of piping, use minimum of 6-inch length of nipple with valve which may drain that portion of piping only. Provide hose end valves on all piping 2-1/2 inches, and larger and drain cocks on piping 2 inches and smaller.
2. Pipe drains from safety valves and other items where discharge is infrequent or have test levers over edge of equipment or as indicated. Install drains on copper piping with a male iron pipe adapter and threaded brass cap except where valve drains are required.
3. Regardless of pipe size, where drains are installed on piping over electrical equipment or over other piping on equipment where access to drain valve is Mechanical: General Requirements
City of Anaheim 15010-4 06/26/13
difficult, pipe these drain valves to accessible location with hose bib adapter such that system may be drained without damage to equipment.
4. Coordinate work to avoid piping over electrical components (not rated NEMA 4 or better) or provide minimum 16 GA 316 stainless steel pans to protect the electric components. Slope and pipe these pans to drains.
5. Provide 1/8-inch thick heavy wire 316 stainless steel screens with maximum 3/8- inch openings on drains from potable water supply.
C. Vents:
1. Pipe vents from pressure regulating devices in compliance with applicable codes.
2. Provide 1/8-inch thick heavy wire 316 stainless steel screens with maximum 3/8- inch openings on vents from potable water supply.
D. Sleeves:
1. Furnish and install sleeves where required for installation of work under this Division.
2. Where sleeves are set in walls for future connections, close opening with lightweight concrete.
3. Set sleeves true to line, grade, position and plumb or level and maintain so during construction.
E. Pipes and Anchors:
1. Furnish and install pipe anchors as indicated, or as required to permit complete installation of system.
2. Anchors of sufficient strength structural shapes and stainless steel rods with turnbuckles are acceptable unless detailed otherwise.
F. Equipment Anchors:
1. Comply to requirements of Section 11005.
G. Electric Wiring, Motors and Controls:
1. Comply to requirements of Sections 11005 and 13440 and Division 16.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Cutting, Fitting, Repairing, Patching, and Finishing:
1. Arrange and pay for cutting, fitting, repairing, patching, and finishing of work of other trades where it is necessary to disturb such work to permit installation of mechanical work. Perform work only with craftsmen skilled in their respective trades.
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City of Anaheim 15010-5 06/26/13
2. Avoid cutting, insofar as possible, by setting sleeves, frames, and related work and by requesting openings in advance. Assist other trades in securing correct location and placement of rough-frames, sleeves, openings, and related work for piping.
3. Before cutting obtain permission from Engineer. Cut holes neatly and as small as possible to admit work. Include cutting where sleeves or openings have been omitted. Perform cutting in manner so as not to weaken walls, partitions or floors. Drill holes cut in floors without breaking out around holes.
4. Where cutting of holes through reinforced concrete is necessary, cut by rotary type drill. Use of pneumatic hammer type drills, impact type electric drills, and hand or manual hammer type drills will not be allowed. Locate holes so as not to affect structural sections such as ribs or beams. Layout holes in advance and perform drilling only after approval by Engineer.
5. Where alterations are necessary, including outside trenching, disturbing lawns, walks, paving, etc., or where new or old work join, cut, remove, patch, repair and restore adjacent surfaces and leave in as good condition as existed prior to start of work.
B. Installation of Equipment:
1. Comply to requirements of Section 11005.
2. Use galvanized structural steel installed in areas of high humidity or locations where moisture may collect due to condensation.
3. Use structural steel members conforming to ASTM A36. Furnish with shop coat of red lead primer. Retouch primer after field welding.
C. Provisions for Later Installation:
1. When mechanical work can not be installed as structure is being erected, provide and arrange for building-in of boxes, sleeves, insets, fixtures or devices necessary to permit installation later. Lay out chases, holes or other openings which must be provided in masonry, concrete or other work.
2. Verify nature and arrangements of materials and construction to which this work attaches or passes through.
D. Access to Equipment for Maintenance:
1. Install equipment and piping in such manner as to permit access for normal maintenance. Maintain easy access to motors, drives, compressors, and arrange piping, conduit, and related work to facilitate maintenance. Perform relocation of pipes and other obstacles required to permit access at request of Engineer at no additional cost to Owner.
E. Painting:
1. See Section 09900.
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City of Anaheim 15010-6 06/26/13
2. If factory finish on equipment is dama ged in shipment or during construction, refinish equipment to satisfaction of Engineer.
END OF SECTION 15010
Piping and Appurtenances
City of Anaheim 15060 - 1 6/26/2013
SECTION 15060
PIPING AND APPURTENANCES
PART 1 - GENERAL
1.01 DESCRIPTION
Requirements specified in the General Conditions and Special Provisions form a part of this Section. Furnish all tools, equipment, materi als and supplies including all labor required for complete installation, testing, and flushing of piping and appurtenances all as shown on the Drawings and specified herein. All appli cable parts of the WSSS shall govern over the requirements of this Section.
1.02 SCOPE OF WORK
A. Work Included in This Section. The Work of this Section shall include the furnishing, installation, and testing of pipe , pipe supports, fittings, specials, thrust blocks, and all required appurtenances as shown on the Drawings and as required to make the entire piping system operable. The systems include water, chemical, air, and drainage piping. The Work sh all include, but not be limited to, the following items:
1. Piping from the water production system to distribution system.
2. Instrumentation piping to gages and pr essure switches and all tees, flanges, thread-o-lets, nipples, fittings, etc., as required for process connections to instrumentation except where these are specifically required to be furnished under Division 13 or integrally with the mechanical equipment. Coordinate the Work of this Section with Division 13.
3. Piping for the introduction of chemicals into the water being treated.
4. Piping for system quality sampling.
5. Drainage piping.
B. Related Work Specified Elsewhere.
1. Trenching, Backfilling and Compaction re lated to the installation of piping and appurtenances.
2. Concrete Thrust Blocks and encasement.
3. Process Valves and Regulators.
4. Painting and Protective Coatings.
5. Instrumentation signal tubing.
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1.03 CONTRACTOR SUBMITTALS
A. General. Shop and erection drawings, together with other required information specified, shall be submitted in accordance with the requirements of Special Provisions of these Specifications and the requirements specified in this Section.
B. Shop Drawings. Shop drawings, complete with material, grade, and class for all pipe, fittings, and couplings and for all jo ints, coatings, and appurtenances shall be submitted. Detailed catalog and engineer ing data sheets shall be submitted for all components such as flexible couplings, rubber gaskets, and insulating joints, and a proposed schedule for delivering and installing the piping shall be included.
C. Erection Drawings.
1. General. Complete erection drawi ngs for all buried and exposed piping shall be submitted. The drawings shall show and identify the pipe, pipe joints, fittings, couplings, joint harne sses, wall sleeves with sealant and backup thicknesses, wall castings, hangers, saddles, straps and other supports, and miscellaneous details.
2. Buried Piping. Erection Plans and Prof ile Drawings for all buried pipe shall show the following information:
a. Location, length, wall thickness, and t ype of joint for each pipe section and fitting to be furnished and installed;
b. Pipe axis station and elevation at all changes in gradient or horizontal alignment;
3. Exposed Piping. Erection and eleva tion drawings for all exposed piping shall show the location of the pipe, jo ints and couplings, critical clearances, orientation of valves, spacings of hangers and supports, and the location and size of anchor bolts.
D. Erection Procedure. The installation draw ings shall be supplemented with a set of written procedures for performing the fiel d piping installation. The procedures shall cover in detail the preparation and making of the push-on, mechanical, flanged, welded, caulked, flared, hard-s oldered, chemically-welded and screwed joints and couplings; measures to ensure integrity of interior pipe lining and exterior protective coating at all joints and couplings; the method of backing up and sealing the annular spaces in pipe sl eeves; and the installation and adjustment of pipe hangers and other supports.
E. Protective Coating. A protective coa ting schedule shall be submitted, showing shop and field surface preparations, mate rials, methods of application, dry thicknesses and tests for defects, a ll in conformance with Section 09900, "Painting and Protective Coatings" unless specified otherwise in this Section.
F. Testing Procedures. Procedures fo r testing the piping, and arrangements for obtaining and disposing of water for the tests shall be fully described. The equipment for testing shall be itemized. Details of bulkheads, flanges, or caps for the testing of the pipe shall be included with the submittal.
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City of Anaheim 15060 - 3 6/26/2013
G. Disinfection. Procedures for disinfecti on of potable water piping shall be fully described including the type of chlorine used, method of application, and details of bulkheads, corporation cocks, caps a nd chlorine feeding equipment shall be included with the submittal.
H. Calculations. Manufacturer's calculati ons of wall thickness for steel pipe and outlet design calculations shall be included in the submittal.
1.04 PRODUCT HANDLING, DELIVERY AND STORAGE
A. General. Pipe shall at all times be handled with equipment designed to prevent damage to the interior or exterior coati ng of the pipeline. Steel pipe with cement mortar lining or having any other special coating or lining shall only be handled with wide canvas or rubber covered slings . Bare cables, chains hooks, or metal bars shall not be allowed to come in contact with the coating.
B. Shipping. When making shipments, a ll chains, cables and hold-down equipment shall be carefully padded where in contact with the pipe. For steel pipe, when the deformation exceeds one percent of the di ameter, each end of the pipe shall be properly braced with approved interior supports or spiders.
C. Unloading. Unloading from the trucks shall be done with care using slings as indicated above for steel pipe. No pipe sh all be allowed to fall from trucks. Pipe shall only be unloaded using a crane or fork lift.
D. Gaskets. Gaskets shall be stored in containers or wrappers which will protect the gaskets from ozone and other atmospheric deterioration.
PART 2 - PRODUCTS
2.01 GENERAL
A. General Requirements. All pipe, fittings, couplings, and appurtenant items shall be new, free from defects or contamina tion, and wherever possible, shall be the standard product of the manufacturer. They shall be furnished in pressure or thickness classes as specified or show n. Unless otherwise indicated the size shown shall be the nominal pipe diameter.
B Length. All pipe shall be furnished in a maximum of 40 foot lengths, unless indicated otherwise.
C. Raised Face Flanges. When carbon steel or stainless steel flanges or flanged valves with raised face will be bolted dir ectly to flat faced FRP, plastic, or cast iron flanged fittings or valves, the ra ised face shall be removed or spacers approved by the valve or pipe manufacturer may be installed to allow bearing over 100 percent of the flange area.
D. Joints. All pipes above ground shall ha ve screwed or flanged joints. Welded pipes will be permitted, provided that ther e are sufficient flanges at valves and Piping and Appurtenances
City of Anaheim 15060 - 4 6/26/2013
equipment to permit easy disassembling. Buried pipes shall have bell and spigot joints, unless welded, flanged or other joints are shown or specified.
E. Mechanical Couplings and Expansion Joints. Pipe mechanical couplings and expansion joints shall be provided at locations shown on the Drawings as a minimum requirement.
F. Grooved Fittings. The Contractor, with the Engineer's approval, may provide Victaulic, Gustin Bacon or approved equal grooved end pipe fittings and connections in lieu of screwed or flanged fittings for steel, cast iron or ductile iron pipe unless otherwise shown on the drawings. Grooved joints and couplings shall conform to paragraph "Mechanical Couplings" herein.
G. Screwed Flanges. Where pipe is furnis hed with screwed on flanges, the flange is to be screwed tight on the pipe until th e pipe end projects beyond the face of the flange. The flange shall then be faced to give a flush finish of the pipe and flange.
