california addendum no. 2 · addendum no. 2 . 7, 2016. hyperion treatment plant headworks odor...

C I T Y O F L O S A N G E L E S C A L I F O R N I A

Addendum No. 2 July 7, 2016

Hyperion Treatment Plant Headworks Improvements (CIP 2409) and

Headworks Odor Control Upgrade (CIP 2344) W.O. SZH11746 and SZH11748

ERIC GARCETTI MAYOR

GARY LEE MOORE, PE, ENV SP CITY ENGINEER

Bidders are required to acknowledge receipt of this addendum in the space provided on page 1-4 of the Bid Proposal. This addendum consists of this two-page transmittal and 2 attachments of 62 pages. Bidders are hereby notified of the following changes: I. MODIFICATIONS TO SPECIFICATIONS:

1. Replace Technical Specification Volume III Section 17400 Process Instrumentation and Control with attached Section 17400 Process Instrumentation and Control - ADDENDUM 2 (Attachment No. 1) (for CIP 2409). Replacing section 1.1, subsection L. from: “Procured by the Contractor from the “sole-sourced” equipment manufacturers. Installed by the Contractor.” to read as: “Procured by the Contractor from the “sole-sourced” equipment manufacturers (Vulcan is the sole-source manufacturer for the common control panel used for each Drum Screen/Screw Press pair). Installed by the Contractor.”

2. Replace Technical Specification Volume III Section 11840 Mechanically-Raked Bar Screens with attached Section 11840 Mechanically-Raked Bar Screens - ADDENDUM 2 (Attachment No. 2) (for CIP 2409). a) Replacing sections 2.2, subsection W. from: “A discharge chute, minimum thickness of 0.1575" (4mm) with a transition chute shall be provided and designed with 0.1-inch vacuum minimum for each Bar Screen to divert screenings discharged from the screen to a sluiceway. The discharge chute shall be made of Type 316 Stainless Steel. The discharge chute shall be mounted at an angle of 30 degrees.” to read as: “A discharge chute, minimum thickness of 0.1575" (4mm) with a transition chute shall be provided and designed with 0.1-inch vacuum minimum for each Bar Screen to divert screenings discharged from the screen to a sluiceway. The discharge chute and transition chute shall be made of Type 316 Stainless Steel. The discharge chute shall be mounted at an angle of 30 degrees.”

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C I T Y O F L O S A N G E L E S C A L I F O R N I A

Addendum No. 2 July 7, 2016

Hyperion Treatment Plant Headworks Improvements (CIP 2409) and

Headworks Odor Control Upgrade (CIP 2344) W.O. SZH11746 and SZH11748

ERIC GARCETTI MAYOR

GARY LEE MOORE, PE, ENV SP CITY ENGINEER

b) Replacing section 2.2, subsection X. from: “A screenings diverter chute shall be provided for each Bar Screen and designed with 0.1-inch vacuum minimum. The screenings diverter chute shall direct screenings into the transition chute for discharge into the sluiceway or, by engaging a lever, re-direct screenings to a dumpster (provided by others) adjacent to the sluiceway. The transition chute shall bolt to the screenings diverter chute. Gaskets shall be made of Buna-N.” to read as: “A screenings diverter chute made of Type 316 Stainless Steel shall be provided for each Bar Screen and designed with 0.1-inch vacuum minimum. The screenings diverter chute shall direct screenings into the transition chute for discharge into the sluiceway or, by engaging a lever, re-direct screenings to a dumpster (provided by others) adjacent to the sluiceway. The transition chute shall bolt to the screenings diverter chute. Gaskets shall be made of Buna-N.”

ATTACHMENTS: Attachment No. 1 to this addendum is Technical Specification Volume III Section 17400 Process Instrumentation and Control - ADDENDUM 2 for CIP 2409 HTP Headworks Improvements (52 pages). Attachment No. 2 to this addendum is Technical Specification Volume III Section 11840 Mechanically-Raked Bar Screens - ADDENDUM 2 for CIP 2409 HTP Headworks Improvements (10 Pages).

Sincerely, ________________________________ Julie K. Sauter, PE Division Engineer

Project Award and Control Division Bureau of Engineering

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HTP CIP 2409 PROCESS INSTRUMENTATION AND CONTROL

HEADWORKS IMPROVEMENTS DIVISION 17

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SECTION 17400

PROCESS INSTRUMENTATION AND CONTROL - ADDENDUM 2

PART 1 -- GENERAL

1.1 THE REQUIREMENT

A. This section sets forth the general specification and requirements for the instrumentation work for the construction of the Hyperion Treatment Plant (HTP) Headworks Improvements project.

B. A single System Contractor, through the use of a qualified Instrumentation Subcontractor, shall furnish, install, and place into service the operating process instrumentation, all the control systems, and all the appurtenant work, being provided under this section of these Specifications and the integration of the Control and Instrumentation system and control devices provided under this project all in accordance with the requirements of the Contract Documents. The prime Contractor may act as a System Contractor provided the prime Contractor has been qualified to do the work as required in paragraph 1.1 C herein for Instrumentation Subcontractors.

1. Supply and install complete instrumentation systems as indicated on the Contract Drawingsand as specified herein. Complete all required engineering work such as installation details,As-built drawings, Shop submittals, test procedures, training syllabuses and materials, andsimilar work described in this Specification, to produce a complete, fully documented andproperly operating process instrumentation and control system (PI&CS). PI&CS as usedherein shall represent the entire instrumentation and control system to be furnished andinstalled under this Contract. It will be necessary to produce additional drawings and textrecords in order to complete this work.

2. Due to the complexities associated with the interfacing of numerous control system devices, itis the intent of these Specifications to have the Instrumentation Subcontractor assume fullresponsibility for the integration of the control and instrumentation system with existingdevices and devices provided under other Specification sections with the objective ofproviding a completely integrated PI&CS properly interfaced to the plant wide DCS(Distributed Control System) and free of signal incompatibilities and other problems.

3. As a minimum, the Instrumentation Subcontractor under the direction of the Contractor shallassume full responsibility for the following:

a. Implementation of the control and instrumentation system;

1). Provide all engineering, labor and materials required to; prepare analog hardwaresubmittals; design, develop, electronic drafting (AutoCAD) and submit loop drawings and control panel designs; prepare test plan, training plan, and spare parts submittals; procure hardware; fabricate panels; factory test panels; supervise the installation of all instrumentation devices and control panel devices; perform and document all loop tests, system commissioning, and the performance of the Thirty (30) day test for the entire PI&CS.

2). Provide all engineering, labor, and materials required to prepare Operations and Maintenance Manuals, conduct training classes, and to submit "as-built" or record drawings which reflect the installed state of the PI&CS at the time of acceptance.

b. Integration of the PI&CS with instrumentation and control devices being provided underother specification sections;

1). Provide all engineering, labor, and materials required to review vendor drawings andto design, develop, electronically draft and submit all requisite loop drawings and "As-Built" loop drawings associated with;



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a). Equipment being provided under other Divisions of these Specifications.

b). Owner furnished or existing equipment.

2). Provide all engineering, documentation, labor, and materials required to resolve signal, power, or functional incompatibilities between the control and instrumentation system and interfacing devices.

3). Provide all engineering, labor, and materials required to; supervise and install all instrumentation and control panels (including City supplied equipment); verify compliance with the manufacturer’s installation recommendations; supervise the performance and document loop testing.

c. The design, development, drafting and submission of all required loop drawings and as-built loop drawings associated with;

1). Equipment provided under Division 17;

2). Equipment provided under other Divisions of these Specifications

3). CITY furnished equipment.

4). It is the intent of these specifications that all instrumentation loops associated withthis project shall be drafted and documented in a CITY approved format as Loop Drawings and shall be submitted for CITY review and approval.

5). All loop drawings shall be developed in an electronic format (AUTOCAD).

6). The As-Built (final version) shall be submitted both in hard copy and electronic format.

d. All instruments shown on the loop drawings shall be itemized in an instrumentationsummary generated by the Instrumentation Subcontractor. The instrument summaryshall be on Microsoft Excel, and hardcopy format and shall list all of the key attributes ofeach instrument provided under this contract. As a minimum, attributes shall include:

1). Tag Number2). Reference Drawing No.3). Loop Drawing Number4). Service5). Area Location6). Associated LCP, PLC, PCM, or RTU7). Calibration Range8). Manufacturer9). Model Number

4. The Instrumentation Subcontractor shall obtain from the Contractor the required informationon those primary elements, valve actuators, vendor packages, and other control equipment ordevices which are furnished by others but are required to be interfaced under this Division.

5. The Instrumentation Subcontractor shall coordinate his work to ensure that:

a. All components provided under this Section are properly installed.

b. The proper type, size, and number of control wires with their conduits are provided andinstalled.

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c. The proper type, size, and number of flexible pneumatic tubes with their conduits areprovided and installed.

d. Proper electric power circuits are provided for all instrumentation components andsystems.

C. Instrumentation Subcontractor Experience Requirements: Prior to award, Contractor shall submit to the CITY documentation listed below for his proposed bid listed Instrumentation Subcontractor:

1. Documentation describing at least two projects of similar size and complexity that have beensuccessfully completed in which the Instrumentation Subcontractor performed systemengineering, system fabrication and installation, documentation (including schematic, wiringand panel assembly drawings), field testing, calibration and start-up, operator instruction andmaintenance training. In addition, list the following information for each project:

a. Name of plant, owner, contact name and telephone number.

b. Name of manufacturer for the majority of instrumentation furnished.

c. Type of equipment furnished (i.e., transmitters, recorders, indicators, etc.).

d. Approximate number of input functions to the system, analog and digital.

e. Approximate number of output functions from the system, analog and digital.

f. Contracted cost of the instrumentation and Control System including change orders cost.

g. Date of completion or acceptance.

2. Identify individual responsible for office engineering and management, and the individual whowill be responsible for field testing, calibration, start-up and operator training for this project.Include references of recent projects of these persons.

3. Documentation showing that the Instrumentation Subcontractor has been in theinstrumentation and control systems business for minimum of four years.

D. If the Instrumentation Subcontractor does not meet the experience requirements, the Contractor shall be responsible for substituting the bid listed Instrumentation Subcontractor with one having the required experience and documentation at no extra cost of the City.

E. The Contractor shall assign the Instrumentation Subcontractor full responsibility for the complete operation of the PI&CS including all new and modified instrumentation and control systems. The Contractor shall have said Subcontractor perform all engineering and coordination necessary in order to select, furnish, install, connect, calibrate, and place into operation all sensors, instruments, alarm equipment, control boards, panels, computers, process control modules, human-machine interfaces, accessories and all other equipment as specified herein. Furthermore, said Subcontractor must calibrate and demonstrate the operability of said systems in accordance with the Contract Documents.

F. The Subcontractor shall provide all engineering work and installation drawings to produce a complete instrumentation system. If it is necessary to produce additional drawings in order to complete and document the work, such drawings shall be made at no additional cost to the CITY.

G. The Subcontractor shall meet with the CITY to review the requirements for making the HMI and controls provided with the Bar Screen LCPs, compatible with the Bar Screens HMI faceplates in the Plant DCS (Honeywell).

H. The Instrumentation Subcontractor shall examine all drawings, specifications, and details to become fully acquainted with the method of construction and to evaluate the quantity of Work to

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be performed. In case of conflicting or incomplete technical information, the Instrumentation Subcontractor shall include costs in its lump sum bid to coordinate the resolution of these conflicts and deficiencies with the ENGINEER at no additional cost to the CITY. Resolution of these discrepancies shall be obtained from the ENGINEER by the Instrumentation Subcontractor prior to purchasing of the instrument item.

I. Instrumentation Subcontractor shall note that the equipment loop, logic and elementary diagrams are based on non-certified vendor information and indicate minimum scope of supply from the Equipment Manufacturer. The Instrumentation Subcontractor shall include all costs in this bid to add additional instruments, wiring, computer inputs/outputs, controls, conduit, interlocks, electrical hardware, drawing revisions etc., into the design based on Equipment Manufacturer's final certified prints. Such changes to instrumentation and electrical work shall be incorporated into the scope of work at no additional cost to the CITY.

J. Provide all instrumentation and all related wiring as specified on any one of the following instrument or electrical documents: instrument location drawings, Instrument Index, I/O Tabulation, Loop Descriptions, one-line electrical diagrams, or as indicated on any other Contract Document. Indication of required instrumentation work on any one of these Contract Documents shall require supply and installation of the instrument and related wiring, supports and appurtenances at no additional cost to the CITY.

K. Provide all equipment, all materials, all labor supervision, all consumables and all scaffolding for the installation of the instrumentation systems, in accordance with the drawings and specifications, including the following:

1. Provide field engineering design, as required, for mounting and supporting details of all fieldmounted components.

2. Provide coordination, as required, between manufacturer's drawings and Contract InstallationDrawings.

3. Provide any additional schematics and any additional interconnection diagrams that may berequired to facilitate erection or completion of equipment installation.

4. Assemble and make interconnection of instruments disconnected for shipping purposes.

5. Remove all temporary supports, all bracing or other foreign objects that were installed ininstrument control panels or other equipment to prevent damage during shipping, storageand/or erection.

6. Coordinate work with that of the different trades and disciplines so that interference betweenconduit, piping, equipment, architectural and structural work shall be avoided.

7. Install and support all instruments and all instrument piping not installed and supported byothers. The Instrumentation Subcontractor shall furnish all hardware and all stands requiredto mount these items and provide modifications, as required, to meet actual site conditions.

8. All piping shall be field measured prior to fabrication/or erection. Any significant discrepanciesbetween drawings and field measurements shall be reported to the ENGINEER. The CITYshall not be responsible for any costs for rework because of failure to field measure prior toinitiating fabrication.

9. Capillary tubing shall be adequately supported and protected. All extra tubing shall becarefully coiled, tied, and protected at the instrument location.

10. Provide temporary instrument air purging to all panels on site before being permanentlyinstalled only where the environment requires purge.

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L. The modification shall consist of the demolition of some existing equipment and associated instrumentation and the installation of new and additional equipment and instrumentation. The work shall be performed in accordance with the requirements shown in the attached specifications, data sheets and drawings. The Contractor shall install and terminate all the Instrumentation and Control wiring between the field instruments/equipment, MCC (Motor Control Center)/Motor Starters, Local Control Panels/Stations, and the DCS. The following is a partial list of the scope requirements:

1. Bar Screens*2. Bar Screen control panels and control stations *3. Level Sensors4. Float Level Switch5. Rotary Drum Screens*6. Screw Presses*7. Rotary Drum Screen and Screw Press control panels*8. E-Stop pushbuttons*9. 120VAC Solenoid Valves*10. Fiber-Optic cables & accessories11. Type Z Purge Systems*12. Pressure Gages13. PLCs*14. HMIs*15. Miscellaneous instruments and equipment required by the Contract Documents but not listed

above.

* Procured by the Contractor from the “sole-sourced” equipment manufacturers (Vulcan is thesole-source manufacturer for the common control panel used for each Drum Screen/Screw Press pair). Installed by the Contractor.

M. In case of conflict between the Bill of Material included in GENERAL REQUIREMENTS, Section 01112 and the Technical Specifications, the Technical Specifications shall govern.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. The WORK of the following Sections applies to the WORK of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this WORK.

1. Section 11000 Equipment General Provisions

2. Section 11800 Rotary Drum Screen

3. Section 11840 Bar Screen

4. Section 11900 Screw Press

5. Section 16010 Wastewater Facilities General Electrical Requirements

6. Section 16100 Basic Materials and Methods

B. The monitoring and control system configurations indicated are diagrammatic. The locations of equipment are approximate unless dimensioned. The exact locations and routing of wiring and cables shall be governed by structural conditions and physical interferences and by the location of electrical terminations on equipment.

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C. All equipment shall be located and installed so that it will be readily accessible for operation and maintenance. The CITY reserves the right to require minor changes in location of equipment prior to roughing in without incurring any additional costs or charges.

D. Determine exact routing and final terminations for all wiring and cables. A site visit and review of the existing system control panel is mandatory.

1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS

A. Comply with the reference specifications of the GENERAL REQUIREMENTS

B. Procure all necessary permits, pay all associated costs, and shall furnish the ENGINEER with evidence of permit procurement prior to the commencement of the Work.

C. The equipment, materials and installation shall comply with the applicable standards, specifications and regulations of the following:

1. Instrument Society of America (ISA).

2. American Petroleum Institute (API).

3. National Electrical Manufacturers Association (NEMA).

4. Occupational Safety and Health Administration (OSHA).

5. American National Standards Institute (ANSI).

6. Military Standards (MIL Standards).

7. National Fire Protection Association (NFPA).

8. Scientific Apparatus Makers Association (SAMA).

9. Institute of Electrical and Electronic Engineers (IEEE).

10. National Electrical Code (NEC).

11. Insulated Cable Engineers Association (ICEA).

12. Local Power and Telephone Companies.

13. Local Authorities having jurisdiction over the work.

14. City of Los Angeles Electrical Code (CLAEC)

15. Underwriters Laboratories (UL)

16. City of Los Angeles, Department of Public Works, Bureau of Sanitation, “ Operator InterfaceGraphic Display Standards”

17. National Institute of Standards and Technology (NIST)

18. Society of Automotive Engineers (S.A.E)

19. American Society for Testing and Materials (ASTM)

20. Steel Structures Painting Council (SSPC)

21. Other authorities or standards mentioned or inferred by this Specifications, but not specificallylisted above.

D. All electrical equipment, components, devices, etc. shall be Underwriters Laboratories APPROVED (have the UL label and/or be listed with reexamination in UL Publication Reference

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No.1). Alternatively, the equipment, etc. shall be APPROVED by a testing laboratory recognized by the City of Los Angeles and shall conform to all applicable requirements of the City of Los Angeles Department of Building and Safety.

1. Review and approval by the CITY Department of Building and Safety Electrical TestLaboratory (ETL) requires submittal of the equipment, components or devices and any currenttesting documents to the ETL. Where major equipment is submitted to ETL for approval, theContractor shall submit to the ENGINEER a detailed schedule showing the approval processand approximate equipment delivery dates to ensure that there will be no effect on the projectcompletion date. No electrical equipment will be approved for delivery to the jobsite withoutETL approval. All costs incurred in the approval process shall be the responsibility of theContractor and shall be included in the Bid.

2. Particular products being specified in the Contract Specifications does not express or implyapproval by UL, the Department of Building and Safety or any other testing laboratory. Shopdrawing approval by the ENGINEER shall not supersede the requirements of the Departmentof Building and Safety for listed equipment.

1.4 SUBMITTALS

A. Submittals shall be made in accordance with Section 01330, Shop Drawings / Submittals of the GENERAL REQUIREMENTS.

B. Shop Drawings: Coordinate the work required in these Specifications so that a complete PI&CS for the facility will be provided and will be supported by accurate shop and record drawings. The Instrumentation Subcontractor shall prepare and submit complete and organized shop drawings, as specified herein. Interface between the field instruments, Local Control Panels/Stations, MCC/Motor Starters, DCS and other new or existing equipment related to instrumentation and control shall be included in the shop drawing submittal.

