document 00310 bidding sheet

BIDDER NAME:_____________________________

DOCUMENT 00310 BIDDING SHEET

Price for construction of Colorado River Aqueduct

Access Covers and Water Tank Improvements

Item Description Amount

1 Mobilization for the lump sum of

$ 300,000.00

2 Construction of all work in the contract, except for work covered under the other bid items on this bidding sheet, as specified and shown on the drawings for the lump sum of

$_______________

3 Overburden Excavation and Fill with Class “C” Concrete for the Stairways at Intake, Eagle, and Hinds Pumping Plants.

Quantity Unit Price

$______________ 70 C.Y. $_______

Total of items 1 through 3 $_______________

END OF DOCUMENT

October 5, 2009 00310-1 1562 (construction contract) Addendum 2

September 1, 2009 02680-1 1562 (construction contract) Addendum 2

SECTION 02680

REMOVAL AND DISPOSAL OF QUAGGA MUSSELS AND QUAGGA MUSSEL-INFESTED WATER PART 1 GENERAL

1.01 SCOPE

A. This section specifies the requirements for removal and disposal of dreissenid bugensis (a species of invasive mussel commonly known as the quagga mussel) and disposal of water infested with veligers (quagga larvae that are not visible to the human eye).

B. The untreated water at this work site originated from a source water reservoir known to be infested with quagga mussels. The water at this work site may or may not contain visible quagga mussels; however it is assumed the water does contain veligers. The Contractor shall take all necessary measures to prevent adult quagga mussels or veligers from leaving the job site and entering into uninfested water bodies.

1.02 REFERENCES

A. General

1. The publications listed below form a part of this specification to the extent referenced.

2. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition available on the date of the Notice Inviting Bids shall be used.

B. American National Standards Institute (ANSI)

1. ANSI/NSF 60, Drinking Water Treatment Chemicals

C. California Assembly Bill 1683.

D. California Department of Fish and Game, Boat Cleaning Guide Book

E. Metropolitan Water District of Southern California, Quagga Mussel Control Program – Part II, Water Releases Management Plan, May 30, 2008.

1.03 SUBMITTALS

A. Plans: The Contractor shall submit plans for removal of quagga mussels and disposal of veliger-infested water.

B. Test Reports and Certifications: Certification indicating the calcium hypochlorite or sodium hypochlorite to be used meets the requirements of ANSI/NSF 60 shall be submitted.

C. Test Reports: Certification indicating utilization of free chlorine for inactivation of quagga mussels followed by dechlorination shall be submitted.

D. Permits or Notification: Copies of permits or notifications for disposal of quagga mussel-infested water that are required by authorities having jurisdiction or copies of correspondence confirming that permits or notifications are not required shall be submitted.

PART 2 PRODUCTS

2.01 GENERAL

A. All chemicals and equipment required for removal and disposal of quagga mussels and quagga mussel-infested water shall be provided by the Contractor.

2.02 CHEMICALS AND EQUIPMENT

A. The chemicals shall be certified as meeting the requirements of ANSI/NSF 60 by a product certification organization accredited for this purpose by ANSI.

PART 3 EXECUTION

3.01 GENERAL

A. The Contractor shall not use any construction equipment known or suspect of having been infested with quagga mussels without prior decontamination to ensure that the equipment is “mussel-free”. In addition, all equipment that was in some way in contact with the infested water shall be thoroughly cleaned before moving to another site as specified herein below. Refer to the California Department Fish and Game Boat Cleaning Guide Book for additional information. (http://www.dfg.ca.gov/invasives/quaggamussel/)

Removal and Disposal of Quagga Mussels and Quagga Mussel-Infested Water

1562 02680-2 September 1, 2009 Addendum 2 (construction contract)

B. All equipment that has been in contact with quagga mussel-infested water shall be cleaned, drained and dried for a minimum of 5 days in the summer heat, or up to 30 days in cooler, moist or wet weather prior to being used at another work site. If sufficient drying time is not available for water in recesses to evaporate and/or attached adult mussels to die, decontamination or chlorination is required. Decontamination is accomplished by washing the equipment with scalding hot water of at least 140 degrees Fahrenheit. The Contractor shall take all necessary safety precautions to prevent scalding when working with hot water. Chlorination is accomplished by immersing the equipment in chlorinated water for a minimum contact time of 1 hour with a residual greater than 0.5 mg/L.