The flanges shall then be drilled, after att achment to the pipe, to ensure bolt hole alignment.
H. Pipe Schedule. Unless otherwise indi cated on the plans, pipe materials shall conform to the piping schedule included at the end of this Section.
2.02 STEEL PIPE (SIZES UP TO 36 INCHES)
A. AWWA C200 Pipe. Pipe shall be AWWA C200 with finished inside diameter after interior lining equal to diameters indicat ed on drawings. The minimum steel plate thickness shall be 0.25 inches and interior mortar lining shall be per AWWA C205.
Steel pipe flanges shall be Flat Face St andard Steel Class F flanges per AWWA C 207. All pipe flanges shall be compatible with the valves, meters, pumps discharges, and other fittings indicated on the drawings. Couplings shall be sized to be compatible with pipe outside diameters.
GENERAL
All steel pipes shall be fabricated in accordance with AWWA C200. Cylinders shall be fabricated from hot-rolled carbon steel sheets or plates conforming to AWWA C200.
The outside diameter of the steel cylinder shall be as indicated on the plans.
Pipe of the type specified herein shall be the product of one company in the business of designing and manufacturing pipe of the type specified.
FIELD WELDING
All field welding shall be in accordance with AWWA C206.
PIPE FLANGES
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City of Anaheim 15060 - 5 6/26/2013
Flanges shall be standard steel-ring flanges in accordance with AWWA C207, Class F (300 psi), with carbon steel bolts ASTM A193 Grade B7 and carbon steel nuts ASTM A194 grade 2H. Flanges, gaskets, nuts, bolts, and method of attachment shall be in accordance with AWWA C207. Flanges shall be compatible with the existing valves and other fittings indicated on the drawings.
PIPE FITTINGS
Fittings shall be in accordance with AWWA C208.
INTERNAL DESIGN PRESSURE
The internal design pressure is 200 psi, minimum.
PIPE WALL DESIGN STRESS
Pipe wall design stress shall be 50% minimum yield.
MINIMUM WALL THICKNESS
Minimum wall thickness shall be 0.25 inches.
INSPECTION
City or its authorized representative may inspect work and material at the manufacturer’s plant. The interior of each pipe section and special shall be clean and free of foreign materials when they are delivered to the site of the work.
CEMENT MORTAR LINING
All steel pipe and fittings shall be cemen t mortar lined and mortar coated in accordance with AWWA C205. The thickness of the lining and coating, expressed in inches, shall be as listed in the following table.
Type V cement shall be used for coa ting and Type II cement shall be used for lining.
Diameter (Inches) Lining Thickness (Inches) Coating Thickness (Inches) 12 and below ½ ¾
14-21 5/8 7/8
24 and above ¾ 1
PIPE SPECIALS
Pipe specials shall be field fabricated, fiel d cut and welded to fit the existing offsets and dimensions. Pipe specials shall have a minimum wall thickness of 0.25-inches.
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FLEXIBLE COUPLING FOR STEEL PIPE
Sleeve type couplings shall provide a flex ible, water tight connection between two plain ends as described on the construction drawings. All couplings shall be standard steel couplings, with body not less than 7 inches long. Bolts for exposed steel couplings shall be hot-dip galvanize d. Steel couplings shall be epoxy primed with a minimum thickness of 3.0 mils prior to shipment.
Steel sleeve type couplings shall be Dresser Industries, Inc. – Style 38.
INTERNAL BRACING AND HANDLING
Pipe sections shall be braced internally as soon as practical after cement mortar lining has been applied. Bracing shall re main in the pipe until installation and backfilling have been completed. Pipe sec tions shall be braced within 12-inches of each end with two 2x4s wedged in the pipe at right angles to each other (for 18-inch diameter pipe and smaller). Pipe shall be lifted by means of a padded forklift or belt slings in such a manner as to minimi ze bending of the pipe section and prevent damage to the coating. When being trans ported, pipe shall be supported in such a manner that will prevent distortion or dama ge to the lining or coating. When not being handled, pipe shall be stockpiled on timber cradles or properly prepared ground with all rock points eliminated. Any pipe section that becomes damaged as a result of improper handling or stockpiling sh all be repaired to the satisfaction of the City or shall be replaced with a new unit.
DRAWINGS AND SPECIFICATIONS
Drawings and specifications for the pipe, fittings, flanges, etc. shall be submitted by the manufacturer.
END CONNECTIONS
Pipe ends shall be welded and butt stra p (except as otherwise indicated on the drawings).
SHOP TESTING
Upon completion of welding, but prior to lining and coating, each special shall be bulk headed and tested under hydrostatic pre ssure of not less than one and one half times the pressure for which the pipe ha s been designed, provided, however, that if straight pipe used in fabricating the sp ecial has been previously hydrostatically tested, the circumferential welds may be tested by a dye penetration process using Turco Dry-Check, or approved equal, w ith no further hydrostatic test. Any pinholes or porous welds which may be rev ealed by the test shall be chipped out and rewelded and the special retested.
Pipe of the type specified herein shall be the product of one company in the business of designing and manufacturing pipe of the type specified.
Contractor shall certify with documents signed and dated by authorized representatives of both pipe manufacturer a nd the pipe fabricator that all pipe and Piping and Appurtenances
City of Anaheim 15060 - 7 6/26/2013
fittings have been manufactured and tested in accordance with these specifications.
An Affidavit of Compliance shall be furnished for the pipe.
Contractor shall furnish rubber gasket mate rials test reports and an Affidavit of Compliance for materials.
B. Mill-type steel pipe shall be welded or seamless steel pipe conforming to ASTM A53-860 type S or E, grade B, standard weight.
1. Grooved Ends. Conform to AWWA C606.
2. Flanges. Flanges shall be in accord ance with paragraph 2.01G "Flanges" of this section.
3. Wall Thicknesses. Unless specifically st ated otherwise in the Pipe Schedule in this Section or elsewhere in thes e Specifications, black steel pipe shall have the following minimum wall thickness:
Pipe Wall Pipe Wall
Diameter Thickness Diameter Thickness
1/2" 0.109" 5" 0.258"
1" 0.133" 6" 0.280"
1-1/2" 0.145" 8" 0.322"
2" 0.154" 10" 0.365"
2-1/2" 0.203" 12" to 16" 0.375"
3" 0.216"
4" 0.237"
The minimum wall thickness specified above shall be for pipe before application of linings and coatings. The diameters indicated on the plans shall be the final inside diameter after application of interior linings.
C. Fittings. Provide welding fittings or groove d fittings as indicated in the Schedule.
No fabricated fittings are permitted unless specifically called out on Drawings or with permission of Owner.
1. Welding Fittings. Forged steel conforming to ASTM A-234, standard weight to match pipe.
2. Grooved Fittings. Conform to paragraph "Mechanical Couplings" herein.
D. Buried Steel Pipe. The exterior of burie d steel pipe shall be cement mortar coated as shown on the drawings and shall conform to AWWA Standard C205 and Federal Specification SS-P-385a. Cement shall be Type V and coating thickness shall be 1-inch.
E. Mortar Lining of Steel Pipe. Lining may be placed by the centrifugal, pneumatic, or hand method, whichever is applicable. Cement shall be Type II. Material requirements and application procedures for the field joint application of cement Piping and Appurtenances
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mortar shall be as stated in AWWA Designation C205-80, Field Joint Appendix.
Lining thickness shall be ½ inch.
F. The interior of all welded joints sh all be accessible for patching and inspecting the mortar lining. Welded joints for piping 12" and smaller shall be not more than 12" from the nearest pipe end. Welded jo ints for piping larger than 18" shall not be more than 36" from the nearest pipe end. All other joints in or between pipe and fittings shall be made using slip-on flanges at pipe ends and welding neck flanges on welding-type fittings ends; provided, that groove-type couplings may be installed on joint members 12 inches and smaller in nominal diameter, as appropriate.
2.03 DUCTILE IRON PIPE
Ductile iron pipe shall be cement mortar lined unless otherwise indicated in the pipe schedule and shall conform to the following requirements:
A. Pipe and Specials. Unless otherwise sp ecified elsewhere, ductile iron pipe shall have a minimum wall thickness in accordance with Class 52 for sizes 4 inches to 12 inches, a minimum wall thickness in acco rdance with Class 51 for sizes above 12 inches, and shall conform to the requirements of ANSI/AWWA Specifications:
ANSI/AWWA C150/A21.50 and AWWA/ANSI C-151/A21.51
B. Fittings. Fittings in pipe lines rate d at 175 psi and less shall conform to the requirements of ANSI/AWWA C110/A21.10, Class 350 for up to 24 inches.
C. Lining and Coating.
1. Mortar Lining. Ductile iron pipe and f ittings furnished for this project shall be cement mortar lined with seal coat per ANSI Specification A21.4 (AWWA C104).
2. Coatings. Exterior surfaces of exposed pipe shall be coated in accordance with Section 09900 "Painting and Protectiv e Coatings". Exterior surface of buried pipe shall be coated with a bituminous coating per ANSI/AWWA C- 151/A21.51.
3. Provide polyethylene encasement prot ection for all buried ductile iron pipe per AWWA C105.
D. Joints. Exposed joints shall be flange d or restrained mechanical joints unless otherwise shown on Drawings. Buried joints shall be push-on or mechanical joints. Joints shall conform to the requirements of ANSI A21.15 (AWWA C115) or A21.11 (AWWA C111). Push-on joints sh all be restrained with Field Lok ® gaskets and mechanical joints shall be restrained with Megalugs ®.
E. Grooved End Fittings and Joints.
1. Grooved end ductile iron pipe shall conform to AWWA C-606, of the latest revision, for rigid grooving dimensions.
2. Fittings shall conform to the requi rements of ANSI Specification A-21.10 or AWWA C-110, of the latest revisi on, with the exception of the end Piping and Appurtenances
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preparation. End preparation shall be a radius grooved configuration conforming to AWWA C-606.
3. Couplings shall conform to AWWA Standard C-606. Coupling gaskets shall be suitable for use with ductile iron pipe.
4. Transition flanges, Victualic Style 341/342, or equal shall be used to facilitate connection from grooved pipe or fittings to 125# cast iron flanged valves, pump, pipe, fittings, or other equipment. The transition flanges shall be malleable iron conforming to ASTM Specification A-47 or ductile iron conforming to ASTM A-536. Gaskets sh all have properties as designated by ASTM D-2000 and shall be suitable for the required service.
F. Thrust Restraint. The connecting jo ints between existing pipe and existing valves are not known. The Contractor shall exercise due caution during the abandonment of pipe and valves, including any temporary bracing until permanent restraints are serviceable.
Permanent restraints shall follow the details shown on the plans and as called for by the water inspector after a field determ ination can be made. The City’s water inspector will verify that the thrust re straint device proposed by the Contractor will be acceptable for the site conditions.
2.04 POLYVINYL CHLORIDE SCHEDULE PIPE AND FITTINGS
Pipe and fittings shall conform to the following requirements:
A. Polyvinyl Chloride Pipe. Polyvinyl Ch loride Pipe shall be of unplasticized compounds suitable for use with chemicals and sewage, as shown on the Drawings and as specified and shall bear the seal of approval to this effect from an accredited testing laboratory. Pipe shall conform to the requirements of ASTM Designation D1785, Schedule 80, Designation PVC 1120, and the fiber stress for deriving the short-time burst pressure requirement in accordance with Table 6, therein, shall not be less than 6,000 psi at 73.4 ºF.