C. During the period of preparation of this submittal, the Contractor shall authorize direct, informal liaison between the Instrumentation Subcontractor and the ENGINEER for exchange of technical information. As a result of this liaison, certain minor refinements and revisions in the Systems as specified may be authorized informally by the ENGINEER, but these shall not alter the scope of work or cause increase or decrease in the Contract price. During this informal exchange, no oral statement by the ENGINEER shall be construed to give formal approval of any component or method, nor shall any statement be construed to grant formal exception to or variation from these Contract Documents.

D. Submit an analog hardware submittal that utilizes detailed shop drawings and data prepared and organized for easy reference. Section Tabs, Sequential page numbering and Table of Contents / Index Tables shall be used throughout. All shop drawings shall include the letter head and/or title block of the Contractor responsible for this project. The title block shall include, as a minimum, the Contractor’s registered business name and address, project name, drawing name, revision level, and personnel responsible for the content of the drawing. The quantity of submittal sets required shall be as specified in Section entitled, "Contractor Submittals." The analog hardware submittal shall be submitted as a complete bound package at one time within ninety (90) calendar days of receipt of Notice to Proceed, and shall include:

1. Drawings showing definitive diagrams for every instrumentation loop and system. Thesediagrams shall show and identify each component of each loop or system using legend andsymbols from ANSI/ISA S5.4, extending the format as shown on the O-I Drawings and asdefined by the most recent revision in ISA. Each System or Loop diagram shall be drawn ona separate drawing sheet with no more than ten loops per drawing. Develop, submit, updateand maintain in an as-built condition the loop drawings for all loops in this project includingvendor supplied packages, equipment supplied under Division 17 and CITY suppliedpackages. The loop drawings shall also show all software modules and linkages. In additionto the expanded ISA S5.4 requirements the Loop Diagrams shall also contain the followingdetails:

a. ISA tag number

b. Functional name of each Loop

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c. Tag number of the loop

d. Reference name, drawing, and Loop diagram numbers for any signal continuing off loopdiagram sheet.

e. MCC Panel, circuit, and breaker numbers for all power feeds to the loops andinstrumentation (i.e., 24VDC and 120VAC).

f. Designation and if appropriate terminal assignments associated with every manhole, pullbox, junction box, conduit and panel the loop circuits pass through.

g. Vendor panel, instrument panel, conduit, junction boxes, equipment and DCSterminations, termination identification wire numbers and colors, power circuits, andground identifications.

2. Fully executed ISA-S20 data sheets for each component, together with a technical productbrochure or bulletin. The technical product brochures must be complete enough to verifyconformance to all Contract Document requirements. The data sheets, as a minimum, shallshow:

a. Component functional description used herein and on the Drawings;

b. Manufacturer's model number or other product designation;

c. Project tag number used herein and on the Drawings;

d. Project system or loop of which the component is a part;

e. Project location or assembly at which the component is to be installed;

f. Input and output characteristics;

g. Scale range and units (if any) and multiplier (if any);

h. Requirements for electric supply (if any);

i. Requirements for air supply (if any);

j. Materials of component parts to be in contact with, or other wise exposed to, processmedia;

k. Special requirements or features.

3. A complete index shall appear in the front of each bound submittal volume. A separatetechnical brochure or bulletin shall be included with each instrument data sheet. The datasheets shall be indexed in the submittal by systems or loops, as a separate group for eachsystem or loop. If, within a single system or loop, a single instrument is employed more thanonce, one data sheet with one brochure or bulletin may cover all identical uses of thatinstrument in that system. Each brochure or bulletin shall include a list of tag numbers forwhich it applies. System groups shall be separated by labeled tags.

4. Drawings showing both schematic and wiring diagrams for control circuits: Complete detailson the circuit interrelationship of all devices within and outside each Control Board shall besubmitted first, using schematic control diagrams. Subsequent to return of this first submittalby the ENGINEER, piping and wiring diagrams shall be prepared and submitted for review bythe ENGINEER; the diagrams shall consist of component layout drawings to scale, showingnumbered terminals on components together with the unique number of the wire to beconnected to each terminal. Piping and wiring diagrams shall show terminal assignments from

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all primary measurement devices, such as flow meters, and to all final control devices, such as pumps, valves, chemical feeders and vendor panels. Should an error be found in a shop drawing at any time in the project, it shall be corrected including any field changes found and a "Record" drawing shall be prepared and submitted for review and approval by the ENGINEER prior to the acceptance of the project. Furnish all necessary equipment suppliers’ shop drawings to facilitate inclusion of this information. Respond to all comments on the shop drawing re-submittals made by the ENGINEER either by noted corrections or stating why it was not revised. Any resubmittals received by the ENGINEER which do not contain responses to the ENGINEER's previous comments shall be returned marked "Rejected." No further review by the ENGINEER shall be performed until responses are made to all comments.

5. Assembly and construction drawings for each alarm annunciator, local indicating panel andfor other special enclosed assemblies for field installation: These drawings shall includedimensions, identification of all components, surface preparation and finish data, nameplates,and the like. These drawings also shall include enough other details, including prototypephotographs, to define exactly the style and overall appearance of the assembly; a finishtreatment sample shall be included.

6. Installation, mounting, and anchoring details for all components and assemblies to befield-mounted, including conduit connection or entry details.

7. A bill of material list shall be submitted for each field mounted device or assembly as well ascabinet assemblies and sub assemblies. Bills of material shall include all items within anenclosure. The submittal shall be a complete and detailed bill of materials. An incompletesubmittal shall be rejected and no further evaluation performed until a completed and detailedbill is submitted.

E. Organization and Binding of Shop Drawings: The organization of the initial shop drawing submittal shall be compatible to eventual inclusion with the technical manuals submittal and shall include final alterations reflecting "record" conditions. Accordingly, the final approved multiple-copy shop drawing submittal shall be separately bound in standard size, 3-ring, loose-leaf, vinyl plastic, hardcover binders suitable for bookshelf storage. Binder ring size shall not exceed 2-inches. Binders shall be of the type specified in Section 01782, Technical Manuals of the GENERAL REQUIREMENTS.

F. Technical Manuals: In addition to updated shop drawing information to reflect actual existing conditions, each set of technical manuals shall include installation, connection, operating, troubleshooting, maintenance and overhaul instructions in complete detail. This shall provide the CITY with comprehensive information on all systems and components to enable operation, service, maintenance and repair. Exploded or other detailed views of all instruments, assemblies and accessory components shall be included together with complete parts lists and ordering

instructions. Technical Manuals shall be in accordance with Section 01782, Technical Manuals of the GENERAL REQUIREMENTS.

G. Control Panel Engineering Submittal: The Instrumentation Subcontractor shall submit a control panel engineering submittal (CPES) for each control panel being provided under this Specification Section. The CPES shall completely define and document the construction, finish, layout, power circuits, signal and safety grounding circuits, fuses, circuit breakers, signal circuits, internally mounted instrumentation components, faceplate mounted instrumentation components, internal panel arrangements, and external panel arrangements. All panel drawings shall, as a minimum, be "B" size with all data sheets and manufacturer specification sheets being "A" (8.5 X 11) size. The submittal shall be in conformance with NEMA Standard ICS 1-1.01, and shall be submitted as a singular complete bound volume or multi-volume package within 120 calendar days after contract award and shall have the following contents:

1. A complete index shall appear in the front of each bound volume. All drawings and datasheets associated with a panel shall be grouped together with the panels being indexed by

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systems or process areas. All panel tagging and nameplate nomenclature shall be consistent with the requirements of the Contract Documents.

2. Construction drawings drawn to a 1-1/2-inch = 1-foot scale which define and quantify the typeand gage of fabrication steel to be used for panel fabrication, the ASTM grade to be used forstructural shapes and straps, panel door locks and hinge mechanisms, type of bolts and boltlocations for section joining and anchoring, details on the utilization of "UNISTRUT" andproposed locations, stiffener materials and locations, electrical terminal box and outletlocations, electrical access locations, print pocket locations, writing board locations and liftinglug material and locations.

3. Physical arrangement drawings drawn to 1-1/2-inch = 1 foot scale which define and quantifythe physical groupings comprising control panel sections, auxiliary panels, subpanels, andracks. Cutout locations with nameplate identifications shall be provided.

4. Schematic/Elementary diagrams shall depict all control devices and circuits and theirfunctions.

5. Wiring/Connection diagrams shall locate and identify electrical devices, terminals andinterconnecting wiring. These diagrams shall show interconnecting wiring by lines, designateterminal assignments, and show the physical location of all electrical and control devices.

6. Interconnection diagrams shall locate and identify all external connections between the controlpanel/control panel devices and associated equipment. These diagrams shall showinterconnecting wiring by lines, designate terminal assignments, and show the physicallocation of all panel ingress and egress points.

7. Control sequence diagrams shall be submitted to portray the contact positions or connectionsrequired to be made for each successive step of the control action.

8. Completed ISA-S20 data sheets for all instrumentation devices associated with each controlpanel supplemented with manufacturer specification sheets which verify the productsconformance to the requirements of the Contract Documents.

9. A bill of material which enumerates all devices associated with the control panel.

H. Test Procedure Submittal: The Instrumentation Subcontractor shall submit the procedures proposed to be followed during the tests required under this project. Procedures shall include statement indicating test objectives, test descriptions, forms, and checklists to be used to control and document the required tests. Prior to the preparation of the detailed test procedures, submit outlines of the specific proposed tests. Submittals shall include examples of the proposed forms and checklists. Once the Preliminary Test Procedure Submittals have been reviewed by the ENGINEER and returned stamped either "no exceptions noted" or "make corrections noted", the Instrumentation Subcontractor shall submit the proposed detailed test procedures, forms, and checklists. Once the detailed Test Procedures Submittals have been reviewed by the ENGINEER and returned stamped either "no exceptions noted" or "make corrections noted", the tests may be scheduled. Upon completion of each required test, a copy of the signed-off test procedures shall be submitted as test documentation. These requirements shall apply to the factory testing of all panels, and all on-site tests.

I. Training Submittals: (Refer to GENERAL REQUIREMENTS, Section 01820– Operations and Maintenance Training.)

J. Instrument Installation Detail and Submittal: Submit the following data 180 days after Notice to Proceed:

1. Detail and Instrument Installation drawings

2. Bill of Materials.

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3. Prior to acceptance, the control valve supplier shall submit function test verificationcertifications and hydrostatic leak test certifications.

K. Submittals not organized as described above and incomplete submittals for a given Loop will not be accepted.

1.5 QUALITY ASSURANCE

A. Accuracy: The accuracy of each instrumentation system or loop shall be as determined as a probable maximum error; this shall be the square-root of the sum of the squares of certified "accuracies" of the designated components in each system, expressed as a percentage of the actual span or value of the measured variable. Each individual instrument shall have a minimum accuracy of ±0.5 percent of full scale and a minimum repeatability of ±0.25 percent of full scale unless otherwise specified. Instruments which do not conform to or improve upon these criteria are not acceptable.

B. Where materials and equipment are specified to conform to the standards of the Underwriter's Laboratories, the label of, or listing with reexamination in UL Publication Reference No. 1, shall be accepted as sufficient evidence that the items conform to Underwriter's Laboratories requirements. In lieu of such label, listing of the materials or equipment by a recognized approved testing laboratory as stated in the CITY of Los Angeles Electrical Code will be acceptable as interpreted by the CITY's Department of Building and Safety.

1.6 PRESUBMITTAL CONFERENCE

A. Arrange and conduct a Pre-submittal Conference on the PI&CS work within 15 days after the award of the Contract. The Instrumentation Subcontractor shall allow one eight-hour working day for the conference. The purpose of the Pre-submittal Conference shall be to informally review and approve the manner in which the Instrumentation Subcontractor intends to respond to the Contract requirements before any submittals are prepared. The Instrumentation Subcontractor shall prepare the following items for presentation at the Pre-submittal Conference:

1. A list of equipment and materials required for the control system and the manufacturer andmodel number which the Instrumentation Subcontractor proposes to use for each item.

2. A list of proposed exceptions to the Specifications and Drawings, along with a briefexplanation of each. Approval shall be subject to formal submittal and review by theENGINEER.

3. An exact one-to-one sample of each type of submittal specified herein.

4. A bar chart type schedule for all system related activities from the Pre-submittal Conferencethrough startup and training. The schedule shall include the dates relative to submittals,design, fabrication, programming, factory testing, deliveries, installation, field testing, andtraining. The schedule shall be subdivided to show activities relative to each major item orgroup of items.

5. Provide 3 copies of Pre-submittal Conference data to the ENGINEER.

B. Keep formal meeting minutes. Prior to adjournment of the conference, all parties must concur in writing with the accuracy of the minutes.

C. Preparation of shop drawings shall not commence until after the Pre-submittal Conference. Submittals required for that conference are exempted.

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1.7 GUARANTEE (see GENERAL REQUIREMENTS: Section 01611 – Guaranty/Warranty)

1.8 MANUFACTURER'S REPRESENTATIVE SERVICES (see GENERAL REQUIREMENTS: Section 01430 – Manufacturer’s Field Service)

1.9 SHOP INSPECTION

A. Shop Inspection and Performance Testing: Arrange for shop inspection and performance testing of the equipment according to GENERAL REQUIREMENTS Section 11000 Equipment General Provisions.

1. All panels and equipment shall be subject to shop inspection in accordance with Section01453 Sampling, Testing and Fabrication Inspection of the GENERAL REQUIREMENTS.

2. The equipment shall be performance tested and witnessed by the INSPECTOR and/or theControl System ENGINEER in accordance with Section 01453 Sampling, Testing andFabrication Inspection of the GENERAL REQUIREMENTS.

a. Performance testing shall be conducted at the Manufacturer's shop or factory.

3. For all equipment, obtain and submit the following to the ENGINEER at least 6 weeks beforetest date for approval:

a. The Manufacturer's factory test procedure, including test raw data and report forms, andtesting schedule prior to equipment testing.

b. Obtain and submit to the ENGINEER for approval the final factory test reports prior toshipping of equipment.

B. Field Performance Test and Reports: All equipment shall be performance tested after installation at the field operating site according to Section 11000 Equipment General Provisions.

1. Testing shall not start until all preliminary checks and calibrations have been completed, theinstallation has been certified ready for testing by the Manufacturer's representative, and thetest forms and procedure have been approved by the ENGINEER.

2. All test information shall be recorded on forms provided by the CITY or approved by theENGINEER. If forms are not available from the CITY, prepare test forms and submit forapproval prior to the scheduled start of the test.

3. Submit the test procedure for approval prior to the scheduled start of the test.

4. Prepare a field performance test report, including all raw data, and submit the report within 14calendar days after approved completion of the equipment field test.

1.10 PERSONNEL TRAINING (Refer to GENERAL REQUIREMENTS, Section 01820 – Operations and Maintenance Training).

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PART 2 -- PRODUCTS

2.1 GENERAL

A. Provide all instrumentation and related wiring as specified on any one of the following instrument or electrical documents:

1. Instrument Location Drawings, Instrument Index, Instrument Data Sheets, Loop & Logic

Diagrams, I/O Tabulation, Loop Description, One-Line Electrical Diagrams, or as indicated on any other contract document.

2. Indication of required instrumentation work on any one of these contract documents shall

require supply and installation of the instrument and related wiring, supports, appurtenances, etc., at no additional cost to the CITY.

3. Assume full responsibility to perform all engineering to select, furnish, install, program, test,

calibrate, and place into operation all instrumentation, control panels, and programmable controller for a complete and functional system.

4. Where manufacturer’s names, model numbers, and other information are given in the

Contract Documents, it is not intended to limit the scope of requirements unless specifically stated. Therefore each product, instrument, control panel, device, equipment, and other item furnished for use on this project shall be provided with all standard, optional and custom functions and features needed to comply with all requirements of the Contract Documents.

5. Where applicable see Instrument Data Sheet/s in Attachment C and the Contract Plans and

other parts of these Specifications for additional requirements.

B. The monitoring and control system configurations indicated are diagrammatic. The locations of

equipment are approximate unless dimensioned. The exact locations and routing of wiring and cables shall be governed by structural conditions and physical interferences and by the location of electrical terminations on equipment. All equipment shall be located and installed so that it will be readily accessible for operation and maintenance. The CITY reserves the right to require minor changes in location of equipment prior to roughing in without incurring any additional costs or charges. The Instrumentation Subcontractor shall review the existing site conditions and examine all shop drawings for the various items of equipment in order to determine terminations for all wiring and cables. All deviations from the Drawings or Specifications must be approved in writing by the ENGINEER.

C. All meters, instruments, and other components shall be the most recent field-proven models

marketed by their manufacturers at the time of submittal of the shop drawings unless otherwise specified to match existing equipment.

D. All panel mounted instruments shall have matching style and general appearance. Instruments

performing similar functions shall be of the same type, model, or class, and shall be of one manufacturer.

E. All instrumentation shall be rated for operation in the ambient conditions at the equipment

installation locations. NEMA 4X rated 316 Stainless Steel enclosures suitable for the environment shall be furnished in all general purpose areas. All enclosures used in hazardous areas must be either NEMA 7 or Type X/Z purged. Since the bar screens area is Class I Div. 2, all 8 bar screen local control panels shall be Z purged with instrument air and all 8 bar screen control stations shall have a NEMA 7 enclosure.

F. All instrumentation in hazardous areas shall be approved for use in the particular hazardous

classification in which it is to be installed.

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G. Analog measurements and control signals shall be electrical as indicated herein, and shall vary in direct linear proportion to the measured variable, except as noted. Electrical signals outside control board(s) shall be 4 to 20 milliamperes dc except as noted. Signals within enclosures may be 1-5 volts dc. Dropping resistors shall be installed at all field side terminations in the control panels to ensure loop integrity.

H. All control panels shall be provided with redundant power supplies which are configured in a

fault-tolerant manner to prevent (a) interruption of service upon failure, and (b) interruption of service necessitated by the replacement of a power supply. All power supplies shall have an excess rated capacity of forty (40) percent.

I. Each control loop shall be individually fused via fused terminal blocks except as otherwise noted

in the Specifications or approved by the ENGINEER. .

J. Equipment or methods requiring redesign of any project details are not acceptable without prior

approval of the ENGINEER. Any changes inherent to a proposed alternative shall be at no additional cost to the CITY. The required approval shall be obtained in writing by the Instrumentation Subcontractor prior to submittal of shop drawings and data. Any proposal for approval of alternative equipment or methods shall include evidence of improved performance, operational advantage and maintenance enhancement over the equipment or method specified, or shall include evidence that a specified component is not available. Otherwise, alternative equipment (other than direct, equivalent substitutions) and alternative methods shall not be proposed.

K. All field mounted instrument and control equipment mounted outside of protective structures shall

be equipped with suitable surge-arresting devices to protect the equipment from damage due to electrical transients induced in the interconnecting lines from lightning discharges or nearby electrical devices. Protective devices used on 120VAC inputs to field mounted equipment shall be secondary surge protectors conforming to the requirements of IEEE Standard 28-1972 (ANSI C62.1-1971).

L. Provide all equipment, material, labor supervision, consumables, scaffolding, etc., for the

installation of the instrumentation systems in accordance with the drawings and specification listed herein.

1. Provide field engineering design, as required, for mounting and supporting details of all field

mounted components.

2. Provide coordination, as required, between manufacturer's drawings and contract installation drawings.

3. Provide any additional schematic and interconnection diagrams that may be required to

facilitate erection or complete the installation of equipment.

4. Assemble and make interconnection of instruments disconnected for shipping purposes.

5. Remove all temporary supports, bracing or other foreign objects that were installed in instruments, control panels or other equipment to prevent damage during shipping, storage and/or erection.