3.02 REMOVAL OF MUSSELS FROM EQUIPMENT

A. The Contractor shall thoroughly clean all interior surfaces in contact with untreated water including equipment and accessories to remove mussels. The removal may include scraping, brushing, vacuuming to remove all live mussels, larvae and eggs. All removed items and infested water shall be contained in a holding tank for desiccation prior to disposal as specified herein.

3.03 DISPOSAL OF MUSSELS INFESTED WATER

A. Desiccation (drying out of a living organism) shall be utilized to kill of quagga mussels and veligers. The method of killing mussels, larvae and eggs, and disposal of mussel-infested water must be approved in advance by the Engineer.

B. Disposal of mussel-infested water requires identification of area hydrology and the potential for infestation of downstream water bodies. Water shall be discharged and contained within a secure area such that water cannot spill into an existing water body.

C. Water shall not be disposed into Metropolitan’s conveyance, distribution, or storage systems. Subject to approval of the Engineer in advance, water may be disposed into the reclamation plant or sludge basin if the work is at a water treatment plant and the Contractor did not contaminate the water during the course of its work.

D. Utilization of desiccation will require water to be contained within a secure area until the areas is completely dried due to evaporation and/or percolation.

E. The disposal of dreissenid (invasive mussels) infested water shall be in accordance with the applicable laws and regulations.

F. The Contractor shall obtain permits or make notification for the disposal of water used in disinfection from authorities having jurisdiction.

G. The Contractor shall also conform to the requirements of the Metropolitan discharge permits.

END OF SECTION

October 14, 2009 09900-9 1562 Addendum 2

Painting

C. Upon completion of painting work, masking tape, tarps, and other protective materials shall be removed using care not to scratch or otherwise damage finished surfaces.

Table 1. Paint Products and Conditions for Use Surface System

No. When the surface gets

painted What does it get painted with?

1st coat (DFT) 2nd coat (DFT) 3rd coat (DFT)

Underside coating for Cl2 protection of carbon steel manhole covers and transition covers

CS-1F

Field

AQMD rule 1113 applies to field applications –VOC limit = 100 g/l

Subject to humid, immersed, or non‐UV environment, exterior and interior surfaces of equipment such as pumps, valves, pipe and fittings

(products suitable for application to bare and galvanized prepared steel)

high‐solids epoxy (See notes 1 & 2)

Industrial Environmental Coatings EC 230 (0)

Raven Linings A‐6 (0)

3M Scotchkote 323 (<100)

See note 1

(See Table 2, Test #2)




If required to achieve total dry film thickness of 26 + 4 mils




Architectural carbon steel

CS-2


Exterio bottom of sleceted transition cover plates (see drawings)

The epoxy base coat shall be a contrasting color to the top coats.

1st coat (DFT)

(6‐8.0 mils DFT)

Ameron: Amerlock II VOC (84)

Raven Linings Aquata‐pox A‐6 (0)

2nd coat (DFT)

(6‐8.0 mils DFT)


Raven Linings Aquata‐pox A‐6 (0)

Additional Coats will be applied to achieve a final DFT of 36 to 40 mils

(6‐8.0 mils DFT) Ameron: Amerlock II VOC (84) Raven Linings Aquata-pox A-6 (0)

Architectural carbon steel

NS-4


Exterior steel supports, hand rails, etc

The epoxy base coat shall be a contrasting color to the top coat.

The polyurethane top coat shall be safety yellow, Federal Specification 595 a, Color No. 13655.

1st coat (DFT)

(6‐8.0 mils DFT)


Sherwin Williams Recoatable Epoxy Primer (90)

2nd (6‐8.0 mils DFT) Ameron: Amershield VOC Polyurethane (84) Sherwin Williams HS Polyurethane 100 (66) Raven Linings Aquata-pox A-6 (0)

Notes: 1. Surface cracks or irregularities and expansion joints shall receive extra coating and surface preparation as recommended by the coating

manufacturer and approved by the Engineer. 2. Primer and application rate shall be as recommended by manufacturer's technical data sheet for the appropriate substrate and as approved by

the Engineer.