B. Polyvinyl Chloride Pipe Fittings. Fittings shall conform to the requirements of ASTM Designation D2467-76a, Class 12454- B for socket type and ASTM Designation D2464-76 for threaded type.
C. Rigid, Unplasticized Compounds. Compounds for pipe and fittings shall conform to the requirements of ASTM Designation D1784-81, Class 12454-B.
D. Joints in PVC Pipe and Fittings. Joints shall be the solvent-welded socket or flanged type. Flanges, where shown, sh all be 150-pound, and shall be of the same material as the pipe.
E. Bolts. Bolts for use with PVC flanges shall be type 316 stainless steel.
F. Gaskets. Gaskets shall be Viton only.
2.05 STAINLESS STEEL TUBING AND FITTINGS
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A. Stainless steel tubing shall conform to ASTM Standard A269-84c for Type TP316 and shall have a wall thickness not le ss than 0.065-inch. Fittings for tubing installation shall be compression-type made from Type 316 stainless steel and shall have a pressure rating equal or greater than that of the tubing. Fittings shall be “Swagelok”, Parker-Hannifin, or an approved equal.
B. Stainless steel tubing shall be inst alled in accordance with the applicable requirements for installing copper tubing. Every cut made on tubing shall be reamed. Bends in tubing shall be made with elbow fittings, except that bends may be made with a proper bending tool if a bend without a fitting has been indicated on the Drawings and only when specifically permitted by the Engineer.
C. Tubing shall be installed with stainless steel accessories as shown on the drawings in a workmanlike manner to the satisfaction of the Engineer. Only mechanics and pipefitters skilled in their respective trades shall be engaged in this work. Parallel lines shall be held truly parallel by means of an adequate number of supports. No waviness or sagging of the lines will be permitted.
D. All tubing and connecting piping shall be flushed out with hydraulic fluid to assure the Engineer that all lines are free from obstructions, dirt, and foreign matter. The lines shall show no leaks dur ing the operational testing of the pumps.
All leaks shall be repaired to the satisfac tion of the Engineer. All tests shall be made in any manner that will prevent complete inspection and tests of the installation.
2.06 MECHANICAL COUPLINGS
A. Grooved End Couplings. Couplings sh all engage and lock the grooved or shouldered pipe ends allowing some degree of contraction, expansion, and angular deflection. Coupling housing sha ll be of ductile iron or malleable iron and shall consist of two or more segments held securely together by at least two steel bolts. Sealing gasket shall be of su ch design that internal pressure in the pipe increases the tightness of the seal and shall be of materials suitable for the intended service. The coupling shall have a rated working pressure not less than the pressure rating of the pipe. Couplings shall be Victaulic style 7 or 77, Gustin- Bacon No. 125 or approved equal.
B. Flexible Couplings. Flexible (sleeve) couplings shall be of the full sleeve type, split sleeve type, or flanged adapter type , as shown on the Drawings, specified herein, or as otherwise permitted by th e Engineer. They shall provide the requisite pipe flexibility without jeopardiz ing pipe joint integrity due to hydraulic thrust, and shall have the same pressure-ra ting as the pipe. Couplings shall have all metal bearing surfaces and shall be pr ovided with 316 stainless steel bolts and age hardened steel nuts. Flexible c ouplings shall be restrained unless the Engineer has given his approval to omit this feature for specific cases. For ductile iron pipe installation, the WSSS material call outs for flexible couplings shall govern over these specified herein.
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1. Full Sleeve Type Couplings shall be properly gasketed and shall be of a diameter to fit the pipe. Each coupling shall consist of a steel middle ring, 2 steel followers, 2 gaskets, and the necessary steel bolts and nuts to compress the gaskets. The couplings shall be Dresser Style 38, Smith-Blair Type 411, or equal. Couplings to be insta lled underground shall be painted with 30 mils high build epoxy.
2. Split Sleeve Type Couplings shall cons ist of one gasket, 2 housing clamps, and 2 bolts and nuts to obtain the flexibility for connecting the piping. Steel shoulders shall be provided and welded to the pipe ends to accommodate the couplings. The couplings shall be Kuhns, Ductile Iron Pipe Lock Coupling; M.B. Skinner Seal; or equal.
3. Flexible Flanged Coupling Adapters shall be of the sleeve type, consisting of steel middle ring, steel followers, gaskets, and steel bolts and nuts to compress the gaskets. The couplings sh all contain anchor studs of strength adequate to hold the pipe together under a pull equal to the longitudinal strength of the pipe at a tensile stre ss of 20,000 psi, and shall be Smith-Blair No. 913, Dresser Style 128, or equal. Couplings to be installed underground shall be painted with 30 mils high build epoxy.
2.07 WALL CASTINGS
Wall castings shall be flanged cast iron or fabr icated steel construction with wall thickness and lining equivalent to the attached pipe, except in no case shall the wall thickness be less than 0.1345-inch. The casting shall incorporate a water stop/thrust reaction ring cast-on or secured to the barrel by continuous welds on bot h sides of the ring. The ring shall have a minimum width of 7/8-inch and a minimum thic kness of 1/4-inch for 4" and smaller barrel size, increasing uniformly to 4-inches mini mum width and 1/2-inch minimum thickness for 36-inch barrel size.
2.08 PIPE HANGERS AND SUPPORTS
Unless otherwise shown or specified, pipe ha ngers, brackets, saddles, clamps, and other supports shall be adjustable type conforming to the requirements of ANSI B31.1, Section 6; shall have ample strength and rigidity to resist the hydraulic thrusts at changes in direction and at dead ends as well as the dead weight loads and the load carried; and shall be hot-dip galvanized. Where not specifically identified or called out on the Drawings, computations showing adequacy of Contractor selected ha ngers and supports to meet these requirements shall be submitted with the Shop Drawings. Hangers and supports so identified on the Drawings does not relieve the Contractor from meeting all requirements specified herein.
Wherever possible, brackets shall be used in lieu of hangers.
A. General. Hangers and supports sha ll include all hanging and supporting devices of metallic construction shown, specified, or required for pipe lines, apparatus, and equipment other than electrical e quipment. The Contractor's working drawings, as required herein, shall show the quantity, type, design, and location of Piping and Appurtenances
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all hangers and supports required under the various Contract items. Hangers and supports shall be painted the same as required for the supported piping.
1. Where specified or shown, bolts, stud bolts, rods, yokes, and nuts of hangers and supports shall be of 316 stainless steel for submerged application and 304 stainless for other applications. Bo lts shall not be less than 1/2-inch diameter unless otherwise called for on the Drawings.
2. Except where otherwise shown, speci fied, or required, hangers, supports, anchors and concrete inserts shall be the standard types as manufactured by Elcen Co., Grinnell Co., Fee and Ma son Manufacturing Co., or equal meeting the requirements specified he rein. Unless otherwise approved by the Engineer, all hangers, supports, and concrete inserts shall be listed with the Underwriters' Laboratory.
B. Design. Hangers and supports shall be adequate to maintain the pipe lines, apparatus, and equipment in proper position and alignment under all operating conditions and have springs where necessa ry. Hangers and supports shall be of standard design where possible, and be best suited for the service required, as approved by the Owner. Where required, th ey shall be screw adjustable after installation. Supporting devices shall be designed in accordance with the best practice and shall not be unnecessarily heavy. Sufficient hangers and supports shall be installed to provide a working sa fety factor of not less than 4 for each hanger, assuming that the hanger is supporti ng 12 feet of pipe filled with water.
Hangers and supports shall be designed to resist all induced thrusts and lateral loads as required for seismic design by Uniform Building Code, 1997 edition.
1. Hangers and supports shall be designe d and selected in accordance with MSS Standard Practices: SP-58, Pipe Hangers and Supports - Materials and Design; and SP-69, Pipe Hangers and Supports - Selection and Application.
C. Supports for PVC Piping. Rigid plastic piping normally shall be supported by the same type of hangers used with steel pipe, except that in no instance will C- clamp, or other point-bearing supports be allowed. Riser clamps, if required, shall be full-circumferential type only. Support spacing shall be based on the plastic pipe manufacturer's recommendations for the service conditions but not more than 5 feet on center.
D. Saddle Stands. Saddle stands shall be of adjustable type. Each stand shall consist of a length of wrought pipe f itted at the base with a standard screw threaded cast iron flange and at the top with an adjustab le saddle or roll. The base flange shall be bolted to the floor or foundation. Stanchions shall be of similar construction to the saddle stand, except that they shall be fitted at the top with cast iron pipe saddle supports or with pipe stanchi on saddles with yokes and nuts. Where adjustable supporting devices are not required, pipe lines 3 inches in diameter and smaller may be supported on approved cas t iron, malleable iron, or wrought steel hooks, hook plates, ring or ring plates.
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E. Anchors. Anchors shall be furnishe d and installed where specified, shown, or required for holding the pipe lines and equipment in position or alignment.
Anchors shall be designed for rigid fastening to the structures, either directly or through brackets. The design of all anc hors shall be subject to approval by the Owner.
1. Anchors for piping shall be of the cast iron chair type with wrought steel strap, except where anchors form an integral part of pipe fittings or where an anchor of special design is required.
F. Inserts. Inserts for concrete shall be fu rnished galvanized and shall be installed in the concrete structures where required for fastening supporting devices. They shall be designed to permit the rods to be adjusted horizontally in one plane and to lock the rod nut or head automatica lly. Nail slots shall be provided in the exposed flanges of the insert. Inserts shall be designed to carry safely the maximum load that can be imposed by the rod which they engage.
G. Materials. No use shall be made of wire, straps, chains, etc., for supporting piping nor shall cast expansion shields be used for anchoring bolts. Hangers and supports of metallic construction shall conform to the requirements specified herein and to the following standards:
1. Structural steel ASTM A36 and A283
2. Steel bars (grade 1022) ASTM A107
3. Steel castings (grade N-1) ASTM A27
4. Iron castings (grade 35) ASTM A42
5. Cast iron pipe fittings ANSI B16.1 (class 125)
6. Malleable iron castings ASTM A47
7. Bolting materials, steel
a. Bolts, yokes and stud bolts ASTM A307
b. Nuts ASTM A563
c. Physical requirements
(1) Tensile strength 60,000-72,000 psi
(2) Yield strength 38,000-50,000 psi
(3) Elongation 27 percent maximum
(4) Reduction of area 35-55 percent
8. Bolting materials, silicon bronze
a. Bolts, stud bolts, yokes and nuts (alloy A) ASTM B98 b. Physical requirements:
(1) Tensile strength 70,000 psi minimum
(2) Yield strength 38,000 psi minimum
(3) Elongation 17 percent maximum
9. Bolting materials, stainless steel
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a. Bolts, stud bolts and nuts ASTMA 276 (type 316)
b. Physical requirements:
(1) Tensile strength 75,000 psi minimum
(2) Yield strength 30,000 psi minimum
(3) Elongation 35 percent maximum
(4) Reduction of area 45 percent maximum
10. Where specified or shown, bolts, stud bolts, rods, yokes and nuts of hangers and supports shall be of stainless steel as specified above with dimensions, threads and sizes equivalent to those specified in steel.
H. Supports for Piping. Brackets for support of piping from walls and columns shall be made of welded wrought steel and shall be designed for three maximum loads classified as follows:
1. Light 750 pounds
2. Medium 1,500 pounds
3. Heavy 3,000 pounds
When medium or heavy brackets are bolted to walls, back plates of adequate size and thickness shall be furnished and insta lled to distribute the load against the wall. When used on concrete walls the back plates shall be cast in the concrete.