6. Coordinate his work with that of the different trades so that interference between conduit,

piping, equipment, architectural and structural work shall be avoided.

7. Install and support all instruments and instrument piping not installed and supported by others. Furnish all hardware and stands required to mount these items and modify to meet actual site conditions.

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8. All piping shall be field measured prior to fabrication/or erection. Any significant discrepancies between drawings and field measurements shall be reported to the ENGINEER. The CITY shall not be responsible for any costs for rework caused by failure to field measure prior to initiating fabrication.

9. Adequately support and protect capillary tubing. All extra tubing shall be carefully coiled, tied,

and protected at the instrument.

M. The equipment loop, logic and elementary diagrams are based on non-certified vendor information and indicate minimum scope of supply from the equipment manufacturer. Include additional costs in the Bid to cover contingencies such as additional instruments, wiring, computer inputs/outputs, controls, conduit, interlocks, electrical hardware, etc., into the design based on equipment manufacturer's final certified vendor prints. Revise or produce new loop, logic, or elementary diagrams to meet the equipment manufacturer's wiring requirements. Such changes to instrumentation and electrical work shall be incorporated into the scope of work at no additional cost to the CITY.

N. Provide the following:

1. Install all pneumatic tubing and make connections at control panels, instruments and control

valves. All tubing and pipe fittings and instrument valves shall be 316 stainless steel (SS).

2. Provide field engineering and design to install instrument air supply headers and individual air supply taps and lines as herein specified.

3. Install adequate support for pneumatic tubing runs in accordance with drawings and

specifications.

4. Check all air supply branch headers by blowing with clean air before placing in service and check for tightness.

5. Clean all transmission and control tubing by blowing with dried and filtered air prior to

connecting to instrument components.

6. Leak test all pneumatic control circuits in accordance with ISA Recommended Practice RP-7.1.

7. Set at manufacturer's recommended supply pressure, all instrument air regulators.

8. Installation, wiring, termination, and installation tests for all analog instruments local control

panels, Control System Interfaces (CSIs), panels and equipments furnished by the CITY.

9. Equipment supply, installation, installation tests, and startup of the Air Purge System as required for the Local Control Panels and panels supplied by the CITY. The panels shall be continuously purged with instrument air at the rate of one complete volume change per day. The air supply system shall consist of all necessary piping, filters, flow/pressure regulators, valves, fittings, and accessories required to extend from the instrumentation air purge headers to all Local Control Panels only where the environment requires purge.

2.2 SPARE PARTS

A. Obtain and submit from the manufacturer a list of suggested spare parts for each piece of equipment according to the provisions of Section 01781, Spare Parts, of the GENERAL REQUIREMENTS.

B. Furnish the name, address, and telephone number of the nearest distributor for each piece of

equipment. All equipments and instruments furnished for this project shall have local authorized distributor and service center.

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C. During the term of this Contract, notify the ENGINEER in writing about any manufacturer's modification of the approved spare parts, such as part number, interchangeability, model change or others. If the ENGINEER determines that the modified parts are no longer applicable to the supplied equipment, provide applicable spare parts and/or replace the equipment to ensure compatibility of the items furnished.

2.3 CONTROL PANELS (INCLUDING CONTROL STATIONS AND SWITCH STANDS)

A. General

1. The Instrumentation Subcontractor shall furnish, supply and install all control panels andenclosures for this project needed for complete installation of instrumentation and controlequipment as shown on the drawings and specified herein.

2. All panels and enclosures shall be rated NEMA 4X 316 Stainless Steel , In hazardous areasall panels and enclosures shall be either NEMA 7 or have Type X (for Class I Div. 1) or TypeZ (for Class I Div. 2) purging. Refer to the detailed narrative specs for each enclosure forspecific instructions on which method to use.

3. Dimensions shall be in accordance with manufacturer's requirements. Elevations andhorizontal spacing shall be subject to ENGINEER's approval.

4. Furnish, supply and install all control panels for this project in accordance with the below listedspecifications. This section, also, covers requirements for local control panels being suppliedby the Equipment Manufacturer. Additionally, due to the corrosive nature of environments atsolids handling plants, the control panels shall be provided with all required taps, fittings,rotameters, and regulators for an air purge system.

5. This specification covers the requirements for the fabrication of instrument panel boards,mounting, heavy-duty lifting eye anchor into reinforced top, finishing, piping and wiring ofinstrument equipment.

6. Front of panel layouts for all control panels shall be submitted to the ENGINEER for reviewand approval prior to start of fabrication. Refer to other requirements as outlined in ParagraphQ - Drawings, below.

7. All conduit entries shall utilize Myers hubs or equivalent, providing at least NEMA 4X integrity.They shall be made watertight at the point of entry into the cabinet with o-ring or gasket seals.In runs of PVC coated conduits, the hubs shall also be PVC coated in accordance with theconduit manufacturers requirements for fittings and accessories.

8. Doors shall be a maximum width of 36-inches, shall have full length piano type hinges, a 3-point vault type latching mechanism with rollers on the ends of the latch bars and ¼-turn pad-lockable handle(s). All shall be 316 Stainless Steel. No external door clamps shall benecessary to achieve the full NEMA 4X rating of the panel. On enclosures located in publicareas, door handles shall be equipped with vandal resistant pad-lockable covers.

9. Provide a fiber optic patch panel on any control panel that needs access to external fiber opticcable(s).

10. Fiber-Optic Communications Data Link to Plant DCS: All needed communications modules,network interface modules, patch panels, connectors and other accessories shall be furnishedand installed for a complete communications data link to the Plant DCS system. This workshall provide all necessary equipment, software, programming to include but not limited to thefollowing:

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11. Contractor shall provide, and install all necessary interfaces, switches, and patch panels forconnection to the Honeywell DCS system.

12. Fiber Optic Converters for interfacing from electronic signals and copper conductors to FOcable and signals.

13. Ethernet Communications Modules / Converters for interfacing to Ethernet protocol whereverneeded.

14. Software Drivers necessary for communicating between proprietary or otherwise differentsoftware.

B. Mounting of Instruments

1. The panel vendor shall provide cut-outs, and shall mount all instrument items shown orspecified to be panel mounted, including any instruments specified to be furnished by othervendors but installed in the control panel (if applicable).

2. The panel vendor shall also mount, inside the panels, other instrument accessory items asrequired and/or specified.

3. Enclosure for all the front panel mounted instruments shall be NEMA 4X rated. Instrumentswhich are not rated NEMA 4X shall be covered with a door and a window to provide overallNEMA 4X rating.

4. Equipment mounted on the interior of panels shall be installed with due regard to accessibilityfor commissioning adjustments, servicing requirements and cover removal.

5. Spare space shall be kept clear of wiring, etc., to give maximum space for future additions.

C. Piping Requirements for Control Panels:

1. General Requirements:

a. The panel vendor shall furnish terminal connections near the top, rear of the panel for alltubing and piping which connect to instruments, valves, instrument air supply and otherpressure leads to the panel. Terminal connections for tubing are to be bulkhead tubeunions as described below. Those for pipes shall be threaded couplings, plugged forshipping purposes. All fittings requiring penetrations to the cabinet exterior shall be sealedwatertight with gaskets or O-rings.

b. All tubing, pipe fittings and instrument valves shall be 316 Stainless Steel.

c. Each terminal connection shall have an engraved metal or plastic plate with a terminal andinstrument tag number.

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d. The panel vendor shall furnish the air supply pressure reducing station, all instrument and

supply piping and all pneumatic tubing or piping to terminal connections and between instrument items located within the confines of the panel and supporting framework.

2. Air Supply Piping:

a. The panel vendor shall furnish air supply tubing from a point of entry near the top of the panel framework to the inlet side of the pressure reducing station, or alternately to the inlet side of individual filter regulators.

b. Tubing, fittings, and valves downstream of the filters at the air supply reducing stations

shall be 316 Stainless Steel.

c. The low pressure instrument air supply header tubing shall extend from the down stream side of the main pressure reducing valves across the length of panel which includes air users. Where the header must be broken for shipping purposes, stainless bulkhead tube fittings shall be provided at the panel section junctions.

d. A separate air supply take-off consisting of 3/8" O.D. stainless steel tubing shall be

furnished for each item requiring an air supply, plus at least ten percent spare take-offs. Take-offs for 3/4-inch size headers may be made by using 3/4-inch x 3/4-inch x 3/8-inch 316 Stainless Steel reducing tees.

e. Each take-off (and the main supply line) shall be fitted with a 316 Stainless Steel full bore

ball shut-off valve. Provide circular type handle for manual operation with tag number shown thereon.

f. The dead end of the air header (opposite supply end) shall be fitted with a plugged 316

Stainless Steel full bore valve for cleanout or drain.

g. The connection from the shut-off valves at the air header to the instruments shall be by means of a ¼-inch or 3/8-inch O.D. 316 Stainless Steel tubing as specified in the material requisition.

h. All tube fittings shall be Swagelok or equal and all valves shall be Whitey (Swagelok) or

equal. All shall be #316 Stainless Steel.

D. Electrical Requirements

1. Contractor shall furnish and install all the necessary conduits, wireways, switches, and electrical fittings with wire for all circuits to instruments and other panel electrical devices to assure a complete and acceptable installation.

2. Signal and low voltage wiring shall be run separately from power and 120/240 VAC control

wiring. And 240 VAC wires shall run separately from 120 VAC wires. 3. Configuration of wires, instruments, and controls shall be from lower voltages to higher

voltages from top to bottom in the separate sections of the panel.

4. Conduit, wireways, junction boxes and fittings shall be installed for all control and signal wiring, including all thermocouple or resistance thermometer lead wire.

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5. Each terminal connection shall have a plastic plate with a terminal and instrument tag

number. All wiring shall be identified with stamped tubular wire markers (or heat shrinks) at each end of the wire. The markings shall be permanent and machine printed.

6. Freestanding panels shall be provided with an interior, door switch controlled, 40 watts

minimum, fluorescent back-of-panel light. One light shall be provided for every 4-feet of panel width and shall be mounted inside in the top of the back-of-panel area.

7. Freestanding panels shall be provided with a 15-amp, 120 VAC, ground fault interrupted (GFI)

service outlet circuit within the back-of-panel area. The circuit shall be provided with three-wire, 120 VAC, 15-ampere, duplex receptacles, one for every 4-feet of panel width (two minimum per panel) and spaced evenly along the back-of-panel area.

8. Panels shall be so sized as to adequately dissipate heat generated by equipment mounted in

or on the panel.

9. Where panels are mounted outside or in unshaded areas, they shall be provided with thermostatically controlled refrigeration type air conditioning to prevent overheating of the equipment. Thermostatically controlled heaters shall be provided that will maintain cabinet inside temperature above 40 F at night and during cold weather. .

10. Provide a hand switch controlled 100-watt incandescent light and a breaker protected

120VAC, 15-amp duplex receptacle within each smaller panel

E. Wiring Methods:

1. Wiring methods and materials for all panels shall be in accordance with the N.E.C. requirements for General Purpose (no open wiring) unless otherwise specified. Open wiring in close cabinet type panels is allowed when specified in the material specifications. Unless otherwise specified by the material specification, design and installation of materials shall conform to the requirements of the latest edition of the following standards and codes as a minimum.

a. The National Electrical Code b. All National Safety Codes c. American Petroleum Institute Standard RP-550 d. Applicable Local Law and Regulations

2. Unless otherwise specified by the Material Specifications, all instruments, alarm systems and

motor controls shall be powered at 120 VAC, 60-Hertz.

3. At a location near the top (or bottom) of the panel, the panel fabricator shall furnish terminal block connections for the main power supply entry and a power disconnect switch with door interlock and exterior handle.

4. Power supply switches for alarm units shall be three-pole type, arranged to open both the

power and alarm circuits. Each annunciator shall be equipped with a separate switch.

5. Provide DIN-rail mounted circuit breakers to distribute power to all internal panel instruments and equipment. Instruments located on the same panel section and serving the same process unit may be connected to a common branch circuit from the power supply. The numbers of circuits depends on the circuit load as noted herein. A 15-amp, two-pole circuit breaker shall be provided in each branch circuit. Individual circuit load shall not exceed 10 amps. For maintenance and safety purposes, manual disconnecting means shall be provided for each instrument in the form of knife-blade switch type terminal blocks or disconnect switches at the instrument. Different panel sections or different process units must not use common branch circuits.

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6. When instruments do not come equipped with integral fuses, the panel fabricator shall furnish and install fuses as required for the protection of individual instruments against fault currents. Fuses shall be mounted on the interior back of the panel, in fuse holders and each fuse shall be identified by a service name tag. Fuses shall be as manufactured by:

a. Bussman; b. GE;

c. Square D;

d. Or equal,.

7. Where alarm units are single unit types, one switch may be used to disconnect not more than

six alarm units located on the same or adjacent panels.

8. All signals shall be standard 24 VDC (discrete) and 24VDC at 4-20 mA (analog).

9. Splicing of wire shall not be allowed. All connections shall be made on terminal blocks. Where instruments come from the manufacturer with permanently connected, potted and sealed cables, they shall be run continuously from the instrument to the entry terminal blocks at the associated Local Control Panel, PCM, etc. without intermediate splices or terminations.

10. All instrument and wiring entering or leaving the panels shall be on terminal blocks. All instrument loops shall be fused with knife blade switches and Blown Fuse Indicators (LED) (Phoenix Contact, Model UK 10,3-HESILED N 690, or equal). The terminals shall be grouped as to its signal type and shall be numbered.

11. Step-up/down transformers, Interposing relays and other relays shall be furnished installed to integrate with MCCs and PLCs in the panel.

F. Material:

1. Wire for all 120VAC circuits shall be No. 14 AWG (and for 240 volt circuits shall be No. 12 AWG) stranded with lugs with Type THWN or THHN insulation. These shall be UL listed and labeled. All terminals for external wiring connections shall be suitable for wire sizes No. 16 through 12 AWG. For wiring inside the control panel, the Contractor shall use the wire size recommended by each device’s manufacturer.

2. Flexible conduit is not allowed except when specifically approved by the ENGINEER in writing.

3. Conduit fittings with PVC coating shall be cast fittings by:

a. Crouse-Hinds; b. Appleton;

c. OZ Gedney;

d. Or equal.

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4. Splicing of wires in conduits shall not be permitted. All wire terminations shall have crimped wire lugs and shall be terminated on terminal strips or terminal blocks in pull boxes or panels.

5. For case grounding, panels shall be furnished with a 1/4" x 1" copper ground bus complete

with solderless connector for one No. 4 AWG bare stranded copper cable. The copper cable shall be furnished and installed and connected to a system ground loop.

G. Electrical Locations:

1. When Contract drawings or Specifications call for thermocouple actuated instruments, the

thermocouple lead wire shall be installed, without junction or splicing. The panel vendor shall furnish dedicated empty conduit or wireway running from the instrument(s) to the top or bottom of the panel as called for in the material specifications or as otherwise required. Sizing of the conduit or wireway shall be in accordance with the number and size of wiring enclosed.

2. Single case (no remote logic) annunciator units installed at the top of a panel may be

considered as being a terminal box when top of panel wire entry is specified. If bottom of panel entry is specified, a terminal box shall be provided at the bottom of the panel and wired to the annunciator. Terminals shall be identified with plastic marker strips.

3. Terminal boxes for incoming and outgoing signal leads shall be located at the top or bottom of

the panel as specified in the material specification, or as otherwise required.

H. Color Codes for Panel Indicators and Controls:

1. Unless otherwise noted, the following color code and inscriptions shall be followed for the lenses of all indicating lights:

STATUS INSCRIPTION(S) COLOR ON ON RED OFF OFF GREEN OPEN OPEN RED CLOSED CLOSED GREEN LOW LOW RED FAIL FAIL RED HIGH HIGH RED

2. Lettering shall be black (on white and amber lenses). Lettering shall be white (on red and green) lenses.

3. Unless otherwise noted, the following color codes and inscriptions shall be followed for all

pushbuttons:

LABEL / ABBREV.

INSCRIPTION(S) COLOR

OO ON / OFF GREEN / AMBER OC OPEN / CLOSE GREEN / AMBER

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OCA OPEN / CLOSE / AUTO GREEN / AMBER / BLUE OOA ON / OFF / AUTO RED / GREEN / AMBER MA MANUAL / AUTO AMBER / BLUE SS START / STOP RED / GREEN RESET RESET RED

4. All unused or non-inscribed buttons shall be black.

5. Lettering shall be black (on white and yellow buttons). Lettering shall be white (on black, red

and green buttons).

I. Construction Methods:

1. Materials: Type 316 Stainless Steel shall be standard. Other types may be proposed in writing for use in specific service locations, but must be reviewed and approved by CITY.

a. Panel section faces shall be #10 gage minimum thickness for free standing panels and

#14 gage minimum thickness for smaller panels. All materials shall be level and smooth, with no visible dings, dents, sags, scratches or other blemishes.

b. Relay rack: To accommodate devices such as relays, interposing relays and

transformers, high density type panels shall utilize standard relay racks with #14 gage 316 Stainless Steel frame and supports.

c. Structural Shapes and Strap Steel: ASTM A-283.

d. Bolting Material: Commercial quality 316 Stainless Steel bolts, nuts and washers, all 1/2-

inch diameter with UNC threads. Carriage bolts shall be used for attaching end plates. All other bolts shall be hex head machine bolts. All nuts shall be hot pressed hex, American Standard, heavy. Standard wrought washers shall be used for foundation bolts and attachments to building structures. All other bolted joints shall have S.A.E. standard lock washers.

2. Construction:

a. All dimensions shall be in accordance with vendors’ requirements. b. The elevations and horizontal spacing shall be subject to the ENGINEER’s approval.

J. Fabrication Requirements:

1. When used, end plates, top plates and top closure panels (to hung ceiling) shall be furnished

as required by the material requisition. End plates, top plates and top closure panels shall be removable with countersunk bolts to match panels. Top closure panels shall be furnished in lengths which match the widths of standard panels, except that one top closure panel may extend across two 4-feet 6-inches wide or five 2-feet 0-inches wide standard panels. The vertical joints of these panels shall align with the vertical joints of the standard panels.

2. End closure or rear closure doors shall be provided. Such doors shall be flush fitting and

gasketed and be of the hinged lift-off type with lockable door handles. A common key shall be provided for all doors on one panel assembly. Where removable access panels are specified they shall be furnished with dished handle fasteners. Screw driver ¼-turn or Dzus type fasteners are not acceptable.

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3. The flanged edges of all panels shall be straight and smooth. Corners shall be welded andground smooth.

4. The face of the panel shall be true and level after flanging.

5. All panel cut-outs and holes may be cut or drilled by any standard method that will not causedeformation. Burrs and sharp edges shall be ground smooth.

6. All seams shall be welded and ground smooth. There shall be no exposed sharp edges on theinside or outside of the enclosure.

7. The cabinet bottom flange for anchoring to the foundation pad shall be rolled (not welded)from the vertical walls of the cabinet and shall run around the entire inside perimeter of theenclosure at the manufacturer’s standard width.

8. Adjacent panel sections shall assemble with faces flush. Gaps or cracks shall not be visiblefrom the front of the assembled instrument board.

9. Stiffeners shall be welded to the back of panels as required to prevent panel deformation dueto the weight of front of panel mounted instruments.