July 2009 15060-1 1562 (construction contract) Addendum 2

SECTION 15060 GENERAL MECHANICAL PIPING

PART 1 GENERAL

1.01 GENERAL

A. It is required that there be furnished to the Metropolitan Water District of Southern California (Metropolitan), equipment and documentation in accordance with these specifications. Types and quantities are set forth in the drawings and equipment list.

B. All equipment furnished shall be new, unused, and manufactured in accordance with these specifications and the latest manufacturing practices.

C. Equipment shall be tested according to the manufacturer's specifications, and as detailed herein. The Contractor shall furnish all necessary labor, materials, and equipment required for testing and shall accomplish the required tests at no additional cost to Metropolitan.

D. Equipment inspection shall be done at the factory and/or final destination.

E. All piping shall be built and installed in accordance with the following codes, unless otherwise specified:

1. ASME B31.1 for industrial and HVAC piping

2. ASME B31.3 for hydrocarbon and chemical piping.

F. Furnish all labor, materials, equipment, and incidentals, and install complete piping systems including all hangers, supports, restraints, structural connections, concrete inserts, anchor bolts, and expansion units.

1.02 REFERENCES

A. General

1. The publications listed below form a part of this specification to the extent referenced herein. In the event of a conflict between the text of this specification and the references sited herein, the text of this specification shall take precedence.

2. Where a date is given for reference standards, that edition shall be used. Where no date is given for reference standards, the latest edition available on the date of the Notice Inviting Bids shall be used.


1. ANSI/NSF 61, Drinking Water System Components - Health Effects

C. American Society of Mechanical Engineers (ASME)

1. ASME Boiler and Pressure Vessel Code (BPVC)

a. BPVC Section V Nondestructive Examination

b. BPVC Section VIII Rules for Construction of Pressure Vessels

c. BPVC Section IX Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators

2. ASME B1.1, Unified Inch Screw Threads (UN and UNR Thread Form

3. ASME B16.47, Large Diameter Steel Flanges

4. ASME B16.5, Pipe Flanges and Flanged Fittings

5. ASME B31.1, Power Piping

6. ASME B31.3, ASME code for Pressure piping

7. ASME B36.10, Welded and Seamless Wrought Steel Pipe

8. ASME B36.19, Stainless Steel Pipe

General Mechanical Piping

1562 15060-2 July 2009 Addendum 2 (construction contract)

D. The American Society for Nondestructive Testing Inc. (ASNT)

1. ASNT SNT-TC-1A, Recommended Practice

E. American Society for Testing and Materials (ASTM)

1. ASTM A47, Standard Specification for Ferritic Malleable Iron Castings

2. ASTM A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

3. ASTM A105, Standard Specification for Carbon Steel Forgings for Piping Applications

4. ASTM A167, Standard Specification for Stainless Steel and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

5. ASTM A181, Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

6. ASTM A182, Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

7. ASTM A193, Standard Specification for Alloy Steel and Stainless Steel Bolting Materials for High-Temperature Service

8. ASTM A194, Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service

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

10. ASTM A276, Standard Specification for Stainless Steel Bars and Shapes

11. ASTM A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength

12. ASTM A380, Standard Specification for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

13. ASTM A515, Standard Specification for Pressure Vessel Plates, Carbon Steel, Intermediate- and Higher-Temperature Service