Where the use of back plates is not prac ticable, the brackets shall be fastened to the wall in such a manner that the safe bearing strength of the wall will not be exceeded. Pipe rolls or chairs shall be of the cast iron type. Pipe rolls shall be provided with threaded rods.
I. Spacing of Hangers. Pipe support sp acing requirements are indicated on the Drawings or elsewhere in these Specifica tions, but in no case shall the spacing of hangers exceed the following:
MAXIMUM UNSUPPORTED PIPE SPAN
(FEET)
NOMINAL PIPE DUCTILE PVC SCH 40 OR 80
SIZE-INCHES IRON STEEL MAX T=130
o
F
1/2 - 5 3.0
3/4 - 6 3.0
1 - 7 3.33
1-1/4 - 7 3.33
1-1/2 - 9 3.5
2 - 10 3.5
2-1/2 - 11 4.0
3 - 12 4.25
3-1/2 - 13 4.25
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4 8 14 4.5
5 10 16 -
6 10 17 4.8
8 10 19 -
10 10 22 -
12 - 23 -
14 - 25 -
16 - 27 -
* Spacing for guides, legs, supports shall be based on the manufacturer's recommendation for a temperature difference of 75 oF.
J. Where concentrations of valves, fittings , and equipment occur, closer spacing of supports will be required. In no case sh all any total hanger load (weight of piping, insulation, and contents) exceed the following load carrying capacities for hot rolled steel rod ASTM A36-77a):
Nominal Rod Maximum Safe Load - Pounds
Diameter - Inches Maximum Temperature 650
oF
1/2 1,130
5/8 1,810
3/4 2,710
7/8 3,770
1 4,960
Nominal Rod Maximum Safe Load - Pounds
Diameter - Inches Maximum Temperature 650
oF
1-1/8 6,230
1-1/4 8,000
1-3/8 9,470
1-1/2 11,630
K. Support of Vertical Pipes. Where ver tical pipe runs exceed 10 feet, and a support system is not indicated on the Drawings , provide carbon steel riser clamps for support and steadying of the pipe. Where possible, riser clamps shall be fitted and bolted below a coupling, flange, or hub. Maximum spacing of clamps shall be 10 feet.
PART 3 - EXECUTION
3.01 GENERAL
A. Care and Handling of Materials. All mate rials shall be carefully handled in all steps of fabrication, storing, loading, tr ansporting, unloading, storing at the site, Piping and Appurtenances
City of Anaheim 15060 - 16 6/26/2013
and installation, using the means and follo wing the procedures submitted with the approved shop drawings. All steel pipe over 12-inch size shall be fitted after fabrication with internal bracing and stu lls at both ends as a protective measure against deformation and injury to mortar lining. Pipe slings used during handling, and tie-down straps during transit shall be not less than 4-inch wide flat fiber or plastic straps. During storage and in transit, pipe 8-inches and larger shall be rested on saddles or on another support system approved by the Engineer, which will insure freedom from damage of th e barrel, interior lining, and exterior coating. Not less than 3 saddles or other longitudinal pipe supports shall be used during transit.
B. Installation.
1. The different kinds of piping (burie d and exposed) shall be installed in accordance with the approved shop drawings and the erection procedures submitted with the approved shop Drawings. Such procedures and methods shall conform to or exceed the minimum requirement of the pipe manufacturer, and shall be as suppl emented by the provisions specified herein. The interior of pipe, fittings, and couplings shall be clean and free from contamination when installed a nd effective means shall be taken to prevent the entrance of foreign matte r during progress of the work. The types and sizes of pipes and fittings to be used shall be as specified herein and as shown on the Drawings. Where fittings are omitted from the Drawings, they shall be the same size as the piping and in all cases shall conform to the plumbing code requirements.
2. All pipe shall be carefully placed and supported at the proper lines and grades and where practicable shall be sloped to permit complete drainage.
Piping runs shown on the Drawings shall be followed as closely as possible, except for minor adjustments to avoid ar chitectural and structural features.
If relocations are required, they shall be approved by the Owner.
C. Joints. In erecting the pipe, a suffici ent number of screw unions, flanged joints, or mechanical couplings shall be used to allow any section or run of pipe to be disconnected without taking down adjacent runs. Screw unions may be employed on pipelines 3 inches in diameter and under. Flanged joints or mechanical couplings shall be employed on pipe 4 in ches in diameter or larger unless otherwise shown on the Drawings. Dielect ric unions must be installed at the junction of dissimilar metals.
D. Storage and Handling. During stor age, handling, and transporting, every Precaution shall be taken to prevent injury to pipe. Pipe shall be handled only by means of approved hooks on ends of sections , by means of fabric slings, or other methods approved by the Engineer for the pi pe used. Mortar lined pipe shall be kept sufficiently moist to prevent drying out of the mortar lining prior to installation.
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E. Verification of Dimensions. All dimens ions essential to the correct location of the pipe, or fit of piping at equipment and valves, or to the proper location and orientation of pipe sleeves and wall casti ngs, or to the avoidance of obstructions or conflict with other improvements, shall be accurately determined by the Contractor prior to fabrication of the piping involved. All required changes from the nominal locations shown on the Drawi ngs shall be made by the Contractor and shall be included as a part of th e work hereunder and be approved by the Owner.
3.02 BURIED PIPING
A. Buried Pipe Installation. Buried piping shall be laid to the grades and alignment shown on the Drawings, and all trenchi ng, bedding, and backfilling shall conform to the applicable requirements of Divisi on 2; other work shall conform to the following sections of AWWA Standard C600:
Section 2, "Inspection, Receiving, Handling and Storage"; Section 3.l, "Alignment and Grade";
Section 3.3, "Pipe Installation";
Section 3.4, "Joint Assembly";
Section 3.6, "Valve and Fitting Installation";
Section 3.8, "Thrust Restraint";
The foregoing requirements shall govern the work, regardless of the type of pipe installed unless a more stringent requirement is specified. When the work is not in progress, open ends of pipe and fittings shall be securely closed. The piping shall be placed when trench and weather conditions are suitable. No pipe shall be laid in water, and responsibility for the diversion of drainage and dewatering of trenches during construction, including mee ting all safety requirements, shall be borne by the Contractor. All pipe in pl ace shall be approved as to line, grade, bedding, and proper joint construction before backfilling. In all backfilling operations, the Contractor shall be responsible for preventing damage to or misalignment of the pipe.
B. Joint Installation. Installation of jo ints and couplings for buried piping shall conform to the following requirements:
1. Joints for pipe 4-inch diameter and over, shall comply with the supplementary requirements specified he rein, and joints of all sizes shall conform to the applicable requirements specified hereinafter for aboveground piping. Care shall be taken to keep pipe in correct alignment when making joints. Friction or leve r pullers or other approved means of insuring straight pulling shall be used on pipe larger than 8 inches and also on smaller sizes where damage to the end might occur. The "popping-on" of joints will not be permitted. The fitting of piping to valves, hydrants, and wall castings shall be worked out in advance of installation to ensure correct orientation of the mating ends and bedding of approach piping.
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2. Provide restrained type joints at all jo ints of pipe with specials and fittings in piping of lower pressure rating. Welding and qualifications of welders shall conform to the requirements of AWWA Specification C206, with welding procedure and welders to be qualified for the specific type of welding within each section of pipe.
3. The interior mortar lining of pipe at joints shall be smoothly continuous and of full thickness. Flanges, flange bolts, and other exterior surfaces of restrained joints and flanged couplings shall be given two coats of a coal tar base coating suitable for the purpose. Wh ere coatings of pipe and valves or appurtenances do not lie in the same plane, the offset shall be filled gradually with a suitable epoxy putty to provide a smoothly continuous joint.
4. Sleeve type couplings installed underground shall have hot-dipped galvanized sleeves, with steel bolts. Th e complete sleeve and bolts shall be coated with a 20 mils coal tar epoxy and wrapped in 20 mil thick plastic sheeting before backfilling. Cover with sand before backfilling if sand is not required as pipe zone material.
5. Joint Harnesses shall be provided at sleeve type coupling joints. The harnesses shall be tightened just sufficiently to preclude displacement of the downstream piping under hydraulic thrust.
6. Silver solder shall be used for soldered joints in buried tubing.
C. Thrust Blocks. On all pressure pipelin es 4 inch and larger with bell and spigot joints, concrete thrust blocks shall be provided at all fittings and dead-ends, and at bends greater than 22.5 degrees. The conc rete shall conform to the requirements for 2,000 psi (see pg. 03300-3, Sect. 1.04.A.2.b) c oncrete as specified in Section 03300, "Cast in Place Concrete," and shall be placed against properly dampened, undisturbed soil, centered on the thrust resu ltant line. The concrete shall be free of joints, and any mortar contaminating the joints shall be removed.
D. Coverage. Unless otherwise shown on th e Drawings, all buried piping shall have a coverage of at least 36 inches between the top of the pipe and the finished surface. Variations from the pipeline grade and alignment may be allowed to accommodate fabrication with the approval of the Engineer. All changes of grade shall require the approval of the Engineer on the installation drawings.
3.03 ABOVE GROUND NONBURIED PIPING
A. Pipe Installation. Install all piping in accordance with the erection drawings and the erection procedure submitted with th e approved shop or erection drawings.
The horizontal piping shall be run parallel to the building walls and shall be level except where otherwise shown or specified ; parallel lines shall be grouped on the same horizontal or vertical plane wherev er possible. Vertical piping shall be plumb, and the entire piping configuration shall allow adequate clearances for convenient access for painting and preventive maintenance of valves. Piping shall clear obstructions, preserve headr oom, and keep openings and passageways Piping and Appurtenances
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clear. If structural difficulties or other work prevent the running of pipes or the setting of equipment at the point indicated on the Drawings, the necessary minor deviations there from, as determined by the Contractor and approved by the Owner, will be allowed, and shall be s hown on the erection drawings to be furnished. Except as otherwise shown or specified, piping installation work shall conform to the requirements of ANSI B31.1.0 and the printed or written recommendations of the manufacturer of the product involved for the given conditions.
B. Joint Installation. Installation of jo ints and couplings shall conform to the following requirements:
1. Joints and Couplings. Joints and Couplings shall be made in accordance with the specified requirements made part of the erection procedure submitted by the Contractor.
2. Steel Pipe with Welded Fittings. Joints in welded piping shall be made by oxyacetylene or electric arc process in accordance with AWWA Standard C206.
3. Pipe Threads. Pipe threads shall be in accordance with the requirements of ANSI B2.1, and shall be cut full and free from torn or ragged surfaces. No more than three threads on the pipe at any joint shall remain exposed after installation. Threaded joints shall be established with Teflon tape applied to the male ends only. The use of thread cement or caulking of threaded joints to stop or prevent leakage will not be permitted. Sharp-toothed pipe wrenches or similar wrenches shall not be used in making up copper or brass pipe.
4. Flanged Joints. Flanged joints shall be made with gaskets centered in the joint. Bolts, studs, and nuts shall be lubr icated with graphite and oil so that the nuts can be turned by hand. Care shall be taken to prevent excessive initial tension to the bolt and studs and so that the tension applied is as nearly uniform as possible. The rust preventive compound applied to the faces of flanges before shipment sh all be removed before installation.
Where slip-on flanges are used, they shall be fillet welded to the pipe on both front and back sides.