10. Panels shall be self-supporting as defined below.

K. Frameworks and Supports:

1. The rear of each panel section shall have a 316 Stainless Steel framework assembled to it forsupporting conduit, tubing, wireways, switches, air piping and all instrument accessory itemssuch as relay or terminal enclosures, transducers, pressure switches, valves and air relays.The main frame work shall be constructed of standard structural shapes. Special shapessuch as 316 Stainless Steel "Unistrut" may be used for secondary supports. Framework mustnot interfere with instrument connections or access needed for maintenance or adjustments.

2. 316 Stainless Steel framework shall extend 2-feet 8-inches back of the panel face, or asspecified in the material requisition. Where specified, individual adjustable leg supports shallbe provided at the back of the framework so that the entire panel shall be self-supporting.

3. Two removable lifting lugs shall be provided and shall be designed for moving the fullyassembled control panel sections without causing distortion or bending.

L. Preparation of Panel Surface:

1. The surface of the panel shall be prepared for finishing in a manner equal to that describedbelow. The entire surface shall comprise the front and rear face of the panel, both sides andthe edges of all flanges, and the periphery of all holes or cut-outs.

2. All high spots, burrs, welds, and rough spots shall be ground smooth.

3. The surfaces shall be sanded or sandblasted to a smooth, clean bright finish.

4. All traces of oil shall be removed with a solvent.

5. At this point, for non-316 Stainless Steel panels and surfaces, the first coat of primer shall beapplied immediately. However, 316 stainless steel enclosures (including the internal backpanel, hardware, fasteners and accessories), shall require only buffing to a bright finish free ofsurface blemishes – no primer or paint required. However, a layer of Clear-Coat shall beapplied.

M. Panel finishing (for non-316 Stainless Steel surfaces):

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1. A coat of primer shall be applied over the entire panel surface (inside and outside). Minimumdry film thickness of primer coat shall be 1 mil.

2. A second primer coat shall be applied to a minimum dry film thickness of 1 mil.

3. Wet sand to smooth clear finish and then dry.

4. Apply at least two coats of air-dry, epoxy paint over the entire cabinet surface. Dry filmthickness of paint shall be 1 to 2.5 mil. Exterior color shall be light gray or as approved by theENGINEER. Cabinet interior color shall be white.

5. Supply two one-pint containers of air drying, matching paint for field touch-up of the panelface.

N. Instrument Finishing:

1. The final coats applied to painted surface of instrument cases, doors, or bezels which arevisible from the front of panels shall be manufacturer's standard unless otherwise specified.

2. Black japan or "crinkle" finishes on instrument cases are not acceptable.

O. Preparation for Shipment and Shipping:

1. All panels are to be crated for shipment using a heavy framework and skids.

2. The panel sections shall have additional cushioning as needed to protect the finish of theinstruments and panel during shipment.

3. All instruments that are shipped with the panel shall also have suitable shipping stops andinterior cabinet cushioning material installed to protect instrument parts which could bedamaged due to mechanical shock during shipment.

4. Each separate panel section shall be provided with removable lifting lugs to facilitate handling.

5. All shipments shall be by air ride van, unless otherwise specified or approved.

P. Labor and Workmanship:

1. All panels shall be fabricated, piped and wired by fully qualified workers who are properlytrained, experienced and supervised.

2. All personnel used on the project shall be subject to CITY approval.

Q. Drawings:

1. Furnish copies of preliminary drawings for approval. These drawings shall include:

a. Complete panel layouts showing all outside dimensions, locations and dimensions ofpanel cutouts, locations of back of panel stiffeners, and panel face drawings to exactscale.

b. Terminal point locations with coded identification for wiring, and piping connections(includes all pneumatic transmission lines).

c. Back of panel piping.

d. Back of panel wiring, including dimensioned location of connections.

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2. Fabrication of panels, piping and wiring shall not proceed without the CITY’s written release

for fabrication or approval of shop drawings by the ENGINEER.

3. The ENGINEER's requirements for final certified drawings include final approved copies of the above described shop drawings as well as certified drawings of instrument equipment furnished by the panel fabricator.

4. The number of copies of final certified drawings required by the ENGINEER and the required

procedure for identification of these drawings are covered by Section 01330, Shop Drawings / Submittals, of the GENERAL REQUIREMENTS.

R. Inspection and Approval:

1. Panel fabricator must perform the following tests prior to arrival of the ENGINEER and the

INSPECTOR:

a. PLCs and HMIs.

b. All air lines shall be purged and adequately tested for leaks.

c. All alarm circuits shall be rung out to determine their operability and proper function.

d. All electrical circuits shall be checked for continuity and where applicable, proper function.

e. All nameplates shall be checked for correct spelling and correct size of letters.

f. Perform any/all other tests needed to place the panel in proper operating condition.

2. Furnish all necessary testing devices and sufficient manpower to perform the tests required by the ENGINEER and the INSPECTOR.

3. If the above tests have not been performed prior to the arrival of the ENGINEER and the

INSPECTOR, the Contractor shall be liable for back charges by the ENGINEER for the extra time required for the inspection services.

S. Photographs:

1. Fabricator shall furnish two (2) copies of 8 x 10 glossy photographs of the front, rear and all

interior wiring and devices of the finished panel for the ENGINEER's record. 2. Additional photographs shall be provided at the ENGINEER’s request where needed for

proper documentation.

3. Photos shall be taken in digital format and shall be provided to the ENGINEER in both hard copy and digital form.

2.4 GENERAL ENCLOSURE COMPONENTS

A. General Purpose Relays: General purpose relays in the Control Boards(s) shall be plug-in type with 2DPDT contacts rated 10 amperes at 120 volts ac. Each relay shall be enclosed in a clear

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plastic heat and shock resistant dust cover. Sockets for relays shall have screw type terminals. Relays shall be:

1. Potter and Brumfield Type KRP or KUP;

2. Square D Type K;

3. General Electric;4. Allen-Bradley5. Or equal.

B. Time Delay Relays: Time delay relays shall be pneumatic on-delay or off-delay type, with contacts rated 10-amperes at 120/240 VAC. Units shall include adjustable dial with graduated scale covering the time range in each case. Time delay relays shall be:

1. Agastat Series 7000;

2. Pheonix Contact;

3. Weidmuller;

4. Or equal.

C. Slave Relays: Additional relays (slave relays) shall be installed and wired when the number or type of contacts shown exceed the contact capacity of the specified relays and timers.

D. Circuit Breakers: Circuit breakers shall be single pole, 120/240VAC, 15 ampere rating or as required to protect wires and equipment and mounted inside the panels. Branch circuit breakers in control panels shall be miniature, DIN rail mounted, as manufactured by:

1. Pheonix Contact

2. Weidmuller

3. Allen-Bradley

4. Or equal.

E. Nameplates: Nameplates shall be provided for instruments, function titles for each group of instruments, and other components mounted on the front panel(s) as shown on the drawings.

1. A nameplate shall also be provided for each instrument and component mounted inside thepanel(s). They shall be of the same material as those on the front of the panel(s).

2. Nameplates shall be descriptive, to define the equipment tag, function and system.

3. Nameplates for control panels and their associated components shall be fabricated fromlaminated plastic (phenolic material), 1/8 inch thick, having a black exterior and white center.They shall be fastened with 316 Stainless Steel machine screws. Screws shall be applied witha sealant so that the NEMA rating of the panel is not compromised.

4. Nameplates for field instruments shall be fabricated from 316 Stainless Steel.5. Do not use adhesive epoxy to attach nameplates.

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6. Tag numbers for instruments and Equipment numbers for machinery shall be coded to CITY

numbering system.

7. Colors, lettering, styles, abbreviations and sizes of the nameplates shall be in conformance with ISA-RP-60.6 (1984) with an intended viewing distance of three (3) to six (6) feet as shown or as selected by the ENGINEER. Manufacturers shall be:

a. VI-LAM, No. 200, manufactured by N/P Co. b. Formica;

c. Lamacoid;

d. Or equal.

8. Before producing the nameplates, submit a list indicating the wording and tag numbering of all equipment identification Nameplates along with a sample to the Engineer for review and approval.

F. Terminal Blocks: Terminal blocks shall be molded plastic with barriers and box lug terminals, DIN Rail mounted and shall be rated 15 amperes at 600-volts. White marking strips, fastened securely to the molded sections, shall be provided and wire numbers or circuit identifications shall be marked thereon with permanent marking fluid. Terminal block types:

1. Type 1: shall be fused with blown fuse indicator light and knife blade switch, Phoenix Contact

(Model UK 10,3-HESILED N 690), or equivalent by: a. Allen Bradley b. Weidmuller,

c. or equal

2. Type 2: shall be unfused with knife blade switch Phoenix Contact (Model UK 5-MTK-P/P) or

equivalent by:

a. Allen Bradley, b. Weidmuller

c. or equal.

3. Fuses shall be sized to protect the signal circuit wiring and electronic components such as

I/O modules.

G. Signal and Control Circuit Wiring:

1. Unshielded: Conductor shall be flexible stranded copper machine tool wire; these shall be UL

listed and labeled Type MTW and shall be rated 600-volts. Wires for instrument signal circuits and alarm input circuits shall be No. 14 AWG.

2. Shielded: Conductor shall be flexible fine stranded copper twisted-shielded pair; UL listed and labeled Type TC (tray cable), No. 16 AWG with 600-volt rated insulation. Cable shall be: a. Belden No. 3090A; b. Manhattan Wire Products;

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c. American Wire & cable Co.;

d. Or equal.

3. All signal and low voltage wiring shall be run in separate conduits from power and 120VACcontrol wiring.

4. Wire Insulation Colors: Conductors supplying 120VAC power on the line side of adisconnecting switch shall have a black insulation for the ungrounded conductor. Groundedcircuit conductors shall have white insulation. Insulation for ungrounded 120VAC controlcircuit conductors shall be red. All wires energized by a voltage source external to the ControlBoard(s) shall have yellow insulation. Insulation for all DC conductors shall be blue.

5. Wire Marking: Each signal, control, alarm, and indicating circuit conductor connected to agiven electrical point shall be designated by a single unique number which shall be shown onall shop drawings. These numbers shall be marked on all conductors at every terminal usingwhite numbered wire markers which shall be plastic-coated cloth, or shall be permanentlymarked heat-shrink plastic. Manufacturers shall be:

a. Brady Type Bp 500;

b. 3M;

c. Panduit;

d. Or equal

H. Painting: All surfaces shall be thoroughly cleaned and sand blasted per Steel Structures Painting Council Specification SSPC-SP-6 (Commercial Blast) after which surfaces shall receive a prime coat having a dry film thickness of 3-mils, for a total thickness of the complete system of 6 mils. The finished color of the outside surfaces will be selected by the CITY, unless otherwise specified. The inside surfaces shall have a white finish coat. Manufacturers shall be:

1. Amercoat 185;

2. Koppers 622HB;

3. Or equal

2.5 EQUIPMENT SPECIFICATIONS

A. Ultrasonic Level Transmitter: The system shall use ultrasonic ranging to measure the level of liquid and shall consist of a sensor with interconnecting cable and control transmitter unit which can be located up to 100 meters (328 feet) from the sensing unit. Level sensing shall be automatically compensated over the system temperature range of at least 0 to 50 degrees C and shall incorporate non-linear digital filtering and moving average techniques to reduce noise and atmospheric interference. Transmitter shall be microprocessor based. Calibration shall require no reference targets. Accuracy shall be 1 percent or better. Blanking zone shall be 1 foot. In the case of momentary signal loss, relays shall maintain their last state. Output shall be 4 - 20 mA proportional to the range of level sensing. Ultrasonic transmitter shall also have a minimum of five contact outputs (SPDT each) with adjustable set points and deadbands. The ultrasonic unit shall

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be powered by 120VAC. 100 meters (328 feet) of transducer to transmitter interconnecting cable shall be provided. The Ultrasonic Level Transmitter enclosure shall be NEMA 4X and also Explosion-Proof (rated for Class I Div. 2 area). Ultrasonic unit shall be:

1. Milltronics; 2. Magnetrol;

3. Pulsar Process Measurement;

4. Or equal.

B. Pneumatic Systems: Each assembly shall consist of the electrical, electronic, and pneumatic

components defined in the specifications and shown on the drawings. Interconnecting tubing for the low pressure connections shall be ½" stainless steel with stainless steel fittings. The connection from the low pressure connection on each level transmitter shall be piped to a screened breather-drain. Air pressure gages shall be scaled in psig, bubbler tube level gages shall be scaled in inches or feet of W.C. with minor division not to exceed 3" W.C. All level and pressure gages shall have indicating dials that are a minimum of 2.5" in diameter. The purge air flow shall be set by a needle valve and the flow rate shall be indicated on a direct reading rotameter scale. This scale shall be in standard cubic feet per hour (SCFH) units and shall have a scale range of 0.25 to 2.5 SCFH. The differential pressure filter/regulator and rotameter shall be:

1. Wilkerson; 2. Key Instruments;

3. Dwyer,

4. Or equal.

C. Instrument Air Filters: Provide self-contained cartridge type filters designed for in-line mounting in the air piping. Filters shall have the following functions and features:

1. 1 Quart reservoir for trapped moisture. 2. General purpose low pressure drop with excellent water removal characteristics.

3. Metal bowl with sight glass.

4. 50-micron filter element (replaceable)

5. Inlet pressure – 250 psi maximum (at 70 Deg. F ambient temp.)

6. Process connections shall be threaded ¾” NPT. Provide adapter fittings as necessary to

match piping.

7. Manufacturer: Dixon model F17-600A, or equal.

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D. Level Switch (Float Type): Liquid level switches shall be the side mounted float actuated type. The float displaces a shuttle which magnetically actuates hermetically sealed SPDT switch within the unit. The unit shall be NPT threaded to suit field requirements. Switch enclosure shall be NEMA 4X and also Explosion-Proof (rated for Class I Div. 2 area). Process wetted materials shall be 316 Stainless Steel. The switch shall utilize a Mercury Free magnetic reed switch. The float switch shall be supplied as an integral part of the sluiceway. Liquid level switches shall be:

1. Contegra; 2. Siemens;

3. GemsSensors;

4. Or equal.

E. Rotameters: Meters in gas or air services shall be of the standard rotameter design with threaded

ends, bottom entry and top exit with flow control needle valve, vertical mounting, rated for a minimum working pressure of 150PSIG, scale calibrated in engineering units, with a reference accuracy of ±10% of reading or better over the capacity range shown in the data sheets. Rotameters shall be installed in strict accordance with the manufacturer's instructions. Rotameters shall be:

1. Key Instruments;

2. Dwyer;

3. Omega,

4. Or equal.

F. Pressure and Vacuum Gages: Pressure gages shall be provided where shown. In all locations

where pressure may vary from below to above atmospheric head, compound gages shall be installed.

1. Gage Construction: Gages shall be industrial grade with type 316 stainless steel movement

and stainless steel or alloy case or phenol case. Unless otherwise shown or specified, gages shall have a 2(4)-1/2-inch dial, ½ (1/4) -inch threaded connection, a Type 316 stainless steel snubber adapter, and a shut-off valve. Gages shall be calibrated to read in engineering units, with an accuracy of ±1 percent of reading, and shall withstand pressures equal to 150 percent of the rated working pressure or vacuum without failure or damage to the gage. All gages shall be vibration and shock resistant. Pressure gages shall be:

a. Ashcroft;

b. Wika;

c. US Gauge;

d. Or equal.

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2. Diaphragm Seal: Gage shall be equipped with diaphragm seals where indicated in the Contract Documents and/or where gages are attached to systems involving chemical solutions, corrosive fluids, or other liquids containing solids.

a. .For solids content of 1 percent or less utilize:

1). Ashcroft Model 101 2). US Gauge (Ametek)

3). Foxboro

4). Or equal.

b. For liquids having 1 percent or greater solids content, utilize saddle type diaphragm seals:

1). Ashcroft Model 205

2). Wika;

3). US Gauge;

4). Or equal.

c. Additional Requirements for all diaphragm seals:

1). Seal housings, hardware, nuts, bolts, fasteners and accessories shall be all Type 316

stainless steel. 2). Diaphragms:

a). For liquids containing grit / solids, pulsating flow and for pressures over 1 psi,

utilize seals with type 316 stainless steel diaphragms. b). Use an elastomer diaphragm for pressures of 1 psi and below.

. 3). Provide fill connection and valved flushing port size 1/4-inch NPT.

4). Gages/Seals shall be capable of disassembly without loss of fill fluid.

5). Installation: All gages and appurtenances shall be installed at the locations shown in

the Contract Documents and in accordance with the manufacturer's printed instructions. Care shall be taken to minimize the effect of water hammer or vibrations on the gages. Where indicated or necessary for proper operation, gages shall be mounted independently of vibrating piping or machines, and connected to the process with diaphragm seals and flexible capillary tubing.

G. Signal Isolator: Signal isolators shall have complete isolation of the input, output and power circuits. Signal input shall be 4-20 mA into 50 ohms maximum; signal output shall be 4-20 mA into 1000 ohms minimum. Power input shall be 120/240 VAC 60 Hz (or loop-powered). Span and zero shall be adjustable; accuracy shall be ±1 percent of span. Units shall be surface or rack mounted. If installed outdoors, they shall have NEMA 4X rating. If installed in hazardous areas they shall have NEMA 7 (Class I Div 1, Explosion-proof) rating. Signal isolators shall be furnished

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and installed in each measurement and control loop, wherever required, to ensure adjacent component impedance match, or where feedback paths may be generated or to maintain loop integrity when the removal of a component of a loop is required. Signal isolators shall be:

1. Pheonix Contact

2. ACROMAG

3. Action Instruments

4. Or equal

H. Signal Converter: Signal converters shall have complete isolation of the input, output and power circuits. Signal input shall be 1-5 VDC into a minimum of 5 megohms input impedance. Signal output shall be 4-20 mA into 1000 ohms minimum. Power input shall be 120/240 VAC 60 Hz (or loop-powered). Span and zero shall be adjustable; accuracy shall be ±0.1 percent of span. Units shall be surface or rack mounted. If installed outdoors, they shall have NEMA 4X rating. If installed in hazardous areas they shall have NEMA 7 (Class I Div 1, Explosion-proof) rating. Signal converters shall be:

1. Pheonix Contact;

2. ACROMAG;

3. Weidmuller;

4. Or equal.

I. Current Alarm Trip (Switches): Current alarm trips shall be loop-powered and single or dual type as shown. Units shall accept voltage or current input signals. Dead bands shall be factory set at 100 percent of full span for dual trips and adjustable over 100 percent of span for single trips. Alarm trips shall be equipped with 10A DPDT contacts. Alarm trips shall include setpoint dials calibrated 0-100 percent for each trip point. If installed outdoors, they shall have NEMA 4X rating. If installed in hazardous areas they shall have NEMA 7 (Class I Div. 1, Explosion-proof) rating. Alarm trips shall be:

1. Moore Industries;

2. Acromag;

3. Phoenix Contact;

4. Or equal.

J. Selector and Pushbutton Switches: Selector and pushbutton switches shall be rated 10-amperes at 600 volts, shall be heavy-duty, oil-tight and shall have the number of positions and poles indicated. Operators shall be nickel or chrome plated. The hand switches shall be lockable in the OFF or STOP position. Switches shall be:

1. Honeywell;

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2. Allen-Bradley;

3. Omega; 4. Or equal.

K. Indicating Lights: Indication lights shall be high-brightness LED, push-to-test type, and shall be

NEMA 4X (and if installed in classified area also NEMA 7), heavy-duty, oil tight. Each light shall have a screwed-on glass prismatic lens approximately one-inch in diameter. Each light shall have a factory-engraved legend plate, as shown on the Drawings. Indicating lights shall be:

1. Honeywell; 2. Allen-Bradley;

3. Omega;

4. Or equal.

L. Elapsed Time Meter (ETM) / Run Time Meter: A total of 6 elapsed time meters (ETM) shall be furnished as part of the 3 local control panels. Each control panel controls one Drum Screen/Screw Press combination. The ETM shall be connected to the equipment starting circuit in such a way that the ETM will be powered (operating) whenever the equipment is running and will register totalized running time on its indicator.