14. ASTM A516, Standard Specification for Pressure Vessel Plates, Carbon Steel, Moderate- and Lower-Temperature Service

15. ASTM A536, Standard Specification for Ductile Iron Castings

16. ASTM A563, Standard Specification for Carbon and Alloy Steel Nuts

17. ASTM D149, Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies

18. ASTM E94, Standard Guide for Radiographic Testing

19. ASTM E142, Standard Method for Controlling Quality of Radiographic Testing

20. ASTM E165, Standard Test Method for Liquid Penetrant Examination

21. ASTM E709, Standard Guide for Magnetic Particle Examination

22. ASTM F104, Standard Classification System for Nonmetallic Gasket Materials

23. ASTM F436, Standard Specification for Hardened Steel Washers for General Use

F. American Welding Society (AWS)

1. AWS A5.1, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding

2. AWS A5.4, Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding

3. AWS A5.9, Specification for Bare Stainless Steel Welding Electrodes and Rods

4. AWS A5.18, Specification for Carbon Steel Filler Metals for Gas Shielded Arc Welding

5. AWS A5.20, Specification for Carbon Steel Electrodes for Flux-Cord Arc Welding



6. AWS A5.28, Specification for Low Alloy Steel Filler Metals for Gas Shielded Arc Welding

7. AWS D1.1, Structural Welding Code Steel

G. American Water Works Association

1. AWWA C207, Steel Pipe Flanges for Waterworks Service

H. California Plumbing Code (CPC)

I. Chlorine Institute, Inc. (CHI)

1. CHI 6, Piping Systems for Dry Chlorine

J. Compressed Gas Association (CGA)

1. CGA G-4.1, Cleaning Equipment for Oxygen Service

K. Sheet Metal and Air Conditioning Contractors National Association (SMACNA)

1. Seismic Restraint Manual: Guidelines For Mechanical Systems

L. Society of Protective Coatings (SSPC)

1. SSPC SP-1, Solvent Cleaning

2. SSPC SP-2, Hand Tool Cleaning

3. SSPC SP-3, Power Tool Cleaning

4. SSPC SP-5, Joint Surface Preparation Standard White Metal Blast Cleaning

5. SSPC SP-6, Joint Surface Preparation Standard Commercial Blast Cleaning

1.03 SUBMITTALS

A. Submittals shall be in accordance with Section 01300, “Submittals”.

B. Product Data: Manufacturer's data and printed recommendations shall be submitted on the following:

1. Technical data, including recommendations for storage, for all components of each piping system.

2. Welding materials.

3. Representative catalog cut for each different type of item indicating materials of construction, important dimensions, and range of pipe sizes for which that item is suitable.

C. Structural Calculations: Provide structural calculations for the design of all pipe supports, hangers, guides, seismic restraints, and anchors. The Contractor shall employ a California Registered Civil or Structural Engineer to prepare design calculations for all supports, hangers and accessories and for seismic restraint needed for piping and equipment installation. Calculations and shop drawings shall be signed by the above named engineer and submitted to the Engineer. Seismic forces shall be based upon the criteria in Section 01650, “Pipe, Duct, Cable Tray, Raceway, and Bus Duct Supports and Seismic Bracing”.

D. Shop Drawings

1. Shop drawings of pipe and fittings for each piping system shall be submitted showing complete layout plans and the following information:

a. Design Pressure and Hydrostatic or Pneumatic Test Pressure.

b. The length and designation, by number, of each shop-fabricated pipe section and fitting.

c. The complete material description and pipe-centerline location and elevation at changes in grade or horizontal alignment.

d. Details of welding, non-destructive testing, and protective coatings for each shop-fabricated pipe section and fitting.

e. Location, type, and details of all supports, hangers, guides, seismic restraints and anchors. Include magnitude of load transmitted to the structure at each location, magnitude, and direction of thermal expansion and thrust



forces, and type of expansion fittings, anchor, guide, and other pipe supporting appurtenances including structural fasteners.

E. Plans and Procedures

1. The Contractor shall submit a field cleaning procedure for all pipes, fittings, and associated equipment that will come into contact with hydrogen peroxide, liquid oxygen, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, ozone off-gas / vent gas, and/or contactor maintenance air. As a minimum, this shall include all pipe, fittings, and associated equipment, including instruments and valves, in piping systems with a material designation of “LL” as well as other piping systems where liquid oxygen, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, ozone off-gas/vent, or contactor maintenance air service. The procedure shall ensure hydrocarbon and welding residue decontamination of the system in accordance with CGA G-4.1, and shall be approved by the Engineer. Procedure shall state that all pipes, materials, and equipment factory cleaned for oxygen service shall be packaged and labeled as such prior to shipment to the site.

2. Prior to the start of fabrication, a detailed schedule for fabrication of piping and special fittings shall be submitted.