5. Tubing. Tubing which is to be solder ed shall be cut square, and all burrs shall be removed. Both the inside of the fitting and the outside of the tubing shall be well cleaned with steel wool before sweating. Care shall be taken to prevent annealing of fittings or hard-drawn tubing when making connections. Joints for soldered fittings shall be made with a 95-5 tin antimony solder and #50 flux. Tubing to be coupled with flared compression type fittings shall conform to the applicable provisions of the Joint Industry Conference (JIC) Standa rds and the recommendations of the manufacturer.
6. Mechanical Coupling Type Joints of the sleeve, grooved mechanical, split sleeve, and flanged coupling adapter types shall be made in accordance with Piping and Appurtenances
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the printed instructions of the manufact urer. The pipe ends to receive the couplings shall be finished to the outside diameter and surface finish required by the coupling manufacturer. Prior to assembly, all surfaces which will be inaccessible after installation shall be given protective coating.
7. Joint Harnesses shall be provided at sleeve type coupling joints. The harnesses shall be tightened just sufficiently to preclude displacement of the downstream piping under hydraulic thrust.
8. Electrical Insulation joints shall be provided at all connections between dissimilar metals and ferrous and non-ferrous pipe except where the nonferrous pipe is an electrical non-conduc tor. The joints shall be tested after completion to verify non-conductivity.
9. PVC Pipe Joints at fittings and coupli ngs to valves and equipment shall be made in accordance with the manufacturer's printed instructions.
3.04 INSTALLATION OF STEEL PIPE
Install steel pipe as shown on the Drawings. Securely anchor horizontal and vertical pipe by means of pipe hangers or supports. Sufficient unions shall be provided to facilitate taking down pipe. Pipe ends shall be reamed to the full bore of the pipe. Threads shall conform to the requirements of ANSI B2.1-1968. In making up threaded joints, Teflon tape shall be applied to the male ends only.
3.05 INSTALLATION OF DUCTILE OR CAST IRON PIPE
The WSSS shall govern over this specification.
A. Pipe Laying.
1. Inspection. All pipe shall be car efully inspected by the Owner's representative for defects before inst allation. Such inspection shall include light tapping with a hammer while the pipe is suspended in the air. No pipe or fittings which are cracked or which show defects excluded by the Specifications for such pipe or fittings shall be used. All injuries to the protective coating of the pipe or fitti ngs shall be carefully repaired by the Contractor.
2. Cleanliness of Material. All pipes, valves, and fittings shall be carefully cleaned before installation. Every open end of a pipe shall be carefully and securely plugged or capped before leaving the work.
3. Positioning. For bell and spigot pipe , the position or direction of bells, which shall normally face upstream of the flow, may be altered from the positions shown on the Drawings with the permission of the Engineer. Bells and spigots must be thoroughly cleaned and free from oil, grease, blisters, and excess coating before spigots are inse rted into bells. The spigot end of Piping and Appurtenances
City of Anaheim 15060 - 21 6/26/2013
the pipe shall be brought to true line and grade and be inserted to the full depth of the socket before the joints are made. The inner surface of the pipe shall be of uniform width and depth. If any pipe does not allow sufficient space for jointing material, it shall be replaced by one of proper dimensions.
4. Deflection. The maximum deflection in bell and spigot cast or ductile iron pipe joints shall be such that the joint opening measured at the outside of the pipe shall not exceed 0.8 inch and the caulking space shall be not less than
0.24 inch.
5. Anchorage. Anchorage lugs shall be provided where there is a possibility of pulling the joint under pressure. Concrete thrust blocks may be used in lieu of the above for buried pipe.
6. Piping Through the Walls. Where pipes pass through walls, care shall be exercised to insure joints being waterti ght. The pipe shall be free of all dirt and grease to secure a tight bond with the concrete.
B. Rubber-Ring Joints. Between lengths of buried cast or ductile iron pipe, rubber gasket joints may be used. Joints sh all conform to AWWA C111. Installation shall be in accordance with the Manufacturer's printed recommendations. Gasket seats and rubber gaskets shall be thoroughly cleaned before assembly. The completed joint shall have a uniform c ontact by the gasket between the outer surface of the spigot and the gasket seat of the bell.
C. Flanged Joints. Flanged pipe shall be cu t true to length. Joints shall be made up square, with even pressure upon the gaskets and shall be perfectly water-tight.
Gaskets shall fit the inside dimension of the pipe accurately, so that no surplus material projects out into the flow area. The completed joint shall be smooth and properly aligned.
3.06 INSTALLATION OF POLYVINYL CHLORIDE SCHEDULE PIPE
A. Laying. Install plastic pipe where and as shown on the Drawings. The trench for buried plastic piping shall be excavated to six inches below the bottom of the pipe and filled to proper grade with course sa nd, thoroughly tamped. After the pipe is laid the trench shall be backfilled with sa nd to 12 inches above the top of the pipe.
The remainder of the trench shall then be backfilled in accordance with Section 02221.
B. Fittings. Fittings for plastic pipe shall be flanged or of the socket type using the solvent weld process. Transition from plas tic to steel pipe shall be by flanges or by threaded slip joint plastic adapter or fittings . No plastic pipe shall be threaded. No solvent shall be used on threaded end of plastic adapters or fittings.
C. Anchorage. All line valves and fittings at down pipes shall be anchored to the wall in a manner to prevent stress and rotation of the pipe.
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City of Anaheim 15060 - 22 6/26/2013
D. Joints. Joint material for plastic pipe shall conform strictly to the printed recommendations of the pipe manufacturer. Solvent weld connections shall be made as follows:
1. Joints shall be wiped clean and a solvent supplied by the manufacturer applied to both male and female connections.
2. Two applications of the solvent shall be made.
3. The treated surface shall be forced together as soon as the pipe material becomes soft or tacky and give n ¼ turn as recommended by the manufacturer.
3.07 INSTALLATION OF PIPELINES THROUGH CONCRETE STRUCTURES A. Whenever a pipeline or any material term inates at or extends through a structural wall or sump, install the fitting or speci al casting required for the particular installation in advance of pouring the concrete. Otherwise, prepare and submit shop/erection drawings of other insta llation methods and obtain approvals in advance of commencement of work.
B. Whenever any run of pipe is inst alled per approved shop/erection drawings subsequent to placing of concrete, accura tely position the opening in the concrete for such pipelines. Unless otherwise required, all pipes penetrating fluid containing or earth supporting portions of the structure shall be ring flanged.
1. Opening shall be of sufficient size to permit a perfect final alignment of pipelines and fittings without deflection of any part and to allow adequate space for satisfactory packing where pipe passes through wall to insure water tightness around openings so formed.
2. The boxes or cores shall be provided with continuous keyways to hold the filling material in place and to insure a watertight joint.
3. Boxes or cores shall be filled with nonshrink grout or non-shrink concrete. a. Non-Shrink Concrete. All non-shri nk concrete shall contain one (l) pound of Embeco Aggregate per pound of water that is in excess of two gallons per sack of cement.
b. Non-Shrink Grout. Non-shrink grout shall be made with the following proportions:
1 part Type I Portland Cement (1 bag)
1 part Embeco Aggregate (100 lbs.)
1 part clean, well graded concrete sand (100 lbs.)
Approximately 5.5 gallons of water per bag of cement.
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3.08 CHANGES IN LINE AND GRADE
In the event that obstructions not shown on the Drawings are encountered during the progress of the work that will require alterations to th e Drawings, the Owner shall have the authority to change the Drawings and order the necessary deviation from the line or grade. Do not make any deviation from the specified line or grade without approval by the Owner. Should any deviations in line or grade be permitted by the Owner in order to reduce the amount of rock excavation or for other similar convenience to the Contractor, all additional costs for thrust blocks, valves, blow-off assemblies, extr a pipe footage or other additional costs shall be borne by the Contractor.
3.09 WELDING
A. Provide good quality welding. All welding operators shall be qualified under the Standard Qualification procedure of th e American Welding Society. All welds shall be made by an electric shielded arc method of welding. Field welding of all joints shall be in conformance with AWWA C206.
B. The Owner shall have the right at any time to call for and witness the making of test specimens by any welder in accordan ce with these Specifications, and the expense of such tests shall be borne by the Contractor.
C. Welds considered by the Owner to be defi cient in quality, or made contrary to any mandatory provision of these specifica tions, shall be removed throughout its depth to expose clean base metal, but in case of a strictly local deficiency, the weld need not be removed throughout its entire length, provided that sufficient amount shall be removed to insure that sound weld metal, only, remains. A cracked weld shall be removed throughout its length.
3.10 IDENTIFICATION OF PIPING
A. Piping Systems. Identification of piping systems shall conform to the requirements of ANSI Al3.1, "Scheme for th e Identification of Piping System," unless otherwise specified herein.
B. Color Identification. All exposed or unburied pipe less than 4 inches diameter shall be identified by color bands to show its use function. All color bands shall be approved by the Owner. Color bands of an approved taped type may be used on PVC and all other pipe not readily susceptib le to painted finish. Markers shall be adhesive type with extra strength and suitable for continuous duty at 250 degrees F. All markers shall have a protective silicone film.
Both the direction of fluid flow, and the name of the fluid in the pipe shall be stenciled on all pipe at least once every 25 feet and at every change of direction.
Color bands shall be spaced at 15-foot in tervals and every change in direction.
The size of the letters and color bands shall be as specified in the table below:
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City of Anaheim 15060 - 24 6/26/2013
Outside Diameter of Width of Height of Legend
Pipe or Covering Color Band Letters
1/2 to 1-1/4 1 1/2
1-1/2 to 2 1 3/4
2-1/2 to 6 6 2
8 to 10 6 2-1/2
Over 10 6 3-1/2
All dimensions are given in inches.
C. Process Valve Identification. After the painting of process piping is complete, the Contractor shall stencil the tag numbers of all valves numbered on the Drawings, on the pipe adjacent to the valve for pipe 2 inches and over. Characters shall be one inch high minimum and shall be oriented to be visible from the valve operating position. When the valve has exte nded operator shaft or chain operator, the number shall be placed both at the ope rating position and at the valve if the valve cannot be seen from the operati ng position. The latter requirement does not apply if the valve is buried. Valves in pi pes under 2 inches shall have characters as large as the pipe will permit, or at the Owner's option, on an adjacent surface.
Characters shall be preferably white, however, if this would not provide sufficient contrast to the pipe, the Owner may select another color. Paint used shall be of the same type and quality as used for painting the pipe.
3.11 PROTECTIVE COATINGS
Painting and coatings shall conform to the applicable requirements of Section 09900, "Painting and Protective Coatings," and the schedule submitted with the shop and erection- drawings. It shall be the Contractor's respons ibility to fully coordinate the protective coating requirements with the foregoing color code identification requirements to ensure compatibility of materials used.
3.12 TESTING
The Contractor shall perform hydrostatic, leakage, and operational tests as specified herein.
The Contractor shall perform all excavation a nd other work required to locate and repair leaks and correct other defects which may be disclosed or develop under tests; the Contractor shall replace all coating, painting, backfill, or other permanent work removed in locating or repairing leaks and correcting defective piping. All gages and control devices connected to lines being tested must be disconnected for the duration of the test. Water shall not be used in testing air lines, chlorine lines, nitrogen lines, or other gas carrying pipes. High pressure air testing of PVC pipe in exposed or a bove ground installations is not permitted. The Contractor shall furnish and install a chart type recording meter for the pressure tests. The Contractor shall submit to the Owner before and after the test the gage and meter used so that these devices may be tested by the Owner.