The ETM shall have the following functions and features:

1. Five Digit Display (minimum), registering up to 99,999 Hours before returning to zero.

2. Dial / Display: Mechanical, LED or LCD (back lighted).

3. Non-volatile memory and/or battery backup for electronic timing circuits.

4. Non-resettable.

5. UL Listed.

6. NEMA rating to match panel on which it is installed.

7. Operating Voltage: As needed to enable connection directly to (and operation from) the equipment starting or switched power circuit.

8. Dimensions: ETM shall be sized to fit panel on which it is to be installed, but bezel

dimensions shall not exceed 4 inches square (or 4 inches diameter for round meters), and shall not be less than 1.5 inches on a side (or 1.5 inches diameter for round meters)

9. Temperature Limits: -20 to +55 degrees C (or greater).

10. Accessories: Provide necessary gaskets, fasteners and other hardware and equipment

needed for installation and operation.

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11. Manufacturers: Honeywell, Crompton Technology, Veeder-Root, Redington, Cramer, or equal.

M. Solenoid Valve: 120 VAC, 2-Way, Normally Closed, NEMA 4X, 316 Stainless Steel body, UL

listed, weatherproof housing . Solenoid valve shall be:

1. ASCO; 2. Jefferson;

3. Magnatrol;

4. Or equal.

N. Fiber-Optic cable: 8.7 (or 8.2)/125 single-mode, 12-strand, LC/APC-angle polished connectors, flame-retardant outer jacket, indoor/outdoors, listed for plenum or building riser applications, riser-rated, suitable for aerial, duct and riser applications. Color-coded fibers and buffer tubes. Gel-free design. All-dielectric cable construction with no need for grounding or bonding, no preferential bend axis, UV-resistant and listed OFNR, and FT-4. It shall be designed for inter-building and intra-building backbones with water-swellable strength yarns. Fiber cable shall be:

1. Corning; 2. Belden; 3. L-Com; 4. Or equal.

O. OPTICAL PATCH PANEL ASSEMBLIES

A. All cable terminations shall be made in optical patch panel assemblies.

Patch panel assemblies shall be of the pre-assembled chassis type with

associated rack-mounting hardware.

B. To facilitate the transition between outside plant cable and the pre-

connectorized cable assemblies, the fibers shall be fusion spliced

and housed in a splice tray. Splice tray shall be positioned in the

optical patch panel assembly per manufactures recommendation.

Splice attenuation shall not exceed 0.2 db. Splice shall be covered

with a protective sleeve.

C. FO Patch Panels are to be located 'within' the Fiber Optic Terminal

Cabinets (FOTC) enclosures. Where possible, the CONTRACTOR may

place the FOTC within the PCM cabinet.

D. Manufacturer shall be Corning or equal.

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The patch panels shall be provided with desiccant packs to absorb moisture. Packs shall be the largest size available that will fit within the panels. Multiple smaller packs totaling to the same desiccant amount will also be acceptable for Class 1 Div. 2 classification.

Patch Panels shall be manufactured specifically for this purpose and shall be the standard product of the manufacturer and shall be of adequate size to accommodate all connectors and fiber-optic cables installed in them without forcing or damage, including stress-relief loop.

Patch panels shall be fully enclosed with hinged door at front, and shall be installed in the Control Panels to which they pertain or shall be wall or stand mounted nearby as indicated in the Contract Documents.

P. FIBER OPTIC TERMINAL CABINETS

A. FOTCs shall be front access only.

B. Cabinet's frame shall consist of vertical and horizontal tubular aluminum extrusions with a

minimum wall thickness of .150. Front to rear aluminum extruded corners shall be at least

.125 thick.

C. Rear door, top panel, and side panels shall be a minimum 316 Stainless Steel.

D. FOTC shall be NEMA 12 or NEMA 4X, based on Area Classification. Where Area

Classifications dictate NEMA 4X, the cable entry shall be sealed with EYS type fittings.

E. Ten feet of fiber shall be coiled prior to termination to Patch Panel within the Terminal

Cabinets. This requires cable handling and dressing mechanisms within the Enclosures

that shall be subject to the Engineer’s approval as part of the enclosure submittal.

F. FOTC shall be floor mounted, or wall mounted where dictated by obstructions and

seismically rated.

G. FOTCs shall provide for strain relief of incoming cables as well as providing connector

panels and connector couplings adequate to accommodate the number of fibers to be

terminated.

H. All FOTCs shall incorporate radius control mechanisms to limit bending of the fibers to the

manufacturer's recommended minimums.

I. Couplers shall be mounted on a panel that, in turn, snaps into the housing assembly.

J. FOTCs shall have a common key lock that opens all FOTCs installed for this project.

K. FOTCs shall be rack-mounted, unless specified otherwise in the drawings. Size shall be

12-fiber (12 ports), 24-fiber, 36-fiber or 72-fiber.

L. Exceptions, such as wall mounted FOTCs shall be at the approval of the Engineer.

M. Manufacturer shall be Corning or equal.

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Q. Type Z Purge System: Equipment supply, installation, installation tests, and startup of the Type Z

Purge Systems as required for the 8 Bar Screen Local Control Panels. Explosion proof, NEMA 4X, 316L enclosure. The purge system shall reduce the classification within the protected LCP from Class I Div. 2 to nonhazardous. The purge system shall consist of all necessary piping, flow regulators, valves, fittings, and accessories required to extend from the instrumentation air headers to all Local Control Panels. Type Z purging requires that the power shall automatically be disconnected on loss of purge pressure and a re-purge of at least 4 volume changes is required before the power is restored. The Type Z Purge System shall be of the FA (Fully Automatic) style so that it can restart the purge process automatically after a power or air pressure failure.

Type Z Purge System shall be:

1. Pepperl+Fuchs; 2. Bebco;

3. Hoffman; 4. or equal.

R. Digital Panel Meter (DPM): The Digital Panel Meter shall be: 4 ½” digit, loop-powered, LCD,

panel-mount with gasket for NEMA 4X rating. It shall be of sufficient visibility for daytime use.

Digital Panel Meter shall be:

1. Precision Digital;

2. Dwyer;

3. Omega;

4. or equal.

2.6 PROGRAMMABLE LOGIC CONTROLLER

A. General: Program, test, calibrate, and place into operation, a Programmable Logic Controller (PLC). PLC shall be: An Allen-Bradley CompactLogix Programmable Logic Controller (PLC) or Honeywell MasterLogic-200 PLC. Each PLC shall be programmed using Allen-Bradley’s RS5000 (or RS/Studio 5000), or Honeywell’s Programming Language. 1. Allen-Bradley

2. GE

3. Siemens

4. Or equal.

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B. Construction: The PLC Central Processing Unit (CPU) shall be of solid-state design. The CPU

operating logic shall be contained on plug-in modules for quick replacement. Chassis wired logic is not acceptable. The controller shall be capable of operating in a hostile industrial environment (i.e., heat, electrical transients, RFI, vibrations, etc.), without fans, air conditioning, or electrical filtering (up to 60 degrees C and 95 percent humidity).

C. Design - General: The PLC shall have input facilities for the discrete input and 4-20 mA analog

unit signals specified and shown on the drawings. The PLC shall produce isolated output contacts and 4-20 mA signals for control functions. Each CPU shall provide internal fault analysis with a fail-safe mode and a dry contact output for remote location alarming, and a local indicator on the PLC frame in the event of a fault in the PLC.

D. Central Processor: The central processor shall contain all the relays, timers, counters, number

storage registers, shift registers, sequences, arithmetic capability, and comparators necessary to perform the specified control functions. It shall be capable of interfacing sufficient discrete inputs, analog inputs, discrete outputs, and analog outputs to meet the specified requirements plus 25 percent excess capacity. The power supply shall contain capacitors to provide for orderly shutdown in the event the incoming power does not meet specifications. If this occurs the processor shall cease operation, forcing all outputs off. The processor shall have a key type memory protect switch to prevent unauthorized program changes.

E. Memory: The programmable controller memory shall have CMOS semi-conductor memory with

battery backup or EPROM electrically alterable read only memory. The CMOS memory shall be a minimum of 2K with battery backup to retain the program during power interruptions of up to 1 year. An indicator shall show the status of the batteries and a reference shall be available through the discrete outputs, to alarm the operator that the batteries should be changed.

1. The unit shall be supplied with sufficient memory to implement the specified control functions

plus a reserve capacity of 25 percent of the total provided. This reserve capacity shall be totally free from any system use.

2. The memory shall be programmed in a multi-node configuration with multiple series or parallel

contact, counters, timers, and arithmetic functions.

F. Controller: The controller shall be programmed in annotated "ladder diagram" language. It shall be easily reprogrammed with a portable programmer or laptop computer. The PLC system shall be programmed by the VENDOR to accomplish the control and monitoring specified and shown on the drawings. Two documented copies of the operating program shall be furnished which allow direct, step-by-step, reloading of the system program. Copies of this program shall be furnished in the format used in the contract diagrams for conventional relay control systems. These diagrams shall reflect equipment name designations used in the PLC as well as the contract diagram equipment name designations (i.e., timer "Q" in the "Contract Drawing may become timer OL in PLC, Program). Two sets of application software on CD shall be provided.

G. Power Supply: The power supply shall operate at the following:

1. 120VAC RMS plus or minus 15 percent continuously.

2. 120VAC RMS plus or minus 30 percent maximum 30 seconds.

3. 120 VAC RMS plus or minus 100 percent maximum 17 milliseconds.

4. Line spikes at 1000V ac (5000 micro-seconds duration; 0.5 percent maximum duty.

H. Input/Output Modules: All I/O housings and modules shall be rugged construction with modules in

place. Sufficient input and output modules shall be provided to implement the specified control functions plus 20% spare capacity of each type of I/O point. Provide I/O spare rack space for 25% future expansion (all point types). Provide field terminals to accommodate the wires and their

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shields for the future additional I/O. Provide additional Panduit (wireway) to route the wiring required for the future additional I/O.

1. Discrete Input Modules: Defined as contact closure inputs from devices external to theprogrammable controller module. Input modules shall be shielded from short time constantnoise and 60 Hz pickup. Individual inputs shall be optically isolated from low energy commonmode transients to 1500 volts peak from users wiring or other I/O modules. The modulesshall have LED lights to indicate a discrete input.

2. Discrete Output Modules: Defined as contact closure outputs for ON/OFF operation ofdevices external to the programmable controller module. The output modules shall be fused(typically 5A at 120VAC) with blown fuse indicator lights. The output modules shall beoptically isolated from inductively generated, normal mode and low energy, common modetransients to 1500 volts peak. All output modules shall have LED lights to indicate output hasbeen cycled ON by the controller.

3. Analog Input Modules: Defined as analog inputs or 1 to 5V DC, 0 to 10V DC, or 4 to 20 mADC signals, where an analog to digital conversion is performed and the digital result is enteredinto the processor. Inputs are read every scan.

4. Analog Output Modules: Defined as analog output or 1 to 5V DC, 0 to 10V DC, or 4 to 20 mADC signals, where a digital to analog conversion is performed and the analog result isproduced as an output. Outputs are produced on every scan.

5. Discrete I/O Expander: Where required provide I/O expander to enable the controller toaccess additional I/O points.

6. A managed Industrial Ethernet Communication Module (Ethernet/IP switch) with RJ45 andfiber optic ports. The Ethernet/IP switch shall be:

1. Phoenix Contact;

2. Cisco;

3. Allen-Bradley;

4. Or equal.

I. Data Access Panel (HMI): A UL listed, touch-sensitive, marine-rated, explosion-proof., 256 color, 12.5 (10.4) inch Human Machine Interface (HMI), with a NEMA 4X enclosure and conformal coating for protection from dampness, corrosion and contamination. Program logic or sequence changes shall not be made from this panel unless a security code or key lock is used to prevent unauthorized changes. A minimum of 2 levels of password protection shall be provided. Interconnecting cables between the Data Access Panel and the PLC shall be furnished. The HMI graphics screens shall be programmed in so far as practical in accordance with the City of Los Angeles, Bureau of Sanitation, “Operations Interface Graphic Display Standards”. The HMI shall be:

1. Allen-Bradley (“Panel View Plus” 1250) or Honeywell HCiX Series.

2. GE

3. Siemens

4. Or equal.

J. Input/Output (I/O) Section: Defined as heavy duty housing containing input and output control devices that are directly connected to the controller.

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K. Programming Unit: All programming shall be accomplished with a Laptop programmer. The

programmer shall be capable of being directly plugged into the system without the requirement of additional hardware. All programming, monitoring, searching, and editing shall be accomplished with the programmer. These functions shall be capable of being done both "on line" while the process is scanning or "off line." The programmer shall display multiple series and parallel contact, coils, timers, counters, and calculate functions. The programmer shall also be able to monitor the status of all inputs, outputs, timers, counters, and coils. It shall have the capability to disable/force all inputs, outputs, and coils to simulate system operation. It shall also indicate "power flow" through all elements and include a search function to locate any element and its program location. The processor status information, such as error indication and amount of memory remaining, shall be shown on the laptop’s screen. Two sets of system and program development software, on CD, along with documentation shall be provided. Both copies of CD/Documentation shall be delivered to the City’s Contract Administration Inspector (One set of CD/Documentation is for Bureau of Sanitation ownership and the other set of CD/Documentation is for Bureau of Engineering ownership). The Contractor shall provide the City with a permanent license for all software delivered under this contract.

L. Guidelines for PLC/DCS interface:

General:

1. Use contiguous blocks of data

2. Separate data types

3. Separate Read and Write data

Allen Bradley:

1. Use separate array tags

2. Bit arrays

3. Integer arrays

4. Real/Float arrays

Modbus:

1. Read Inputs or Coils for discretes (1xxxxx or 0xxxxx)

2. Read Input Registers for integer values (3xxxxx)

3. Read Holding Registers for Real values (4xxxxx)

M. Shop Drawings: The shop drawings shall include a full description of the PLC system, including documentation of operation theory, programming methods, i.e. ladder logic diagram (All contacts, coils, timers, latches and each section of the ladder shall be clearly annotated and defined. The

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annotation of each of the input contacts representing a field device shall clearly define the status of the device.), data codes and security features, maintenance and trouble-shooting information. Schematics of all cards or units within the system along with point-to-point wiring diagrams shall be furnished after award of contract.

1. The documentation shall, also, provide a sequential flow chart of the logic implemented. The

format of the flow chart and the annotation shall be proposed for acceptance by the ENGINEER before implementation.

2. Two sets of the program and documentation shall be forwarded for review and comments at

least 30 days before factory test.

N. Test: All control panels and other control system equipment shall be factory tested to verify all functions and features of the equipment; both the manufacturer’s published specifications and compliance with all requirements of these Contract Specifications. All electrical equipment containing solid-state logic systems shall be tested for a minimum of 100 hours at an ambient temperature of 120 F prior to shipment from the factory. For testing, the equipment shall be interconnected with devices which will cause it to repeatedly perform all operations and experience all loads on the various components that will be seen in actual service. The ENGINEER may witness testing of the units. Solid-state logic systems shall be tested as complete assemblies. Testing of individual components or modules will not be acceptable. All testing shall be witnessed by the representative of the City Engineer. All costs for travel, lodging, transportation, meals, per-diem and other related expense shall be paid by the Contractor as part of the Contract Bid price. See General Requirements, Section 01453: Sampling, Testing and Fabrication Inspection.

O. Thirty Day Acceptance Test: After start up has been completed, the System shall undergo a 30 day acceptance test. The System must run continuously for 30 consecutive days. During this period, all System functions shall be exercised, and any System interruption and accompanying component, subsystem, or program failure shall be logged for cause of failure, as well as time of occurrence and duration of each failure. A failure shall cause termination of the 30 day acceptance test. When the cause of a failure has been corrected, a new 30 day acceptance test shall be started. Skilled technicians shall respond to all trouble calls by the CITY.

1. The technician responding to a System malfunction, must prepare a report which includes

details concerning the nature of the complaint or malfunction and the resulting repair action required and taken, plus time and date of occurrence and correction.

2. The System Malfunction Report form shall be submitted to the ENGINEER for review and

approval before the time of re-start of testing. Failure to obtain ENGINEER approval for the Report form shall cause postponement of testing.

P. Operations and Maintenance Manuals: Furnish to the ENGINEER 10 complete sets of Operation

and Maintenance manuals. The manuals shall include data sheets, catalog cuts, approved shop drawings, manufacturer’s technical manuals, information drawings, etc., for the system, subsystems, and all components, and shall include names, addresses and telephone numbers of equipment suppliers, representatives and repair facilities.

1. This shall include a complete description of the recommended operating procedures,

maintenance procedures, and spare/replacement parts list for equipment items with catalog data, diagrams, and drawings or cuts describing the equipment.

2. Each set shall include full size assembly and wiring diagrams; drawings showing "as built"

conditions shall be furnished to the CITY.

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PART 3 – EXECUTION

3.1 INSTALLATION

A. The Instrumentation Subcontractor shall utilize personnel provided by its assigned organization to accomplish, or oversee the physical installation of all elements, instruments, accessories or assemblies which it furnishes. The Instrumentation Subcontractor shall employ installers who are skilled and experienced in the installation and connection of all elements, instruments, accessories, and assemblies being furnished under this Contract.

B. In summary, it is the general intent of this Contract that all field wiring, i.e., wiring external to the Local Control Panels, shall be furnished and installed under provisions of Division 16 Electrical. Computer and PCM equipment cables. Data highway and grounding shall be furnished by the manufacturer and installed by the Instrumentation Subcontractor. Further, it is the general intent that all field wiring, i.e., 4-20 mA signal circuits, process equipment control wiring, signal wiring to field instruments, LCPs input and output wiring, be furnished and installed under Division 16 and be terminated and identified under provisions of Division 17 Instrumentation and Control. All control and signal wiring shall be tested for insulation resistance and continuity in accordance with paragraph 3.3 below.

C. The Instrumentation Subcontractor's attention is directed to the electrical and mechanical schematics and details of this project. Referral to these portions of the contract design shall be required in order to understand the full intent and scope of work required.

3.2 CONTROL PANEL SIGNAL AND CONTROL CIRCUIT WIRING

A. Wiring Installation: All wires shall be run in plastic wireways except:

1. Field wiring,

2. Wiring run between mating blocks in adjacent sections,

3. Wiring run from components on a swing-out panel to components on a part of the fixedstructure,

4. Wiring run to panel-mounted components.

5. Wiring run from components on a swing-out panel to other components on a fixed panel shallbe made up in tied bundles. These bundles shall be tied with nylon wire ties, and shall besecured to panels at both sides of the "hinge loop" so that conductors are not strained at theterminals. Wiring shall run for at least 6-inches parallel to hinges when crossing betweenportions of the panel that move in relation to each other such as doors and hinged instrumentsupports.