3. The following additional plans and procedures shall be submitted:

a. Welding Procedure Specifications (WPSs)

b. Welding Procedure Qualification Records (PQRs)

c. Welder Performance Qualifications (WPQs) for welders and welding operators to be employed on the work

d. Contractor Quality Assurance plan outlining testing, inspection and documentation

e. Preheat and interpass procedures, including temperatures

f. Procedure for heat treatment and stress relieving

g. Procedure for shop hydrostatic testing, submitted 10 working days prior to start of tests

h. Non-Destructive testing (NDT) procedures for shop and field testing.

F. Certifications

1. Certifications for compliance with shop cleaning, field cleaning and testing shall be submitted.

2. Certificate of qualification for each welder and record of welding procedures in accordance with ASME BPVC Section IX shall be submitted. Certifications shall include qualifying dates and name of the firm or individual certifying the qualification tests.

3. Certificate of qualification for each nondestructive testing technician and operator shall be submitted. Nondestructive testing technicians and operators shall be qualified to a minimum of NDT Level II, unless otherwise specified herein. Development of procedures and techniques, and code interpretation shall be performed by ASNT SNT-TC-1A, Level III technician.

4. Pipe materials that are in contact with potable water or recovered water which may be treated for use as potable water shall be certified for use in potable water applications. Certification shall be provided from ANSI, NSF 61, EPA, FDA, or USDA that pipe, fittings, lubricants, and elastomeric material products are approved for incorporation into potable water systems.

5. Non-Destructive Test (NDT) reports and weld maps for shop and field testing shall be submitted.

1.04 GUARANTY

Contractor shall warrant and guarantee the equipment per section 01740.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Provisions shall be made in handling, loading, unloading, and storing of pipe and fittings to avoid distortion, scratches, gouges, cracks, dents, and scuffing. Pipe and fittings shall be stored in a flat, horizontal position, protected from the elements until ready for installation.

B. Pipe, fittings, and associated equipment for LOX, oxygen, nitrogen injection, ozone process/off-gas/vent, and contactor maintenance air service shall be handled and stored to maintain packaging integrity and cleanliness.



C. Nonmetallic pipe shall not be stacked.

D. At all times, plastic pipe shall be supported for the full length of the pipe and protected from ultraviolet exposure. Pipe that has been damaged or distorted shall be replaced.

E. In the event that during storage coated pipe is subjected to ultraviolet exposure longer than 90 calendar days, it shall be physically inspected prior to installation in the trench. UV-degradation will be evaluated by the Engineer. Where, in the opinion of the Engineer, the degree of degradation will not affect the integrity of the coating, the Engineer may allow the installation of the pipe; otherwise, the affected section will be rejected.

F. Components of the pipe-joint sealant system shall be delivered to the jobsite in original, unopened containers with the manufacturer's name, labels, product identification, and batch numbers legibly displayed. Components shall be stored in clean, dry, protected areas in which ambient temperatures do not fall below 50° F or rise above 95° F.

PART 2 PRODUCTS

2.01 MATERIALS

A. Line Description

1. Each principal system of piping is identified on the drawings by a line number which designates pipe size and material. No omission in the line numbers from the drawings shall be construed to relieve the Contractor from furnishing and installing all piping called for on the drawings in accordance with the requirements noted thereon. The material specifications letters shown on the drawings are referenced to sections of these specifications in accordance with the following Table 1:

Material Specificatio

n Designation

Table 1. Line Designations

Description

Specification

Section Reference

A1 Carbon Steel, Mortar-Lined, Class 150 15065 A3 Carbon Steel, Mortar-Lined, Class 300 15065 B Brass Tubing and Fittings [B-pipe] 15076 C Copper Tubing and Fittings [C-pipe] 15077 D Poly (Vinyl Chloride) (PVC) Plastic Pipe and Fittings [D-pipe] 15080 E1 Stainless Steel Pipe and Fittings, Flat-Faced [E1-pipe], Class 150 15070 E3 Stainless Steel Pipe and Fittings, Flat-Faced [E-pipe], Class 300 15070 F Ductile Iron Pipe and Fittings [F-pipe] 02614 G Cast Iron Soil Pipe and Fittings [G-pipe] 02612 H Carbon Steel Pipe, Galvanized 15065 I Glass Lined Ductile Iron Pipe and Fittings [I-pipe] 15095 J Corrugated Metal Pipe and Fittings [J-pipe] 02615 K Fabricated Steel Pipe and Fittings [K-pipe] 02662 L Not Used - M Reinforced Concrete Pipe and Fittings [M-pipe] 02616 N Not Used - O Stainless Steel Tubing and Fittings [O-pipe] 15071