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A. Testing Requirements.
1. Drain Pipes or Other Pipelines Ha ving Free Surface Flow Except Storm Drainage Pipelines. Pipe having free surface flow shall be given a water exfiltration test as specified herein. The Contractor has the option of using a low pressure air test in lieu of the water exfiltration test. If excessive groundwater is present which precludes use of the exfiltration test, the Contractor shall use either the low pressure air test or infiltration test.
2. Water Lines and Other Pressure Piping Carrying Liquids. Water lines, sewage force mains and other pressu re piping carrying liquids having bell and spigot gasketed joints shall be given a pressure and leakage test as specified herein.
Pipe Material Test Standard
Ductile Iron AWWA C-600
PVC (AWWA C-900 or C905 Pipe) AWWA C-605
Steel Pipe AWWA C-200
3. Pressure Pipe, Flanged or Welded Jo ints. PVC, steel, ductile iron or other pipe material, with solvent welded, welded, threaded, flanged, grooved end or flexible couplings and joints shall be pressure tested as specified herein.
No leakage shall be permitted.
4. Gravity Storm Drainage Pipe. No sp ecial pressure or leakage testing is required. Leakage shall be minimized by installed in a workmanlike manner with no visible sources of leakage in accordance with the manufacturer's recommendations.
5. Pressure Air and Gas Piping. All pi ping carrying air or other gasses under pressure shall be given a pressure test as specified herein. No leakage is permitted. Low pressure air piping sh all be tested pneumatically. Air pressure of 20 pounds per square inch shall be applied to piping and fittings.
High pressure air piping shall be tested to 200 psi. There shall be no drop in pressure in a 24-hour period. Leaks sh all be located and repaired to the satisfaction of the Owner. Pressure drops due to thermal contraction are acceptable if the pressure returns to the original test pressure after 24 hours.
B. Pressure Tests.
1. General. All piping, including valves, shall be field-tested at a hydrostatic pressure of 50 psi above the pipe pressure class (unless specified otherwise in the Testing Schedule), corrected to th e elevations of the test gage, with duration of two hours minimum, for each pressure test, except as otherwise specified in Testing Schedule. Pi ping conveying liquids between process tankage, not subject to pumping, shall be tested to the maximum possible pressure that can be obtained under st atic conditions. Air piping shall be tested using air or nitrogen.
2. Joint Exposure. All exposed pipe, f ittings, valves, hydrants, and joints shall be carefully inspected before being cast in concrete and/or during the open Piping and Appurtenances
City of Anaheim 15060 - 26 6/26/2013
trench tests. All defects discovered shall be corrected by removal and replacement, as approved by the Owner, and the work then retested to demonstrate satisfactory performance. Where practical, no concrete encasement or backfilling of pipe jo ints will be permitted prior to the satisfactory completion of the tests in any given section.
3. Thrust Blocks. Temporary or permanent thrust blocks shall be placed as required prior to tests, and the Contr actor shall provide all necessary braces, plugs, thrust blocks, caps, flanges, and other materials to permit proper performance of the pressure testing; tests shall not be conducted until the concrete thrust blocks are capable of withstanding the loads produced.
C. Leakage Tests.
1. General. Leakage tests shall be conducte d concurrently with pressure test.
The lowest pressure during the leakage test shall be no less than 5 psi below the pressure used in the pressure test. The allowable leakage for pipes conveying liquids between process tankage (not subject to pumping) shall be determined in accordance with AWWA C-600 Section 4.2 where in the equation, P is the maximum pressure occurring anywhere in the pipeline.
The duration of the test shall be not less than two hours, and measurement shall be made by means of a calibrate d suction tank showing the amount of water required by the test pump to accura tely maintain the specified test pressure. Tests shall be performed onl y in the presence of the Owner, or, if scheduling of tests is such that th e Owner cannot attend due to conflicting commitment, tests may be performed without the Owner's presence if the Contractor obtains written permission to do so from the Owner prior to initiation of testing. No test re port will be accepted unless proof of compliance with the foregoing requirement accompanies the test report.
D. Exfiltration Test.
1. The test shall be conducted between successive manholes by closing the lower end of the pipe to be tested and the inlet pipe of the upper manhole with stoppers. The pipe and manhole shall be filled with water to a point 4 feet above the invert of the pipe at the center of the upper manhole; or if ground water is present, 4 feet above the average adjacent ground water level. Pipe shall be thoroughly wetted prio r to start of test. Duration of test shall be determined based upon field conditions.
2. The allowable leakage will be computed by the formulae:
E = 0.0001 LD (H)
1/2 for mortared joints.
E = 0.00002 LD (H)1/2 for all other joints.
Where:
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City of Anaheim 15060 - 27 6/26/2013
L is length of sewer and house connections tested, in feet.
E is the allowable leakage in gallons per minute of sewer tested.
D is the internal diameter of the pipe in inches.
H is the difference in elevati on, in feet, between the water surface in the upper manhole and the invert of the pipe at the lower manhole; or if ground water is present above the invert of the pipe in the lower manhole, the difference in elevation between the water surface in the upper manhole and the groundwater at the lower manhole.
3. The Contractor shall, at its expense, furnish all water, materials and labor for making the required test. All tests shall be made in the presence of the Owner.
E. Infiltration Test.
1. The end of the pipe at the upper structure shall be closed sufficiently to prevent the entrance of water, and th e outlet of the lower manhole shall be closed to prevent the exit of water. Pumping of groundwater shall be discontinued for at least 3 days, after which the section shall be tested for infiltration.
2. The infiltration into each individua l reach of pipe between adjoining manholes shall not exceed that allowed by the formula in Subsection "Exfiltration Test" where H is the diffe rence in the elevation between the groundwater surface and the invert of the pipe at the downstream manhole.
3. Unless otherwise specified, infiltration will be measured by the Engineer using approved measuring devices furnished by the Contractor.
F. Low Pressure Air Test. Conduct in conformance with ASTM C-828.
3.13 FLUSHING
A. General. All piping shall be flushed clean of all dirt and foreign material following completion of the hydrostatic and leakage test. Air and gas piping shall be purged with air or inert gas as directed by the Owner.
B. Equipment and Supplies. The Contractor shall provide all equipment, and supplies for performing the work, and shall waste the water at locations or by procedures approved by the Owner, and in accordance with NPDES requirements in the Special Provisions. The Contract or shall be responsible for furnishing fittings and all special pipe taps requi red for injecting any required sterilizing solution.
3.14 DISINFECTION
Disinfection of the potable water lines sha ll be performed in accordance with AWWA Standard C651, and the WSSS.
Piping and Appurtenances
City of Anaheim 15060 - 28 6/26/2013
END OF SECTION 15060
Valves: General Requirements
City of Anaheim 15100-1 06/26/13
SECTION 15100
VALVES: GENERAL REQUIREMENTS
PART 1 - GENERAL
1.01 SUMMARY
A. Section includes:
1. Valving, actuators, and valving appurtenances.
B. Related Sections include but are not necessarily limited to:
1. Section 09900 - Painting.
2. Section 11005 – General Mechanical and Equipment Provisions.
3. Section 15060 – Piping and Appurtenances.
4. Section 15101 - Butterfly Valves.
5. Section 15103 - Ball Valves.
6. Section 15106 - Check Valves.
7. Section 15114 - Miscellaneous Valves.
1.02 QUALITY ASSURANCE
A. Referenced Standards:
1. American National Standards Institute (ANSI):
a. B1.20.1, Pipe Threads, General Purpose.
b. B16.1, Cast Iron Pipe Flanges and Flanged Fittings.
c. B16.18, Cast Copper Alloy Sold er Joint Pressure Fittings.
2. American Water Works Association (AWWA):
a. C111, Rubber-Gasket Joints fo r Ductile Iron Pressure Pipe and Fittings.
b. C207, Steel Pipe Flanges for Wate rworks Service Sizes 4 IN through 144 IN.
c. C500, Metal Seated Gate Valves for Water Supply Service. d. C504, Rubber-Seated Butterfly Valves.
e. C509, Resilient-Seated Gate Va lves for Water Supply Service. f. C540, Power-Actuating Devices for Valves and Sluice Gates. g. C550, Protective Epoxy Interior Coatings for Valves and Hydrants.
3. Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS).
Valves: General Requirements
City of Anaheim 15100-2 06/26/13
1.03 SUBMITTALS
A. Shop Drawings:
1. See Special Provisions Section 2-13.
2. Product technical data including:
a. Acknowledgement that products submitted meet requirements of standards referenced.
b. Manufacturer's installation instructions.
c. Valve pressure and temperature rating.
d. Valve material of construction.
e. Special linings.
f. Valve dimensions and weight.
g. Valve flow coefficient.
h. Wiring and control diagrams for electric or cylinder actuators.
3. Test reports.
B. Operation and Maintenance Manuals:
1. See Special Provisions Section 1-09.09.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Refer to individual valve specification sections.
2.02 MATERIALS
A. Refer to individual valve specification sections.
2.03 VALVE ACTUATORS
A. Valve Actuators - General:
1. Provide actuators as shown on Drawings or specified.
2. Counter clockwise opening as viewed from the top.
3. Direction of opening and the word OPEN to be cast in handwheel or valve bonnet.
4. Size actuator to produce required torque with a maximum pull of 80 LB and withstand without damage a pull of 200 LB.
B. Buried Valve Actuators:
1. Provide screw or slide type adjustable cast iron box, 5 IN minimum diameter, and identifying cover.
2. Box base to enclose buried valve gear box or bonnet.
3. Provide 2 IN AWWA standard valve actuator nut.
Valves: General Requirements
City of Anaheim 15100-3 06/26/13
4. Provide stem extension to grade with guide bushing to center extension.
5. Provide cast iron floor stands where shown on Drawings. Stands to be furnished by valve manufacturer with actuator.
a.Stand or actuator to include thrust bearings for valve operation and weight of accessories.
C. Manual Actuators:
1. Provide for all exposed valves not having electric or cylinder actuators.
2. Provide handwheels for gate and globe valves.
a. Size handwheels for valves in accordance with AWWA C500.
3. Provide lever actuators for plug valves, butterfly valves and ball valves 3-inch diameter and smaller.
a. Lever actuators for butterfly valves to have a minimum of 5 intermediate lock positions between full open and full close.
4. Gear actuators required for plug valves, butterfly valves, and ball valves 4-inch diameter and larger.
5. Gear actuators to be totally enclosed, permanently lubricated and with sealed bearings.
2.04 FABRICATION
A. End Connections:
1. Provide the type of end connections for valves as required in the Piping Schedules presented in Section 15060 or as shown on the Drawings.
2. Comply with the following standards:
a. Threaded: ANSI B1.20.1.
b. Flanged: ANSI B16.1 Class 125 unless otherwise noted or AWWA C207. c. Bell and spigot or mechanical (gland) type: AWWA C111. d. Soldered: ANSI B16.18.
B. Refer to individual valve sections fo r specifications of each type of valve on Project.
C. Nuts, Bolts, and Washers:
1. Wetted or internal to be bronze or stainless steel. Exposed to be galvanized.
D. Epoxy Interior Coating:
1. Provide fusion-bonded epoxy interior coating for all ferrous surfaces in accordance with AWWA C550 for all valves on project.