B. Wiring run to control devices on the front panels shall be tied together at short intervals with nylon wire ties and secured to the inside face of the panel using adhesive mounts.

C. Wiring to rear terminals on panel-mount instruments shall be run in plastic wireways secured to horizontal brackets run above or below the instruments in about the same plane as the rear of the instruments.

D. Conformance to the above wiring installation requirements shall be reflected by details shown on the shop drawings for the ENGINEER'S review.

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E. Wire Marking: Each signal, control, alarm, and indicating circuit conductor connected to a given electrical point shall be designated by a single unique number which shall be shown on all shop drawings. These numbers shall be marked on all conductors at every terminal using white numbered wire markers which shall be plastic-coated cloth, or permanently marked heat-shrink plastic.

3.3 INSTRUMENT CABLE TESTS

A. General: The following tests shall be performed on each PI&CS cable which is installed under this Contract. All tests shall be end-to-end tests of installed cables with the ends supported in free air, not adjacent to any grounded object. Complete records of all tests shall be made and submitted to the ENGINEER for review and approval.

B. Continuity tests shall be performed by measuring wire/shield loop resistance of each signal cable as the wires, taken one at a time, are shorted to the channel shield. No loop resistance measurement shall vary by more than ±2 ohms from the calculated average loop resistance value.

C. Insulation resistance tests shall be performed by using a 500 volt megohmmeter to measure the insulation resistance between each channel wire, between each channel wire and the channel shield, between individual channel shields in a multi-channel cable, between each individual channel shield and the overall cable shield in a multi channel cable, between each wire and ground, and between each shield and ground. Values of resistance less than 1 megohms will be unacceptable. Cable testing shall be performed before and after installation.

D. Fiber-Optic cable testing shall include the following: 1. Optical Time Domain Reflectometer (OTDR) test: Single and Multi-Mode, Bi-Directional, “on-

reel” on site, for pre-installation and post-installation testing. No cable installation shall occuruntil the “on-reel” test report has been approved.

2. End-to-End Attenuation Tests.3. End-to-End Bandwidth Tests.

3.4 INSTALLATION, CALIBRATION, TESTING, PRECOMMISSIONING, START-UP AND INSTRUCTION

A. General: All systems specified in the applicable Sections of Division 17, shall be installed, connected, calibrated and tested, and in coordination with the ENGINEER, shall be started to place the plant processes in operation. This shall include final calibration in concert with equipment specified elsewhere in these Contract Documents, including pumps, samplers, valves and chemical feeders. The installation personnel shall be provided with a final reviewed copy of the shop drawings and data.

B. Installation and Connection: Install and connect all field-mounted components and assemblies under the criteria imposed in this Section under "Manufacturer's Representative Services." The installation personnel shall be provided with a final reviewed copy of the shop drawings and data.

1. The instrument process sensing lines and air signal tubing shall, in general, be installed in asimilar manner to the installation of conduit specified under Section 15610 Piping, General ofGENERAL REQUIREMENTS. Individual tubes shall be run parallel and near the surfacesfrom which they are supported. Supports shall be used at intervals of not more than 3 feet ofrigid tubing.

2. Bends shall be formed with the proper tool and to uniform radii and shall be made withoutdeforming or thinning the walls of the tubing. Ends of tubing shall be square-cut and cleanedbefore being inserted in the fittings. Bulkhead fittings shall be provided at all panels requiringpipe and/or tubing entries.

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3. All instruments and connecting lines shall have allowance made for movement of equipmentcaused by seismic loading, vibration, or expansion or contraction caused by temperaturechanges. This shall be demonstrated to the ENGINEER during witnessing of field installationwork prior to startup.

4. All accessory items required for installation and proper operation of the equipment shall beprovided. Such items may include instrument valves, seal pots pigtails, etc.

5. Lines or connections open to atmosphere shall be protected against ingress of foreign matter.Unprotected openings shall have a goose neck, or equivalent, attached to protect againstfalling particles. Bird screen and insect screens shall be installed.

6. Comply with installation detail in the specifications for mounting of the instrument.

7. Verify that all Differential Pressure elements have three valve manifolds.

8. All flexible cables and capillary tubing shall be installed in flexible conduits. The lengths shallbe sufficient to withdraw the element for periodic maintenance.

9. All power and signal wires shall be terminated with spade type lugs.

10. All connectors shall be, at a minimum, watertight.

11. All wires shall be mounted clearly with an identification tag that is of a permanent andreusable nature.

12. All wire and cable shall be connected from terminal to terminal without splices unlessspecifically approved by the ENGINEER and arranged in a neat manner and securelysupported in cable groups. All wiring shall be protected from sharp edges and corners.

13. Verify that all mounting stand and bracket materials and workmanship comply withrequirements set forth in the specifications and drawings.

14. Provide a technical field representative to instruct the installation personnel on any and allinstallation requirements; thereafter, the technical field representative shall be readilyavailable by telephone to answer questions and supply clarification when needed by theinstallation personnel.

15. Finally, after all installation and connection work has been completed, the technical field rep-resentative shall check for correctness, verifying polarity of electric power and signal connect-ions, making sure all liquid or pneumatic process connections are free of leaks, and all othersimilar details. The technical field representative shall certify in writing that for each loop orsystem checked out, all discrepancies have been corrected by the installation personnel.

16. Bear all costs and provide all personnel, equipment and materials necessary to implement allactivities specified herein.

C. Process Connections: Process Connections and root valves shall be located so that they are accessible. Root valves stem and handle shall be installed clear of mainline insulation.

1. Consistent with measuring needs, process connections shall be located to have minimummovement. Therefore, they shall be as close to the system anchor points as possible.

2. For instruments mounted on a local board, the process connection shall be located as closeas practical to the board.

3. Process connections in pipelines shall be oriented to avoid gas pockets in the sensing linesfor liquid and vapor, and to avoid liquid pockets in the sensing lines for gas.

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D. Valves: Root valves shall conform in design to the main-line class. If a globe-pattern root valve is used for pressure ranges of 0-15 psig, or differential pressure ranges of 0-100 inches H20, or vacuum service, its stem shall be installed horizontally. All other globe-pattern root valves shall have the stem vertical. All valves shall be full port ball where available.

1. Relief valves shall be installed without isolation valves.

2. To allow isolation of instruments, each instrument, EXCEPT FOR RELIEF VALVES, shall

have a shutoff valve that is close to the instrument and is readily accessible. Where the root valve serves this purpose, instrument valves are not required.

3. If the root valve for a test point is not accessible, pipe or tubing shall be added and an

instrument valve installed at convenient location.

E. Instruments: Locate locally mounted instruments near the most convenient point of use consistent with good measuring practice and accessibility. Sensing lines shall be as short as practical.

1. When consistent with good measuring practice, local boards or racks may be used to mount

instruments that are grouped together because of common locations or related function.

2. Sensing instruments are preferred to be elevated as follows relative to the process connection in order to avoid gas pockets in a liquid-sensing line or liquid pockets in a gas or vapor sensing line:

Process Fluid Preferred Instrument Elevation

Liquid Below Line

Slurry Below Line

Steam over 20 psia Below Line

Steam not over 20 psia Above Line

Gas/Air Above Line

3. Instruments and local boards shall not block walkways. For use, calibration, and repair, they

shall be accessible without requiring instrument disassembly or the removal of piping, grating, or other structure.

4. Instruments shall be 4' - 6" above the floor. Exceptions may be made for seismic supports,

for instruments accessibility, or for other factors, but must be approved by the ENGINEER prior to the work being done. Sufficient lighting shall be provided for night-time use.

5. Instruments shall be protected against shock and vibration. Because of vibration, electro-

pneumatic signal converters, in particular, shall not be mounted on control valves.

6. High temperature, high humidity and other ambient factors must be considered when locating instruments that require access for service.

7. Fluid-filled sensing systems, or "capillary tubes", shall be sealed to the instrument by the

instrument manufacturer and shall not be repairable in the field. Such systems shall not be opened or cut during or after installation, and shall be routed and protected as required to guard against damage. Avoid sharp bends in capillary tubing (i.e. bend radius shall not be less than 10 times the diameter of the capillary tubing. Excess lengths of capillary tubing shall be neatly coiled in a protected area or enclosure, e.g., coiled inside a protective shipping cap for 12-inch pipe.

8. Manufacturer's installation requirements, including those relating to unsupported span and

minimum bend-radius of capillary tubing, must be submitted for review and approval by the ENGINEER.

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9. All instruments shall have nameplates and tag numbers engraved on tags made of 316 Stainless Steel and attached with 316 Stainless Steel wire.

F. Sensing Lines: Sensing lines shall have a continuous slope to promote their being kept either full

or free of liquid, as appropriate. The slope shall be one inch, or more, per foot of run except that 2 inches per foot is preferred for instruments sensing steam at pressures up to 20 psia.

1. If an instrument having a large dynamic displacement, e.g., a U-tube manometer, is in liquid

service and is mounted above the main line, the sensing line shall descend for at least 36" close to the process connection and before sloping up to the instrument with the intent of preventing the entrapment of a non-condensable in the sensing line and shall be located below process taps.

2. If a sensing line has a liquid purge, the line shall be arranged so that the purge flow is up. If a

gas purge is used into a process liquid, the purge flow shall be down.

3. Low points, except for pigtails, shall have a valved drain connection. Drip or dirt chambers shall be installed where needed. For dirty or freezing services, drain valves shall be a gate or ball type suitable for a Rod-Out tool.

4. High points shall have a vent connection with a manual or automatic vent valve except when

the fluid is a non-condensable gas and except for pigtails. Not for U-Tube Manometers.

5. The discharge of bleed connections shall be piped to a safe disposal point if opening the bleed may create a hazard. The outlet of the valve on an atmospheric bleed shall not be plugged or capped, otherwise potentially hazardous pressure buildup may occur downstream of the valve.

6. Process fluids shall not be piped to a control room, or control panel, except air, nitrogen, or

other inert gas at pressure not exceeding 150 psig.

7. Dead-end sensing lines shall preferably be not over 50 feet long when using 1/4" O.D. tubing. The tubing diameter shall be increased if a line is over 50 feet long or if the sensing instrument has a large dynamic displacement.

8. Hydrostatic head in a sensing line may affect a measurement. The effect of head shall be

considered, particularly for low measuring ranges or low operating pressures.

9. Instruments in steam or vapor service shall have a pigtail or equivalent wet-leg to keep the instrument cool. The pigtail shall be close to the instrument. A wet-leg shall have a filling connection, usually at the top. If the instrument is mounted above the line, it shall be insulated up to the pigtail to minimize refluxing.

10. Use of a condensate pot may be necessary for any measured variable. If used, condensate

and seal pots shall be located as close as possible to the process connection.

11. Pulsation dampers, when required, shall be installed close to the instrument, downstream of the instrument block valve.

12. Sensing lines shall be protected against mechanical loads and wear. Otherwise additional wall

thickness shall be required for mechanical strength. Unsupported spans of process and pneumatic tubing shall not exceed 3 feet in length.

13. Expansion bends shall be provided as necessary to allow for movement of supporting

structures or change of length due to temperature change.

14. Hot lines shall be covered with screens or insulation for personnel protection.

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15. The main-line pipe class shall apply up to the instrument side of the root valve. Beyond that point, the appropriate instrument pipe class shall be used.

G. Fittings: Fittings shall not be used between the process connection and the root valve nor for pipe

on the process side of condensate or seal pots, except that displacement and float-type level instruments are normally installed using pipe fittings.

1. So far as practical, bends rather than fittings shall be used to change the direction of a run of

tubing or pipe. The minimum bending radius for cold-bending of tubing shall be three times the outside diameter of tubing and is covered by ANSI B31.1.

2. The ferrule of a flareless tube fitting shall be harder than the tube on which it is used.

3. Lubricant and sealant compounds shall be used as required by the city and equipment

suppliers.

4. Where a detail specifies a size and type of fitting, a combination of fittings of other sizes but of the same or equivalent type giving the same or better overall effect may be substituted for convenience or if the desired part is not available. Flareless or threaded connections may not be used where weld connections are required. Where a ½” socket-weld fitting is required, a pipe 1/2" tube socket-weld fitting plus a 1/2" x 3/8" tube socket-weld fitting may be substituted. A flareless-end valve may be substituted for a threaded valve with flareless connectors, or vice versa. A weld fitting may replace a threaded or flareless fitting unless maintenance access will require the ability to make and break the connection. Each substitution shall require written approval of the ENGINEER.

5. Welding shall conform to project requirements.

H. Instrument Installation Notes - Flow: Condensate pots are not required for a sensing element,

e.g., a force balance flow transmitter, which has negligible dynamic displacement. If displacement is not negligible, as for a U-tube manometer, and if the process fluid is either steam, other condensable fluid, water hotter than 250 Deg. F, other fluid that may flash, or moisture laden air then condensate pots shall be used. The pots shall have a volume not less than three times the displaced volume.

1. A pair of condensate pots shall be at the same elevation and as high as, or higher than, the

higher process connection.

2. The pipe from a process connection to a condensate pot shall be insulated for process fluids hotter than 250 Deg. F.

3. A pair of head-type sensing lines shall be run together to the maximum extent practical so as

to keep both lines at the same temperature. If they are to be insulated, they shall be insulated together.

4. Head-type sensing lines shall be checked to make sure that they are connected to the proper

sides, HP and LP, of the instrument.

5. The edges of the holes for orifice taps shall be square or slightly rounded, clean, and free from burrs, wire edges, or other irregularities.

6. A pair of head-type sensing lines shall have an equalizing manifold with bleed valves. Due to

support problems, commercial manifold assemblies with flanged outlets shall not be used in seismic applications, nor is their use recommended for other applications.

7. Flow meter Installation Criteria: The following table lists the straight pipe run requirement up

stream and downstream of each type of meter in terms of the number of required pipe diameters.

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TYPE UPSTREAM DOWNSTREAM

Orifice plates 20 5

Venturi Tubes 20 5

Pitot Tubes 40 10

Propeller Meters 15 4

Ultrasonic Meters 10 5

Magnetic Meters 5 3

I. Instrument Installation Notes - Level: The lower connection on a vessel for piping to a level instrument is preferred to be on the side of the vessel rather than to come vertically down from the bottom. The intent is to minimize the trapping of solids in the sensing lines.

1. Head-type level instruments shall be located below the process connections on the vesselunless a gas purge is used, in which case the instruments may be located at any convenientelevation.

2. A stilling well shall be used in all cases to reduce the turbulence for displacement or float-typeelements located inside a vessel, except for rotary-type floats. A well may be required toprotect a bubble tube against excessive turbulence.

3. So far as practical, level devices shall be placed away from areas of turbulence and shall notinterfere with other vessel parts or instruments, such as thermowells or sample nozzles thatmay be required.

4. Stilling wells and bubble tubes shall be firmly supported. Head room shall be provided topermit withdrawing the tubes for cleaning and maintenance.

5. Gage glasses and their associated level instruments shall be installed adjacent to each other.The gage glasses and the other instruments shall be visible from a walkway.

6. External-chamber level instruments shall be installed with main-line-class pipe. Gate valvesshall be used for root valves and other shutoff valves for these instruments, except that themanufacturer's standard pattern may be used for gage-glass valves.

7. An external-chamber instrument or a differential-pressure-type instrument used to measurelevel in a vessel that is open to atmosphere may have one of its input connections, asappropriate, open to atmosphere instead of being connected to the vessel. An external-chamber instrument thus installed may require additional bracing.

8. A pair of sensing lines for head-type level measurement shall have an equalizing manifoldwith bleed valves. Because of support problems, commercial manifold assemblies havingflanged outlets shall not be used in seismic applications. In other applications, their use is notrecommended for the same reason.

9. The usual level-instrument connections on vessels are:

Head-type instruments:

Piped 3/4" Flanged-mounted 3"

Float or Displacement-type Switches 1-1/2" Displacement-type Transmitters and Controllers:

External 1-1/2" or 2" Internal 4"

Multi-instrument standpipes 3"

10. Displacement and float-type level instruments shall be placed as close as possible to thevessel to improve response. If any external-chamber instrument or a standpipe unavoidably

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cannot be located close to the vessel, the size of the connecting pipes shall be enlarged to facilitate the transfer of liquid on level changes, thereby reducing the loss of response caused by the long sensing and equalizing lines. The ENGINEER shall be consulted in such a case.

J. Instrument Installation Notes - Pressure Differential / Pressure Indicator Transmitter: Condensate

pots are not required for a sensing element, e.g., a force-balance transmitter that has negligible dynamic displacement. If displacement is not negligible as for a U-tube manometer, and if the process fluid is either steam, other condensable fluid, water hotter than 250

oF, or other fluid that

may flash, then condensate pots shall be used. The pots shall have a volume not less than three times the displaced volume.

1. A pair differential-pressure sensing lines shall be run together to the maximum extent practical

so as to keep both lines at the same temperature. If they are not to be insulated, they shall be insulated together.

2. A pair of condensate pots must be at the same elevation and as high as or higher than the

higher process connection.

3. The pipe from a process connection to a condensate pot shall be insulated for process fluids hotter than 250

oF.

4. The differential-pressure sensing lines shall be checked to make sure that they are connected

to the proper sides, HP and LP, of the instrument.

5. A pair of differential-pressure sensing lines shall have an equalizing manifold with bleed valves. Because of support problems, commercial manifold assemblies having flanged outlets shall not be used in seismic applications. In other applications, their use is not recommended for the same reason.

K. Instrument Installation Notes - Pneumatic: Air supply headers shall be sized as noted on the

P&ID. Air-supply branch taps shall come off the top of the header but may come off the side if necessary.

1. Lines for air that is not dry shall be sloped. Dry air lines shall be sloped where possible. Low

points shall have drain connections. Air header drains shall be 1/2" size.

2. Branch isolation valves shall be installed as required to reduce interdependence of branches and to facilitate maintenance.

3. Each pneumatic instrument shall have a local 5-Micron air filter, which may be part of an air

set if the supply pressure is required to be reduced. When pressure is reduced for an instrument, a relief valve, which may be integral with the reducing regulator in an air set is generally required. The regulator shall be provided with a small output-pressure gage if the instrument does not have a supply-pressure gage.

4. Lubricated air may be required for certain piston actuators or other devices, but shall not be

used for any other pneumatic devices. If necessary use a local lubricator.

L. Instrument Installation Notes - Temperature: If a non-standard well or sensor is to be connected to the process pipe or vessel, it is necessary to make sure that there is internal clearance for insertion and that no excessive obstruction to flow is created.

1. Direct-connected readout instruments, e.g., thermometers or indicating transmitters, shall be

located near the most convenient point of use consistent with good measuring practice.

2. Filled-system temperature instruments shall be located in compliance with the manufacturer's limitations, if any, regarding (a) relative elevations of bulb and measuring instrument, and (b) ambient temperatures.

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3. Pressure and Temperature instruments shall be installed to minimize exposure to shock, vibration, and radioactivity, and to avoid temperature extremes.