PART 3 - EXECUTION
3.01 INSTALLATION
Valves: General Requirements
City of Anaheim 15100-4 06/26/13
A. Install products in accordance w ith manufacturer's instructions.
B. Painting Requirements:
1. Comply with section 09900 for painting and protective coatings.
C. Support exposed valves and piping adjacen t to valves independently to eliminate pipe loads being transferred to valve and valve loads being transferred to the piping.
D. For threaded valves, provide union on one side to allow valve removal.
E. Install valves accessible for operation, inspection, and maintenance.
3.02 ADJUSTING
A. Adjust valves, actuators and appurtenant equipment to comply with manufacturers recommendations and station operation. Provide fully functioning valves, operate valve, open and close at system pressures.
END OF SECTION 15100
Ball Valves
City of Anaheim 15103-1 06/26/13
SECTION 15103
BALL VALVES
PART 1 - GENERAL
1.01 SUMMARY
A. Related Sections include but are not necessarily limited to:
1. Section 15100 - Valves: General Requirements.
1.02 QUALITY ASSURANCE
A. Referenced Standards:
1. American Society for Testing and Materials (ASTM):
a. A48, Gray Iron Castings (Class 35 Minimum).
b. A126, Gray Iron Castings for Valves Flanges, and Pipe Fittings. c. D1784, Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride)
(CPVC) Compounds.
2. Federal Specification:
a. WW-V-35B.
1.03 SUBMITTALS
A. Shop Drawings:
1. See Section 15100.
B. Operation and Maintenance Manuals:
1. See Special Provisions Section 1-09.09.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Contract Documents, the manufacturers listed in the applicable articles below are acceptable.
B. Submit requests for substitution in accordance with Specification Section 13.
Ball Valves
City of Anaheim 15103-2 06/26/13
2.02 METALLIC BALL VALVES 1/4 TO 3 INCHES DIAMETER
A. Comply with Federal Specification WW-V-35B Type II, Class A.
B. Acceptable Manufacturers:
1. Apollo.
2. Jamesbury.
3. Watts.
4. Stockham.
5. or approved equal.
C. Materials:
1. Body: Bronze.
2. Stem, stem gland nut: Brass.
3. Ball: Brass, chrome plated.
4. Seats, stuffing box ring, and thrust washer: Reinforced Teflon.
5. Handle: Vinyl coated galvanized steel.
D. Design Requirements:
1. Rated for 400 psi and 250 DegF, for threaded end applications and 285 psi for flanged end applications.
2. Handles showing direction of opening.
3. Stuffing boxes capable of being repacked under pressure and adjustable for wear.
4. Stem with reinforced teflon stuffing box ring and blowout-proof design.
5. Renewable reinforced teflon seats.
6. Ball design which does not allow media contact with stem.
7. Balancing stop for all applications.
8. Bodies with mounting pad for applications requiring actuators.
2.03 PLASTIC BALL VALVES 1/2 TO 4 IN DIA
A. Acceptable Manufacturers:
1. Chemtrol.
2. ASAHI/America.
3. or approved equal.
Ball Valves
City of Anaheim 15103-3 06/26/13
B. Materials:
1. Body, stem, ball, handle, end connectors:
a. PVC ASTM D1784-12454B or CPVC ASTM D1784-23477-B.
2. Seat: Teflon.
3. 0-rings: Viton.
C. Design Requirements:
1. Rated at 150 psi at 75 DegF.
2. Double or true union design.
3. Blocks both directions, upstream and downstream.
4. Union nut capable of compensating for seat adjustments.
5. Body with mounting pad for actuators where required.
2.04 ACCESSORIES
A. Refer to Drawings and valve schedule for type of actuators. Furnish actuator integral with valve.
B. Refer to Section 15100 for actuator requirements.
PART 3 - EXECUTION
3.01 INSTALLATION
A. See Section 15100.
END OF SECTION 15103
Check Valves
City of Anaheim 15106-1 06/26/13
SECTION 15106
CHECK VALVES
PART 1 - GENERAL
1.01 SUMMARY
A. Related Sections include but are not necessarily limited to:
1. Section 15100 - Valves: General Requirements.
1.02 QUALITY ASSURANCE
A. Referenced Standards:
1. American National Standard Institute (ANSI):
a. B16.1, Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250 and 800.
2. American Water Works Association (AWWA):
a. C111, Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings.
3. Manufacturer's Standardization, Society of the Valve and Fittings Industry, Inc (MSS):
a. SP-9, Spot Facing for Bronze, Iron and Steel Flanges. b. SP-71, Cast Iron Swing Check Valves, Flanged and Threaded Ends. c. SP-80, Bronze Gate, Globe, Angle and Check Valves.
1.03 SUBMITTALS
A. Shop Drawings:
1. See Section 15100.
B. Operation and Maintenance Manuals:
1. See Section 14.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Cont ract Documents, manufacturers listed under the valve with types are acceptable.
B. Submit requests for substitution in accordance with Specification Section 13.
Check Valves
City of Anaheim 15106-2 06/26/13
2.02 CHECK VALVES: 2 INCHES AND SMALLER
A. Class 125 Bronze Swing Check:
1. Comply with MSS SP-80.
2. Acceptable manufacturers:
a. Nibco 413B.
b. Stockham B319.
c. Or approved equal.
3. Materials:
a. Body, bonnet, disc: Bronze.
4. Design requirements:
a. 200 psi WOG.
b. Horizontal swing, renewable disc.
B. PVC Ball Check Valves:
1. Acceptable manufacturers:
a. Hayward Industrial Products, Inc.
b. Approved equal.
2. Materials:
a PVC with threaded ends.
b. Seals and seats shall be Viton
3. Design Requirements:
a. True union design
b. Maximum inlet pressure: 150 psi or greater.
2.03 SLANTING DISC CHECK VALVE:
A. Class 125.
B. Acceptable Manufacturers:
1. APCO Series 800-B.
C. Materials:
1. Body: Cast iron.
2. Disc: Ductile iron.
3. Seat: Stainless steel.
4. Seat ring and disc: Bronze or rubber (Buna-N).
5. Pivot pins and bushings: Stainless steel.
D. Design Requirements:
Check Valves
City of Anaheim 15106-3 06/26/13
1. Seat ring: Hand replaceable.
2. Provide bottom mounted buffer.
PART 3 - EXECUTION
3.01 INSTALLATION
A. See Section 15100.
B. Install in accordance with manufacturer's instructions.
END OF SECTION 15106
Miscellaneous Valves
City of Anaheim 15114-1 06/27/13
SECTION 15114
MISCELLANEOUS VALVES
PART l - GENERAL
1.01 SUMMARY
A. Section Includes:
1. Air release and vacuum relief valves.
2. Automatic control valves:
a. Pump Control Valve
B. Related Sections include but are not necessarily limited to:
1. Section 11005 - General Mechanical and Equipment Provisions.
2. Section 15100 - Valves: General Requirements.
1.02 SUBMITTALS
A. Shop Drawings:
1. See Special Provisions Section 2-13.
B. Operation and Maintenance Manuals:
1. See Special Provisions Section 1-09.09.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Subject to compliance with the Contract Documents, the manufacturers listed under the specific valve types are acceptable.
B. Submit requests for substitution in accordance with Specification Section 01640.
2.02 AIR VALVES
A. Vertical Turbine Pump Combination Air Valve (Water)
1. Acceptable manufacturers:
a. APCO Series 146 DAT with Double Acting Throttling Device, Water Diffuser, and No. 50 Air Release Valve.
b. Or approved equal.
Miscellaneous Valves
City of Anaheim 15114-2 06/27/13
2. Materials:
a. Body and cover: Cast iron.
b. Float: Stainless steel.
c. Seat: Buna-N.
3. Design requirements:
a. Line operating pressure: as shown on plans.
b. Capacity 500 scfm at 5 psi differential.
c. Provide butterfly isolation valve, APCO Series 903 or equal. d. Mount 6" min from pipe flange.
B. Combination Air Valve (Water)
1. Acceptable manufacturers:
a. APCO Series 147C
b. Or approved equal.
2. Materials:
a. Body and cover: Cast iron.
b. Float: Stainless steel.
c. Seat: Buna-N.
3. Design requirements:
a. Line operating pressure: as shown on plans.
b. Capacity 500 scfm at 5 psi differential.
c. Provide butterfly isolation valve, APCO Series 903 or equal. d. Mount 6" min from pipe flange.
2.03 WELL PUMP CONTROL VALVE
A. Control valve shall be a diaphragm-actuated hydraulically operated valve as follows:
1. Acceptable manufacturers:
a. Cla-val, Model 61-02.
2. Materials:
a. Body: Ductile iron.
b. Seat insert: Renewable bronze.
c. Disc: Buna-N.
d. Diaphragm: Nylon fabric bonded with synthetic rubber. e. Trim: Stainless Steel.
f. End Detail: Flanged end, 150 lb (125 lb ANSI bolt pattern) Miscellaneous Valves
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3. Design requirements:
a. Size and pattern: as shown on plans.
b. Operating pressure:
1) Maximum as shown on plans.
2) Minimum 0 psi.
c. Flow range:
1) Normal maximum as shown on plans.
2) Normal minimum 0 gpm.
d. Operation:
1) Valve fully open to atmosphere with pump off. When pump is started, valve closes slowly as main line check valve opens. 2) Sequence reverses on pump shut off or power outage.
e. Assembles all control features and hardware on basic valve at factory. f. Use 316 stainless steel for all valve tubing fitting, and exposed portions of the control valve.
g. Include with control valve:
1) Stop valves.
2) Strainer.
3) Valves for opening and closing speed control.
4) Pilot valves.
5) Solenoid valves.
6) Pressure switches as necessary to provide control function. 7) Valve position indicator.
h. Electric components:
1) 110 V, 1 phase.
2.04 PLUG VALVES
A. Construction: Lubricated plug valves shall be the tapered plug, top or bottom entry type, with flanged ends for sizes 3 inches and larger, and flanged or screwed ends for smaller valves, as indicated. Th e body and top plate shall be of cast iron.
The plug shall be of steel or cast iron and the stem shall be of stainless steel or alloy steel, with weather seal and Teflon impregnated packing. The valve body and plug shall have smoothly finished water passages free from sharp corners when the plug is in the wide-open position. The valve shall be rated for ANSI class 150 or 300, or as indicated, between service temperatures of minus 20 to plus 100 degrees F.
Miscellaneous Valves
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Plug valves installed inside the vaults shall be short pattern (gate length) and have flange face to face lengths interchangeable with ANSI Class 125 and API 175 CWP Cast Iron Gate Valves.
B. Sealant System: The valves shall be provided with fittings designed to feed a sealant through a check-valve protected pa ssage in the stem, through the side, or through a stainless steel tube for worm-gear actuated or buried valves. There shall be ducts or grooves in the face of the plug to insure the maintenance of a closed, pressurized sealant system between all cont act surfaces of moving parts. All surfaces of the plug shall be coated with a dry film lubricant, such as polyfluoride, or equal to suit the service, permanently bonded to the metal surfaces. Sealant for LP gas service shall be the Manufacturer's recommended type. The plug shall be held toward the seat by factory-adjusted gland assemblies set for proper sealing and operating torque.
The gland assemblies shall be adjustable from the valve exterior and shall utilize either spring washers or gland deflection to allow plug unseating when pressurized sealant is injected.
C. Actuators: Unless otherwise indicate d, valves 3 inches and smaller shall be lever-actuated; larger valves shall be equipped with manual worm-gear actuators and flywheels for plug valves located inside the vault.
D. Lubricating Gun: Supply a manual lubricating gun for lubricated plug valves in sizes up to 6 inches, inclusive. For larger valves, the CONTRACTOR shall furnish a pneumatically operated lubricating gun and a manual lubricating gun. For installations of more than 6 lubricated plug valves, the number of guns furnished shall be doubled. The guns shall be of the same Manufacturer as the valves. They shall each be equipped with flexible connectors, pressure gauge, and safety valve, with operating instructions and be furnished in labeled tool boxes.
E. Coatings: The interior of the plug valve shall be factory coated with fusion bonded epoxy. Coating shall conform to AWWA Standard C550, “Protective Epoxy Interior Coating for Valves and Hydrants.”
The exterior of the plug valve shall be co ated per the requirements in the Technical Specifications.
F. Manufacturers, or Equal:
Nordstrom – Audco Valves, Inc.
2.05 PRESSURE REGULATOR VALVES
A. Acceptable Manufacturers
1. Hayward Industrial Products, Inc.
2. Or approved equal.
Miscellaneous Valves
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B. Materials
1. All PVC construction.
2. No metal parts shall be in contact with the process fluid.
C. Design Requirements
1. Maximum inlet pressure: 150 psi or greater (non-shock) at 70oF.
2. Hand adjustable to regulate pressures to between 5 and 75 psi.
2.06 LINE STOP
Section 2-16 is hereby added to Section 2 of the WSSS
Where indicated on the Construction Drawings, a line stop shall be furnished and installed per the manufacturer’s recommendations. The line stop shall include the tapping sleeve fitting (fusion bonded epoxy coating), line stop m achine, the completion plug, and the blind completion flange. The line stop shall achieve a guaranteed 95% to 100% water stop at the point of application. At no time shall the existi ng water main be taken out of service. Once the new or existing water main is in operation, the line stop may be removed and the completion plug and blind completion flange in stalled. The line stop shall be manufactured by HYDRA-STOP, INC., IFT Inc. or an approved equal. The manufacturer of the line stop must have installed similar type line stops with in Southern California for a period of not less than three years.
2.07 ACCESSORIES
A. Furnish any accessories required to provide a completely operable valve.
2.08 FABRICATION
A. Completely shop assemble unit including any interconnecting piping, speed control valves, control isolation valves and electrical components.
B. Provide internal fusion-bonded epoxy coating suitable for potable water for all iron body valves.
2.09 SOURCE QUALITY CONTROL
A. Shop hydrostatically test to unit test pressure.
2.10 MAINTENANCE MATERIALS
A. Provide one set of any special tool s or wrenches required for operation or maintenance for each type valve.
Miscellaneous Valves
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PART 3 - EXECUTION
3.01 INSTALLATION
A. General:
1. See Sections 11005 and 15100.
B. Air Release, Vacuum Relief, and Pressure Relief Valves:
1. Pipe exhaust to a suitable disposal point.
2. Where exhausted to a trapped floor drain, terminate exhaust line 6 IN minimum above floor.
3.02 FIELD QUALITY CONTROL
A. Clean, inspect, and operate valve to ensure all parts are operable and valve seats properly.
B. Check and adjust valves and accessories in accordance with manufacturer's instructions and place into operation.
END OF SECTION 15114
Appendix H
Assembly Bill No. 626
Original Dated: September 2016
Assembly Bill No. 626 SECTION 1. Section 9204 or the latest version is added to the Public Contract Code, to read:
9204. (a) The Legislature finds and declares that it is in the best interests of the state and its citizens to ensure that all construction business performed on a public works project in the state that is complete and not in dispute is paid in full and in a timely manner.
(b) Notwithstanding any other law, including, but not limited to, Article 7.1 (commencing with Section 10240) of Chapter 1 of Part 2, Chapter 10 (commencing with Section 19100) of Part 2, and Article 1.5 (commencing with Section 20104) of Chapter 1 of Part 3, this section shall apply to any claim by a contractor in connection with a public works project.
(c) For purposes of this section:
(1) “Claim” means a separate demand by a contractor sent by registered mail or certified mail with return receipt requested, for one or more of the following:
(A) A time extension, including, without limitation, for relief from damages or penalties for delay assessed by a public entity under a contract for a public works project.
(B) Payment by the public entity of money or damages arising from work done by, or on behalf of, the contractor pursuant to the contract for a public works project and payment for which is not otherwise expressly provided or to which the claimant is not otherwise entitled.
(C) Payment of an amount that is disputed by the public entity.
(2) “Contractor” means any type of contractor within the meaning of Chapter 9 (commencing with Section 7000) of Division 3 of the Business and Professions Code who has entered into a direct contract with a public entity for a public works project.
(3) (A) “Public entity” means, without limitation, except as provided in subparagraph (B), a state agency, department, office, division, bureau, board, or commission, the California State University, the University of California, a city, including a charter city, county, including a charter county, city and county, including a charter city and county, district, special district, public authority, political subdivision, public corporation, or nonprofit transit corporation wholly owned by a public agency and formed to carry out the purposes of the public agency.
(B) “Public entity” shall not include the following:
(i) The Department of Water Resources as to any project under the jurisdiction of that department.
(ii) The Department of Transportation as to any project under the jurisdiction of that department.
(iii) The Department of Parks and Recreation as to any project under the jurisdiction of that department.
(iv) The Department of Corrections and Rehabilitation with respect to any pr oject under its jurisdiction pursuant to Chapter 11 (commencing with Section 7000) of Title 7 of Part 3 of the Penal Code.
(v) The Military Department as to any project under the jurisdiction of that department.
(vi) The Department of General Services as to all other projects.
(vii) The High-Speed Rail Authority.
(4) “Public works project” means the erection, construction, alteration, repair, or improvement of any public structure, building, road, or other public improvement of any kind.
(5) “Subcontractor” means any type of contractor within the meaning of Chapter 9 (commencing with Section 7000) of Division 3 of the Business and Professions Code who either is in direct contract with a contractor or is a lower tier subcontractor.
(d) (1) (A) Upon receipt of a claim pursuant to this section, the public entity to which the claim applies shall conduct a reasonable review of the claim and, within a period not to exceed 45 days, shall provide the claimant a written statement identifying what portion of the claim is disputed and what portion is undisputed.
Upon receipt of a claim, a public entity and a contractor may, by mutual agreement, extend the time period provided in this subdivision.
(B) The claimant shall furnish reasonable documentation to support the claim.
(C) If the public entity needs approval from its governing body to provide the claimant a written statement identifying the disputed portion and the undisputed portion of the claim, and the governing body does not meet within the 45 days or within the mutually agreed to extension of time following receipt of a claim sent by registered mail or certified mail, return receipt requested, the public entity shall have up to three days following the next duly publicly noticed meeting of the governing body after the 45-day period, or extension, expires to provide the claimant a written statement identifying the disputed portion and the undisputed portion.
(D) Any payment due on an undisputed portion of the claim shall be processed and made within 60 days after the public entity issues its written statement. If the public entity fails to issue a written statement, paragraph (3) shall apply.
(2) (A) If the claimant disputes the public entity’s written response, or if the public entity fails to respond to a claim issued pursuant to this section within the time prescribed, the claimant may demand in writing an informal conference to meet and confer for settlement of the issues in dispute. Upon receipt of a demand in writing sent by registered mail or certified mail, return receipt requested, the public entity shall schedule a meet and confer conference within 30 days for settlement of the dispute.
(B) Within 10 business days following the conclusion of the meet and confer co nference, if the claim or any portion of the claim remains in dispute, the public entity shall provide the claimant a written statement identifying the portion of the claim that remains in dispute and the portion that is undisputed. Any payment due on an undisputed portion of the claim shall be processed and made within 60 days after the public entity issues its written statement. Any disputed portion of the claim, as identified by the contractor in writing, shall be submitted to nonbinding mediation, with the public entity and the claimant sharing the associated costs equally. The public entity and claimant shall mutually agree to a mediator within 10 business days after the disputed portion of the claim has been identified in writing. If the parties cannot agree upon a mediator, each party shall select a mediator and those mediators shall select a qualified neutral third party to mediate with regard to the disputed portion of the claim. Each party shall bear the fees and costs charged by its respective medi ator in connection with the selection of the neutral mediator. If mediation is unsuccessful, the parts of the claim remaining in dispute shall be subject to applicable procedures outside this section.
(C) For purposes of this section, mediation includes any nonbinding process, including, but not limited to, neutral evaluation or a dispute review board, in which an independent third party or board assists the parties in dispute resolution through negotiation or by issuance of an evaluation. Any mediation utilized shall conform to the timeframes in this section.
(D) Unless otherwise agreed to by the public entity and the contractor in writing, the mediation conducted pursuant to this section shall excuse any further obligation under Section 20104.4 to mediate after litigation has been commenced.
(E) This section does not preclude a public entity from requiring arbitration of disputes under private arbitration or the Public Works Contract Arbitration Program, if mediation under this section does not resolve the parties’ dispute.
(3) Failure by the public entity to respond to a claim from a contractor within the time periods described in this subdivision or to otherwise meet the time requirements of this section shall result in the claim being deemed rejected in its entirety. A claim that is denied by reason of the p ublic entity’s failure to have responded to a claim, or its failure to otherwise meet the time requirements of this section, shall not constitute an adverse finding with regard to the merits of the claim or the responsibility or qualifications of the claimant.
(4) Amounts not paid in a timely manner as required by this section shall bear interest at 7 percent per annum.
(5) If a subcontractor or a lower tier subcontractor lacks legal standing to assert a claim against a public entity because privity of contract does not exist, the contractor may present to the public entity a claim on behalf of a subcontractor or lower tier subcontractor. A subcontractor may request in writing, either on his or her own behalf or on behalf of a lower tier subcontractor, that the contractor present a claim for work which was performed by the subcontractor or by a lower tier subcontractor on behalf of the subcontractor. The subcontractor requesting that the claim be presented to the public entity shall furnish reasonable documentation to support the claim. Within 45 days of receipt of this written request, the contractor shall notify the subcontractor in writing as to whether the contractor presented the claim to the public entity and, if the original contractor did not present the claim, provide the subcontractor with a statement of the reasons for not having done so.
(e) The text of this section or a summary of it shall be set forth in the plans or specifications for any public works project that may give rise to a claim under this section.
(f) A waiver of the rights granted by this section is void and contrary to public policy, provided, however, that (1) upon receipt of a claim, the parties may mutually agree to waive, in writing, mediation and proceed directly to the commencement of a civil action or binding arbitration, as applicable; and (2) a public entity may prescribe reasonable change order, claim, and dispute resolution procedures and requirements in addition to the provisions of this section, so long as the contractual provisions do not conflict with or otherwise impair the timeframes and procedures set forth in this section.
(g) This section applies to contracts entered into on or after January 1, 2017.
(h) Nothing in this section shall impose liability upon a public entity that makes loans or grants available through a competitive application process, for the failure of an awardee to meet its contractual obligations.
(i) This section shall remain in effect only until January 1, 2020, and as of that date is repeal ed, unless a later enacted statute, that is enacted before January 1, 2020, deletes or extends that date.
SEC. 2.
The Legislature finds and declares that it is of statewide concern to require a charter city, charter county, or charter city and county to follow a prescribed claims resolution process to ensure there are uniform and equitable procurement practices.
SEC. 3.
If the Commission on State Mandates determines that this act contains costs mandated by the state, reimbursement to local agencies and school districts for those costs shall be made pursuant to Part 7 (commencing with Section 17500) of Division 4 of Title 2 of the Government Code .