4. Instruments shall not block walkways. For use, calibration, and repair, they shall be

accessible without requiring instrument disassembly or the removal of piping, grating, or other structure.

5. Where a pipe is reduced or enlarged for a temperature connection, consideration shall be

given to the orientation of the pipe and the possibility of the change of pipe size causing high- or low-point pockets that may affect the measurement by entrapment of material or that may accumulate a radioactive substance.

6. Temperature connections shall be located to provide external clearance for insertion and

removal of their sensing elements.

7. The materials and pressure-temperature ratings of pipe fittings used for temperature connections shall conform to the applicable pipe class.

8. Welding shall conform to project requirements.

9. A temperature-well connection to a pipe, which is made by weld-attachment of a fitting or

nozzle, shall be drilled to have a hole approximately the same size as the inside diameter of the fitting or nozzle. The intent is to provide clearance for insertion of the well and to minimize the entrapping of fluid.

10. For threaded connections of stainless steel to stainless steel, lubrication is required to prevent

seizing and galling.

11. Filled-system temperature elements shall be sealed to the instrument by the instrument manufacturer and are not repairable in the field. Filled systems shall not be opened or cut during installation, and shall be routed and protected as required to guard against damage. Excess lengths of capillary tubing for filled systems shall be neatly coiled in a protected area or enclosure, e.g., coiled inside a protective shipping cap for 12 inch pipe, preferably avoiding ambient temperature extremes.

12. Manufacturer's installation requirements, including those relating to unsupported span and

minimum bend-radius of capillary tubing, shall be followed.

M. Calibration: Analog PI&CS equipment shall be calibrated and tested after installation to verify that contract system requirements are satisfied.

1. The Instrumentation Subcontractor shall provide all necessary labor, tools, and equipment to

calibrate and test each instrument in accordance with the manufacturer's specifications and instructions.

2. Each instrument shall be calibrated at a minimum of three points using test equipment to

simulate inputs and read outputs. A fewer number of calibration steps may be used for selected instruments if prior written approval has been obtained from the ENGINEER.

3. All test equipment and instruments used to simulate inputs and read outputs shall be suitable

for the purpose intended and shall have a current calibration record certified to an accuracy greater than that required for the instrument under test. Such test equipment shall have accuracy traceable to the National Bureau of Standards as applicable. All analog instruments shall be calibrated and tested in place without removal.

4. All test data shall be entered on test forms. These test forms shall verify compliance with all

applicable contract accuracy requirements, instrument manufacturer published performance specifications and permissible tolerances at each point of calibration.

ADDENDUM 2



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5. A report shall be delivered to the ENGINEER for each instrument, certifying that the instrument has been calibrated, in the presence of the ENGINEER or the ENGINEER's designated representative and meets contract and system requirements. The report shall include but not be limited to pertinent manufacturers name plate data, units span setting, any error in percent at each test point, switch and alarm set points, valve stroking and controller balancing information, etc.

N. Analog Loop Tests: The Instrumentation Subcontractor shall provide all necessary labor, tools,

and equipment to field test, inspect and adjust each instrument installed under this contract to its specified performance requirement in accordance with manufacturer's specifications and instructions. Any instrument furnished by the Instrumentation Subcontractor which fails to meet any Contract requirement, or any published manufacturer performance specification for functional and operational parameters, shall be repaired or replaced, by Instrumentation Subcontractor at no cost to the CITY. The Instrumentation Subcontractor shall bear all costs and provide all personnel, equipment and materials necessary to implement all installation tests and inspection activities specified herein. Loop tests shall include verification of the proper register locations and values for all HMI signals (PLC, and DCS).

1. At least 15 days before the anticipated initiation of installation testing, the Instrumentation

Subcontractor shall submit to the ENGINEER a detailed description, in duplicate, of the installation tests to be conducted to demonstrate the correct installation of the PI&CS and the anticipated dates the testing will occur.

2. Elements such as controllers, electronic function modules, etc., shall be tested and exercised

by the Instrumentation Subcontractor to demonstrate correct operation, first individually and then collectively as functional analog networks. Each hardwired analog control network shall be tested to verify proper performance within specified accuracy tolerances. Specified accuracy tolerances for each analog network shall be defined as the root-mean-square (RMS) summation of individual component accuracy requirements. Individual component accuracy requirements shall be as specified by contract requirements or by published manufacturer accuracy specifications, whenever contract accuracy requirements are not specified.

3. Each analog network shall be tested by applying simulated analog and/or discrete inputs to

the first element(s) of an analog network (i.e., applying simulated analog and/or discrete signals to element(s) of the network; e.g., controllers, alarms, indicators, valve operators, etc.). For networks which incorporate analog elements, simulated sensor inputs corresponding to 10 percent, 50 percent, and 90 percent of span shall be applied, and the resulting element outputs read to verify compliance to calculated root-mean-square- summation accuracy tolerance requirements. Continuously variable analog inputs shall be applied to verify the proper operation and setting off discrete devices (i.e., alarms, etc.). Provisional settings shall be made on controllers, alarms, etc., during analog loop tests. All analog loop test data shall be recorded on test forms, which include calculated root-mean-square-summation system accuracy tolerance requirements for each output.

4. Air systems shall be tested for leaks in compliance with ISA RP7.1. When installation tests

have been successfully completed for all individual instruments and all separate analog control networks, a certified copy of all test forms signed by the ENGINEER or the ENGINEER's representative as a witness, with test data entered, shall be furnished to the CITY together with an unequivocal statement that all instrumentation has been successfully calibrated, inspected, and tested.

5. If any Contractor supplied device fails to indicate within required tolerance, the Contractor shall make corrections to the loop as necessary and the test shall be repeated until all outputs are within tolerance. If any final element moves in the wrong direction or fails to move over the required range, corrections shall be made as necessary and the test repeated until final element action is correct.

ADDENDUM 2



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6. All circuit modifications required to pass the Loop Tests shall be incorporated into the As-built / Record Drawings and O & M Manual. The loop drawings shall match the existing loop drawing format (consult ENGINEER for sample).

O. System Pre-commissioning: System pre-commissioning shall comply with the requirements

specified herein. Pre-commissioning shall commence after acceptance of all wire, calibrating and loop tests, and all inspections have demonstrated that the PI&CS complies with all contract requirements. Pre-commissioning shall demonstrate proper operation of all systems under this Contract with process equipment operating over full operating ranges under actual operating conditions.

1. All pre-commissioning and test activities shall follow detailed test procedures, check lists, etc.,

previously developed by the Instrumentation Subcontractor and reviewed and accepted by the ENGINEER. All test data shall be acquired using equipment as specified and recorded on test forms, previously reviewed by the ENGINEER, which include calculated tolerance limits for each step. Completion of all system pre-commissioning and test activities shall be documented by a certified report, including all test forms with test data entered, delivered to the ENGINEER with a clear and unequivocal statement that all system pre-commissioning and test requirements have been satisfied.

2. The proper operation of all final control elements, control panels and instrumentation

furnished under this Contract shall be verified by tests conducted in accordance with the requirements specified herein. Where feasible, system pre-commissioning activities shall include the use of water to establish service conditions that simulate, to the greatest extent possible, normal final control element operating conditions in terms of applied process loads, operating ranges and environmental conditions. Final control elements, control panels, and ancillary equipment shall be tested under start-up and steady-state operating conditions to verify that proper and stable control is achieved using motor control center and local field mounted control circuits. All hardwired and software control circuit interlocks and alarms shall be operational. The control of final control elements and ancillary equipment shall be tested using both manual and automatic (where provided) control circuits. The stable steady-state operation of final control elements running under the control of field mounted automatic analog controllers or software based controllers shall be assured by adjusting the controllers, as required, to eliminate oscillatory final control element operation. The transient stability of final control elements operating under the control of field mounted, and software based automatic analog controllers shall be verified by applying control signal disturbances, monitoring the amplitude and decay rate of control parameter oscillations (if any) and making necessary controller adjustments, as required, to eliminate excessive oscillatory amplitudes and decay rates.

3. All electronic control stations incorporating proportional, integral and/or differential control

circuits shall be optimally tuned, experimentally, by applying control signal disturbances and adjusting the gain, reset and/or rate setting(s) as required to achieve a proper response. Measured final control element variable position/speed setpoint settings shall be compared to measured final control element position/speed values at 10 percent, 25 percent, 50 percent, 75 percent and 90 percent of span and the results checked against specified accuracy tolerances. Specified accuracy tolerances are defined as the root-mean-square-summation of individual component accuracy requirements. Individual component accuracy requirements shall be as specified in the Contract or as specified by published manufacturer accuracy specifications whenever Contract accuracy requirements are not specified.

4. The Contractor shall submit an instrumentation and control system Pre-commissioning

Completion Report, which shall state that all Contract requirements have been met, and shall include a listing of all instrumentation and control system maintenance/repair activities conducted during the pre-commissioning testing. Acceptance of the instrumentation and control system pre-commissioning testing must be provided by the ENGINEER in writing before the 30-Day Performance Testing may begin. Final acceptance of the control system

ADDENDUM 2



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shall be upon contract completion as stated in the GENERAL CONDITIONS, Section 01770: Project Closeout.

P. 30-Day Performance Testing: The Instrumentation Subcontractor shall provide start-up support to include the Instrumentation Subcontractor's personnel, electrical personnel, and any instrument manufacturers’ representatives as required during the testing period to produce a fully operational system. This support shall be provided at no additional cost to the CITY. The 30-day performance test shall be successfully completed to the satisfaction of the Engineer prior to issuing the Statement of Completion.

Q. Record Drawings: Keep current an approved set of complete loop and schematic diagrams which shall include all field and panel wiring, piping/tubing runs, routing, mounting details, point-to-point diagrams with cable, wire, tube and termination numbers. These drawings shall include all instruments and instrument elements for the complete instrument loop as furnished under Divisions 13, 15, 16 and 17 of this contract. Drawings shall be a record of work as actually constructed and shall be prepared and submitted as specified in the GENERAL REQUIREMENTS.

3.5 INSTRUMENT LOOP DESCRIPTIONS -- SEE ATTACHMENT "A" (FUNCTIONAL LOOP DESCRIPTIONS)

3.6 INSTRUMENT AND I/O SUMMARY -- SEE ATTACHMENT "B" (INSTRUMENT AND I/O SUMMARY)

A. General: An Instrument and I/O Summary has been compiled for most instruments specified to be furnished under this contract.

B. This index is intended to complement the plans and specifications and shall not be construed as representing a complete itemization of instruments specified to be furnished under this contract. Instruments and I/O not presently included in the index but which can be inferred from the Contract Documents and/or are required elsewhere herein shall be included and incorporated into the instrument and I/O summary.

3.7 INSTRUMENT DATA SHEETS -- SEE ATTACHMENT "C" (INSTRUMENT DATA SHEETS)

A. General: Data sheets have been prepared for most instruments specified to be furnished under this project.

B. The data sheets are intended to complement the Instrument and I/O Summary, plans and specifications and shall not be construed as representing a complete itemization of instruments specified to be furnished under this Contract.

3.8 CALIBRATION AND TEST FORMS -- SEE ATTACHMENT "D" (CALIBRATION AND TEST FORMS)

END OF SECTION

ADDENDUM 2

SECTION 11840 MECHANICALLY-RAKED BAR SCREENS - ADDENDUM 2

(Sole Source)

PART 1 -- GENERAL

1.1 THE REQUIREMENT

A. The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated on the Drawings and specified herein.

B. The CONTRACTOR shall furnish and install eight (8) Mechanically-Raked Bar Screens and appurtenant work as shown, complete and operable, including screens, rakes, drives, mounts, spare parts and all other accessories and appurtenances, in accordance with the Contract Documents.

C. Bar Screen manufacturer has been sole sourced. The CONTRACTOR shall supply Bar Screens manufactured by Headworks Inc.

D. The Mechanically-Raked Bar Screens shall be installed in the existing channels which are 10.0 feet wide by 14.17 feet deep (operating floor to bottom of channel). Each Bar Screen shall be capable of passing 133 million gallons per day of sanitary sewage with a maximum water depth in the channel of 11.5 feet. Screenings shall be mechanically raised on screen to the dead plate and automatically discharged to a discharge chute and into the sluiceway. The screenings diverter chute and transition chute shall be installed between the discharge chute and the sluiceway.

E. The Bar Screens supplier shall design the sluiceway to convey screenings to three existing Chopper Pumps and two existing Grinders and Compactors as specified herein and as shown on the Contract Drawings. The CONTRACTOR shall coordinate to ensure that the discharge arrangements for the sluiceway and the inlet arrangements for the existing Chopper Pumps and Grinders are compatible.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. Section 11000 Equipment General Provisions.

B. Section 09800 Protective Coating.

C. Section 05500 Miscellaneous Metalwork.

D. Section 15020 Noise, Vibration and Seismic Control.

E. Section 16010 Wastewater Facilities General Electrical Requirements.

F. Section 16490 Electric Motors.

G. Section 17400 Process Instrumentation and Control.

1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS

A. Comply with the applicable reference specifications as specified in the GENERAL REQUIREMENTS.

1.4 CONTRACTOR SUBMITTALS

A. Submittals shall be made in accordance with the GENERAL REQUIREMENTS.

B. Comply with Section 11000, "Equipment General Provisions" and Contract Drawings.

HTP CIP 2409 MECHANICALLY-RAKED BAR SCREENS HEADWORKS IMPROVEMENTS DIVISION 11 07/06/2016 11840-1

C. The following submittals and specific information shall be provided.

D. The manufacturer shall submit a General Arrangement Drawing that illustrates the layout of the equipment, principal dimensions and other related data including head loss calculations of Bar Screens and sluiceway, descriptive literature, Electrical Control Drawings, Catalog Cut Sheets for individual components and Drive Motor data.

E. Submit location of the nearest permanent service headquarters of the screen and motor manufacturer for the screen and motor submitted.

F. Submit operating instructions with descriptive literature, including a cross-sectional view of screen and motor combination, which indicates materials of construction, weights, principle dimensions and other important details.

G. Submit evidence of experience in the form of an installation list with contact names and phone numbers.

H. Submit an installation plan including a methodology for lifting the Bar Screens into the Screen Channels of the Headworks Building - Screen Room through existing east roll-up door with rough opening of 11'-7" wide x 12'-2" height or west roll-up door with rough opening of 11'-7" wide x 11'-2" height.

I. Bar Screen anchorage calculations including cover plates with structural steel members shall be prepared, stamped, and signed by a Structural Engineer, currently registered in the State of California. Calculations for post-installed anchors into concrete shall be in conformance with current ACI 318-XX, Appendix D requirements.

1.5 QUALITY ASSURANCE

A. Comply with the applicable subsections of Section 11000, "Equipment General Provisions."

B. The CONTRACTOR shall provide the services of a trained, qualified manufacturer's representative for eight (8) working days based on four (4) trips to assist, check, and certify the installation, start-up of the equipment, and instruct the CITY's operational personnel. If additional services are required to produce a fully operational system, they shall be provided at no cost to the CITY.

C. All materials used shall be new, of high grade, and with properties best suited to the working environment.

D. Manufacturer shall be successful in the experience of manufacture, operation, and servicing of equipment of type, size, quality, performance, and reliability equal to that specified. The manufacturer shall submit evidence of experience having supplied at least twenty-five (25) similar bar screens within the last 5 years. The manufacturer shall also submit evidence of experience having supplied at least twenty-five (25) installations of similar type and size in the USA that have been in successful operation for at least five (5) years.

1.6 DELIVERY, STORAGE AND HANDLING

A. Shipping

1. Ship equipment, material, and spare parts complete except where partial disassembly isrequired by transportation regulations or for protection of components.

2. Pack spare parts in containers bearing labels clearly designating contents and pieces ofequipment for which they are intended.


ADDENDUM 2

B. Receiving

1. Store and safeguard equipment, material, and spare parts.

PART 2 -- PRODUCTS

2.1 EQUIPMENT REQUIREMENTS

A. General: The CONTRACTOR shall furnish and install Mechanically-Raked Bar Screens. The system shall operate by means of a bar screen to retain debris, and a traveling rake mechanism to elevate the debris along the upstream side of the bar screen from the channel invert to the discharge chute. The debris shall then be removed from the rake by a scrapper, and fall through a discharge chute into a sluiceway.

B. Construction: The equipment to be furnished and installed shall be an automatic, self-cleaning Bar Screen of the front cleaned type with a continuous rake entering the bar rack from the upstream side. All designs shall ensure that the maintenance to the mechanisms such as motors, drives, bearings be accomplished at the operating floor level without the use of access ladders or dewatering the channel.

C. The equipment shall be readily adaptable for installation and operation in the structure shown. If equipment which requires a change or modification of the design shown is submitted and accepted, the CONTRACTOR shall prepare and submit for approval, drawings showing all the necessary changes. Such changes shall be made at the CONTRACTOR's own expense and shall include all mechanical, structural, and electrical work.

D. Capacity: Each Bar Screen shall have the following capacity:

1. Bar Screen Identification Numbers - 2701-02 to 2701-09

2. Location - Screen Building

3. Number of Bar Screens - 8

4. Channel Width (feet) - 10.0

5. Channel Depth (feet) - 14.17

6. Maximum Upstream Water Depth (feet) - 11.5

7. Maximum Flow per Bar Screen (MGD) - 133.0

8. Bar Screen Field Width (feet) - 9.0

9. Clear Spacing between Bars (inches) - 0.375 (2701-02, 2701-04, 2701-06 & 2701-08)

10. Maximum head loss at 30% blinding (inches) - 5.52 (at approach velocity of 4.0 ft/s)

11. Clear Spacing between Bars (inches) - 0.75 (2701-03, 2701-05, 2701-07 & 2701-09)

12. Maximum head loss at 30% blinding (inches) - 4.20 (at approach velocity of 4.0 ft/s)

E. Materials: All materials used shall be Type 316 stainless steel suitable for service in a moist, corrosive environment as encountered in wastewater treatment plants.

F. Stainless Steel Bolts: Bolts, anchor bolts, nuts, and washers shall be of Type 316 stainless steel. Wherever stainless steel bolts and nuts are specified, it shall refer to the above material combination, unless specifically excluded.


ADDENDUM 2

G. Anchors: All anchors bolts, nuts, and washers shall be Type 316 stainless steel and shall have the City of Los Angeles Department of Building and Safety Research Report (LARR) numbers.

H. The manufacturer shall state in the operating manual the amount of and specification for any lubricant required. The CONTRACTOR shall have the manufacturer supply the initial lubrication and all necessary sealing fluids.

2.2 BAR SCREEN

A. Screen to be mechanically cleaned. The incline of Bar Screen shall be 15 degrees from vertical.

B. Rakes shall approach channel invert from upstream side of screen and rake upward at upstream face with tines between the bars.

C. The screen shall be designed to be pulled out of the channel. Rubber side seals shall seal between the Bar Screen frame and channel walls. Rubber top seals shall seal gaps between the Bar Screen frame and operating floor.

D. The screenings shall be discharged on downstream side of screen to a sluiceway.

E. The screen frame shall be supplied and delivered requiring no field assembly or field assembly as applicable per Paragraph 1.4-H of this Specification.

F. Framework of screen shall be constructed of Type 316 stainless steel and cross section with a minimum thickness of 0.1575" (4mm). Various parts fastened by welding, riveting, or bolting shall be braced as necessary to ensure a rigid structure. The side frames shall be minimum 0.1575" (4mm) formed to a channel profile. The bottom thickness shall be 0.1575" (4mm). The frame shall have support beams with U-profile thickness of 0.1575" (4mm) on the front above the maximum water line. Wraparound Type 316 stainless steel stiffeners with a thickness of 0.1575" (4mm) formed to a channel profile shall be placed along the screen frame above the maximum design water depth for rigidity. No braces, gussets or stiffeners shall be inside the Screen Frame that will allow for screenings to collect.

G. All bolts, nuts, washers, and fasteners shall be Type 316 stainless steel. Bar Screens and all other accessories and appurtenances such as discharge chutes, diverter chutes, transition chutes, sluiceway with HPE internal spray wash and level switch, covers, etc. shall be fully enclosed and sealed with gaskets made of Buna-N.

H. Equipment Suppliers shall furnish calculations establishing the number, size, type, length, and embedment of Type 316 stainless steel anchor bolts required to mount the equipment safely in accordance with the Seismic characteristics prescribed by the specifications. The installing CONTRACTOR shall supply suitable anchor bolts for each item of equipment in accordance with the equipment Supplier's recommendations, as approved by the Engineer.

I. Screen bars shall be constructed of Type 316 stainless steel. The bar rack shall consist of continuous taper section bars. Round or rectangular bars shall not be used. The dimensions of the bars shall be 0.31" x 0.15" x 1.57" (8mm x 4mm x 40mm).

1. Bars shall be supported from framework and be readily removable. The screen bars shallbe individually replaceable without any welding or cutting. Screen bars that are welded tothe framework or welded into sub-assemblies shall not be allowed. Replacement screenbars shall be available from the screen manufacturer.

2. Bars shall be fastened to a dead plate that extends to the point of discharge. Bars shallextend a minimum of 7.8" (200mm) above the maximum water level.


ADDENDUM 2

3. The screen field shall be accurately constructed to give a clear opening of 0.375" betweenthe bars. There shall be no space wider than the opening between the bars which wouldpermit passage of larger solids through the screen.

J. The dead plate of Type 316 stainless steel plate, minimum thickness of 0.1575" (4mm), shall extend to the point of discharge. The dead plate shall be true and flat such that a close clearance between the raking tines and the plate can be maintained during the cleaning cycle. The back side of the dead plate shall be constructed to guarantee a maximum gap between rake bar and dead plate, leading to the discharge chute without interruption.

K. The raking tines shall have the tooth profile precision cut from a single continuous bar of sufficient thickness and depth to insure adequate stiffness and strength to cope with the specified duty cycle. The rakes shall run in guides on both sides to ensure engagement. The rakes shall clean the bars from the upstream side of the screen. The rakes shall be fabricated from Type 316 stainless steel.

1. The rake material thickness shall be as follows:

a. Thickness of rake bar 0.4724" (12mm)

b. Reinforcement profile 0.2362" (6mm)

c. Side sheets 0.375" (10mm)

2. The rake capacity shall be as follows:

a. Capacity / Rake Bar: 0.183 ft3 / ft (0.017m3/meter) Screen Field Width (SFW)

b. Total Screen Capacity at approximate 10 second cleaning interval: 593 ft3/h(0.183 ft3 x SFW x 360)

c. Total Screen Capacity at approximate 5 second cleaning interval: 1,186 ft3/h(0.183 ft3 x SFW x 720)

3. The rakes shall have a shovel shape to prevent screenings from falling back to the channel.Flat rakes without this feature are not permitted. Rake tines shall penetrate into the screenbar spacing to insure that screenings are completely cleared during each lifting operation.Rake tines are mechanically engaged into the screen bars. During each cleaning stroke,the raking tines shall engage into the bottom of the bar screen grids at the channel invert.Drive chains, chain guides, chain sprockets, bearings, and axles shall be fully replaceablewithout having to remove the screen from the channel.

L. Screenings transported to the top of the screen shall be discharged positively by means of a Type 316 stainless steel scraper mechanism to the discharge chute. The scraper mechanism shall be fitted with a compression spring that allows the scraper to return to its resting position smoothly without any shock. A scraper blade made of a combination of synthetic and other material shall be provided on the scraper.

M. The drive mechanism for the rakes shall incorporate a solid shaft constructed of Type 316 stainless steel. The drive shaft shall be a solid shaft constructed of Type 316 stainless steel.

N. The upper sprocket shall be solid and made of Type 316 stainless steel. The Upper Sprocket shall have a 6.3" (160mm) pitch and a tooth width of minimum 1.063" (27mm). No split sprockets shall be used.


ADDENDUM 2

O. Upper bearings shall be UCFX 4 - bolt flange bearings or equal mounted in the take-up frame assembly. The bearings shall be grease-lubricated. The take-up screw shall be an Acme lead screw made of 18-8 stainless steel. No threaded rod shall be allowed.

P. The lower sprocket shall be solid and made of type 316 stainless steel. The lower sprocket shall have a 6.3" (160mm) pitch, a tooth width of minimum 1.063" (27mm) and a bore of 2.756" (70mm). No split sprockets shall be used.

Q. Bearings for lower submerged sprockets shall be of proven self-lubricating PE (Polyethylene) material and maintenance-free. A ceramic collar-type Headworks® Technox Zirconia Diamond Ceramic shall be bonded onto the stub shaft. No metallic lower bearings or bushing shall be allowed. No lower bearing requiring lubrication shall be allowed.

R. Chains shall be heavy duty roller type with a minimum weight of 6 lbs/ft and made of Type 316 stainless steel of high tensile strength and resistance to corrosion. Chain rollers shall be Type 316 stainless steel. The average ultimate strength of the chain shall be minimum 31,000 pound-force (137,500 Newtons). Chain pins shall be Type 316 stainless steel and hardened.

S. A chain guide shall be securely fixed to the screen frame for the full height of travel and shall not protrude into the flow. The chain guide shall be Type 316 stainless steel L-Profile type with size and thickness 2.65"/1.38"/0.19" (65/35/5mm). Replaceable wear strips on chain guides located below the water level shall not be allowed.

T. The motor, gear box and other components shall be designed to lift the weight of screenings from a Bar Screen. The drive motor shall be 5 HP minimum. The motor shall be an inverter duty rated motor with a 1.15 service factor, rated for continuous duty. The motor shall be controlled by a VFD (variable frequency drive), rated for continuous operation. The drive unit, including the reduction gearbox, shall be directly shaft-mounted and shall be positioned to facilitate maintenance work. The drive motor shall be a TEFC, explosion-proof, heavy-duty type suitable for Class I, Division 2 location, and 480-volt, 3-phase, 60-Hz supply in accordance with Section 16490, "Electric Motors."

U. A VFD (variable frequency drive) and a PLC (programmable logic controller) shall be provided for each Bar Screen. The VFDs shall comply with Section 16310, "Variable Frequency Drive Units." The PLCs shall comply with Section 17400, "Treatment Plant Process Instrumentation and Control."

1. The VFD shall have solid state overload integral. On meeting a blockage, the device shallbe able to automatically reverse the direction of travel of the raking mechanism for anadjustable distance and revert to the forward motion to try and clear the blockage. Thisreversing action can occur to a maximum of three times for any one obstruction. Thedevice shall re-set automatically if the blockage causing the initial overload condition iscleared; or, should the blockage remain upon the completion of the fourth attempt, thescreen shall be tripped and an alarm generated. The reverse function shall be effective onlyin the low speed mode.

V. The rake mechanism shall be capable of 2 cleaning speeds. Normal speed shall have an approximate ten second cleaning interval and high speed shall have an approximate five second cleaning interval. Bar Screens which do not meet these performance criteria shall not be considered.

W. A discharge chute, minimum thickness of 0.1575" (4mm) with a transition chute shall be provided and designed with 0.1-inch vacuum minimum for each Bar Screen to divert screenings discharged from the screen to a sluiceway. The discharge chute and transition chute shall be made of Type 316 Stainless Steel. The discharge chute shall be mounted at an angle of 30 degrees.


ADDENDUM 2

X. A screenings diverter chute made of Type 316 Stainless Steel shall be provided for each Bar Screen and designed with 0.1-inch vacuum minimum. The screenings diverter chute shall direct screenings into the transition chute for discharge into the sluiceway or, by engaging a lever, re-direct screenings to a dumpster (provided by others) adjacent to the sluiceway. The transition chute shall bolt to the screenings diverter chute. Gaskets shall be made of Buna-N.

Y. Covers which are easily removable shall be provided for easy maintenance and designed with 0.1-inch vacuum minimum. Covers shall be constructed of clear impact-resistant polycarbonate material, minimum thickness of 0.25" (6mm) to allow for visual observation during screen operation.

Z. The discharge chute and top of screen shall be fully enclosed and designed with 0.1-inch vacuum minimum. The top of the frame shall be covered with an 11 gauge minimum (3mm) Type 316 stainless steel cover, bolted to the front and back of the screen frame. The sides of the top cover shall be bent to overlap the side frames. The discharge chute shall be enclosed from the top of the frame to the bottom of the chute. The chute and chute enclosure shall be manufactured from a single piece of 0.1575" minimum (4mm) Type 316 stainless steel. The enclosure shall include an access opening with cover. The cover shall be easily removable for maintenance. The cover shall be made of 0.375" (10mm) thick clear, impact-resistant, polycarbonate to allow for visual inspection during screen operation. The polycarbonate cover shall have Type 316 stainless steel handles and be attached to the chute enclosure by four (4) Type 316 stainless steel threaded knobs. The access opening shall be approximately 96" wide by 18" tall.

AA. The Bar Screen Manufacturer shall be responsible for the detailed design of the sluiceway to accept the screenings from the Bar Screens and convey them through three 10" knife gates and piping lines to direct flow to three existing 10" Chopper Pumps and one slide gate to direct the flow to two existing Grinders and Compactors. The sluiceway, minimum 24" wide, shall be fully enclosed and designed with a peak flow of 900 GPM of screenings with a maximum suspended solids concentration of 2% and a minimum of 0.1 inches vacuum. The sluiceway shall have a minimum slope of 1.125% and shall be fabricated from Type 316 stainless steel with both types of clear impact-resistant polycarbonate and Type 316 stainless steel covers. The covers shall have Type 316 stainless steel handles, Type 316 stainless steel friction hinges on one side, and Type 316 stainless steel four pronged blind tapped knobs and swing bolt assemblies on the other side. The sluiceway and covers with gaskets shall be designed with notches at swing bolt assemblies to allow opening of covers without completely removing the knobs from the swing bolts. The design to open covers by completely removing the knobs from the swing bolts shall not be used. Friction hinges shall be designed to hold covers at any angle of 180° range of motion. Each section of hinged cover shall be 5'-6" long maximum with gaskets permanently attached to undersides of covers. A tentative design is shown on the Contract PD Drawings. However, this is merely a possible design and the Manufacturer shall be responsible for the hydraulic and structural design of the sluiceway including its supports and appurtenances. The sluiceway shall be made of either a seamless or welded construction with minimum flanged connections to minimize the potential for future leaks. Thickness of polycarbonate covers shall be 0.25" minimum. Gaskets shall be made of Buna-N.

1. A Level Switch (Float Type) shall be provided, installed, and integrated with the sluiceway inaccordance with Section 17400, "Process Instrumentation and Control" Paragraph 2.5-Dand as shown on Contract Drawings.

2. Type 316 stainless steel hinged covers as specified herein shall also be provided for theexisting sluiceway from tie-in to existing Grinders 2711-04 and 2711-05.

BB. The Bar Screen Manufacturer shall be responsible for the detailed design of the cover plates for the remaining concrete opening of each Bar Screen as specified herein, in compliance with Design Criteria Tables on Contract Drawing O-S-1, and as shown on Contract Drawings. The cover plates shall be designed to support a medium size forklift with a minimum weight of 14,000 lbs and live load of 125 psf. Cover plates and structural steel members shall be Type 316 stainless steel with Fy of 35ksi minimum.


ADDENDUM 2

1. For wastewater sample collection, each cover plate located upstream of each Bar Screenshall have 2'-0" x 2'-0" opening and access cover with heavy duty 316 stainless steel hingesand locking handle. Location of the 2'-0" x 2'-0" opening and access cover to be submittedfor ENGINEER's review and approval prior to fabrication.

CC. Spare Parts shall be provided for each Bar Screen as follows:

1. Two (2) each, rake bars.

2. One (1) each, five (5) foot strand of chain.

3. Eight (8) each, set of scrapper arm wear pads.

2.3 CONTROL SYSTEM

A. Instrumentation and controls shall be provided by the Manufacturer as specified herein and in accordance with Section 17400, "Process Instrumentation and Control" and as shown on Contract Drawings.

B. A Bar Screen Main Control Panel shall be furnished, completely pre-wired and tested, requiring only wall mounting and connection to external wiring in the field by an Electrical Contractor. The Control Panel shall include all equipment required to control one Bar Screen as specified herein.

C. Control panel enclosure shall be sized as required to house equipment and shall be suitable for wall mounting or mounting to strut-type supports. Enclosure shall be rated NEMA 4X Type 316 stainless steel with a pressurization and purge system for a Class 1, Division 2 Classification Area.

D. Each Bar Screen motor shall be controlled by an individual Allen Bradley PowerFlex 700 Variable Frequency Drive (VFD), sized as required for bar screen motor horsepower and suitable for use with variable torque loads. VFD shall include discrete and analog input and outputs as required by control panel manufacturer. No bypass starters shall be required.

E. The VFD shall be controlled by an Allen Bradley CompactLogix Programmable Logic Controller (PLC). The PLC shall be used to control the VFD to operate the screen at two (2) speeds and through the automatic reversing/cleaning shuttle sequence. The PLC shall include discrete and analog inputs and outputs as required.

F. Each Bar Screen shall be controlled in synchronization with ultrasonic level sensors. Upon reaching a predetermined differential set point the screen shall begin operation in low or normal speed and shall shut down after a predetermined time if the differential level is less than the predetermined set point. Upon reaching a second higher predetermined differential set point the screen shall operate in high speed.

G. When an overcurrent is detected the screen shall automatically stop and run in reverse for a predetermined time. The screen shall then stop and return to forward. If the cause of the overload is cleared the screen shall automatically reset in normal operation. If an overload is again detected the reversing cycle is repeated up to four (4) times prior to initiating an alarm contact. The uses of clutches, friction disks or similar devices for overload protection are not acceptable.

H. The Control Panel shall have an Allen Bradley PanelView Plus 600 Operator Interface Terminal (OIT) to allow push button adjustment of counter values, timers and level set points without connecting to the PLC. The OIT shall be suitable for use with an electrical enclosure using a pressurization and purge system.


ADDENDUM 2

I. A separate Local Operator Station rated NEMA 7 shall be provided. The local operator station shall include Hand/Off/Automatic and Forward/Off/Reverse 3-position switches and an Emergency Stop mushroom pushbutton. The Local Operator Station shall be mounted adjacent to the Bar Screen within easy reach of the Operator.

J. Sequence of Operation: 2-Speed Operation

Main Panel On/Off

Local Panel Hand/Off/Auto &

Fwd/Off/Rev

Result Action when Blockage occurs

Comments

On Auto & Any Position

Screen starts in LSP when the rising water differential reaches set level (Level 1).

Screen performs cleaning shuttle up to 4 times. If no success, screen stops and initiates alarm contact.

LSP - Low Speed Mode. Approx. 10-second cleaning interval

On Auto &

Any Position Screen starts in HSP when the rising water differential reaches set level (Level 2).

Screen performs cleaning shuttle up to 4 times. If no success, screen stops and initiates alarm contact.

HSP - High Speed Mode. Approx. 5-second cleaning interval.

On Auto & Any Position

Exercise run Screen performs cleaning shuttle up to 4 times. If no success, screen stops and initiates alarm signal.

X min in LSP, every Y min. (X & Y are Operator adjustable)

On Manual & Forward

Screen operates forward in LSP.

Screen stops immediately. No cleaning shuttle.

On Manual & Reverse

Screen operates in reverse in LSP.

Screen stops immediately. No cleaning shuttle.

On E-Stop Engaged Screen stops immediately.

N/A

On Off & Any Position

Screen will not operate.

N/A

On Hand & Off


N/A

Off Any Position & Any Position


N/A

2.4 PROTECTIVE COATING

A. Except Type 316 stainless steel material, all ferrous metals and all materials exposed or submerged in wastewater shall be shop coated in accordance with Section 09800, "Protective Coating."

B. Cleaning and finishing of stainless steel equipment:

1. After all fabrication and welding has been completed all stainless steel surfaces shall beGlass Bead Blasted prior to equipment assembly. The Bead Blast shall remove all welddiscoloration and surface contaminants and provide for Spontaneous Passivation asrecognized in ASTM A380-99, Cleaning, Descaling, and Passivation of Stainless SteelParts, Equipment, and Systems, 1. Scope, 1.1.1.1. and 6.2.8 Mechanical Cleaning.

2. CONTRACTOR shall submit the cleaning and passivation procedure in compliance with theabove requirements for ENGINEER's review and approval.


ADDENDUM 2

2.5 MANUFACTURERS

A. The manufacturer of Bar Screens has been sole sourced. Bar Screens made by other manufacturers shall not be considered. The sole sourced manufacturer of Bar Screens is:

1. Headworks Inc.800 Wilcrest Drive, Suite 340Houston, Texas, 77042Wayne McCauley(713) 647-6667

Model: MS 1

B. Manufacturers or models not listed above shall not be accepted.

PART 3 -- EXECUTION

3.1 GENERAL

A. Installation of the Mechanically-Raked Bar Screens shall be in strict accordance with the requirements of the manufacturer's written instructions and Shop Drawings provided that nothing contained in said instructions or Shop Drawings shall authorize the CONTRACTOR to vary from the requirements of the Contract Documents.

B. All parts of the mechanism shall be amply proportioned for stresses that may occur during fabrication, erection, and intermittent or continuous operation. Workmanship shall be of high grade in all respects and of the latest design.

C. The CONTRACTOR shall furnish all labor, materials and test apparatus necessary for conducting the field acceptance tests at no additional cost to the CITY.

3.2 FIELD TESTING

A. Each Mechanically-Raked Bar Screen shall be tested upon completion of the installation. Prior to the test, all equipment shall be adjusted and checked for alignment, clearances, supports, and adherence to safety standards, until found satisfactory.

B. The test shall demonstrate the capabilities of the Bar Screen under both normal and extreme operation. The test shall include a demonstration that the Bar Screen is capable of passing the specified maximum design flow at the design water level. As part of the test the flow through the Bar Screen shall be gradually increased and decreased to demonstrate the capability of the screen mechanism to adjust screen speed in accordance with operating conditions. Test results shall also include head loss and solids screen capture quantities and ratio with total solids contained in wastewater.

C. Throughout the test, all equipment shall operate satisfactory without excessive noise, vibration, jamming, or overheating, and perform its specified function satisfactorily. Once the Bar Screen is placed into service, each Bar Screen shall operate continuously without failure, for a period of 30 consecutive days before being accepted.

D. The sluiceway shall also be tested to ensure that it conveys screenings under all operating conditions to the existing Chopper Pumps or to the existing Grinders and Compactors.

E. Demolition of the next two existing Bar Screens shall not be commenced until the two new Bar Screens have been satisfactorily passed field test and transferred to the CITY for beneficial use.

END OF SECTION


ADDENDUM 2