P and Q Not Used - R Carbon Steel, Saran-Lined 15065 S Carbon Steel for Chlorine Service 15065 T Carbon Steel Pipe and Fittings (Unlined) 15065 U Carbon Steel, Polytetrafluoroethylene-Lined 15065 V Fiberglass-Reinforced Plastic (FRP) Pipe and Fittings [V-pipe] 15090 W Not Used - X Polyethylene (PE) Plastic Tubing [X-pipe] 15085 Y Carbon Steel, Rubber-Lined 15065 Z Brass Pipe and Fittings [Z-pipe] 15075



Material Specificatio

n Designation

Table 1. Line Designations

Description

Specification

Section Reference

AA Not Used -

BB Poly Vinyl Chloride (PVC) Plastic, Double Wall Pipe and Fittings [BB-pipe]

15091

CC Titanium Pipe and Fittings [CC-pipe] 15079

DD Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe and Fittings [DD-pipe]

15082

EE Stainless Steel, Teflon-Lined [EE-pipe] 15073 FF Aluminum Pipe [FF-pipe] 15074 GG Carbon Steel for Sulfuric Acid Service 15065

HH and II Not Used - JJ Alloy 20 Pipe and Fittings [JJ-pipe] 15092

KK Hastelloy C Pipe and Fittings [KK-pipe] 15078 LL Stainless Steel Pipe and Fittings, Raised Face [LL] 15072

MM Corrugated Polyethylene Pipe and Fittings [MM] 02610 NN Polyethylene Pipe and Fittings for Natural Gas Service 15094

T/DD Carbon Steel and Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Double Wall Pipe and Fittings [T/DD-pipe]

15084

U/DD PTFE - Lined Steel and Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Double Wall Pipe and Fittings [U/DD-pipe]

15086

2. All welding of stainless steel piping and fittings for LOX, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, and/or ozone off-gas/vent gas shall be completed in the factory to the greatest extent possible.

B. Joint Compound

1. Joint compound for threaded pipe joints shall be a Teflon compound, applied only to the male section of threaded joints.

a. Acceptable Products: Radiator Specialty Co., Bakerseal; or equal.

2. Joint compound in LOX, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, ozone process/off-gas/vent, and contactor maintenance air service shall be approved for oxygen and ozone compatibility.

a. Acceptable Products: Fluoramics, Inc. LOX 8

C. Joint Putty

1. Joint putty shall be a non-sag epoxy formulation.

2. Acceptable Products: Sika Corp., Sikadur No.31; Select Products, GP-3000; or equal.

D. Flanges

1. Unless otherwise shown on the drawings, the dimensions, drilling, and bolting of flanges shall be as follows:

Table 2. Flange Code Specification by Pressure/Size/Type (see notes)

Operating Pressure

(psig) Size (NPS) Flange Type Code Class

Flange Ratings (psig)

Notes

≤ 50 26” to 48” Ring & Hub AWWA C207, C228 B, SB 6,9

≤ 50 26” to 48” Blind AWWA C207, C228 B, SB

≤ 150 ≤ 24” WNF & Hub ASME B16.5 150 275 6

≤ 150 ≤ 24” Blind, Bored Blind ASME B16.5 150 275 7,8



Table 2. Flange Code Specification by Pressure/Size/Type (see notes)

Operating Pressure

(psig) Size (NPS) Flange Type Code Class

Flange Ratings (psig)

Notes

≤ 150 26” to 48” WNF ASME B16.47 Series A, 150 275 6

51 - 150 26” to 48” Blind AWWA C207, C228 D, SD 150

51 - 150 26” to 40” Ring & Hub AWWA C207, C228 E, SE 6

51 - 150 42” to 48” Ring AWWA C207, C228 Table 3

151 - 275 42” to 48” Blind AWWA C207, C228 E, SE 275

151 - 275 42” to 48” Ring AWWA C207, C228 E, SE 275

151 - 300 ≤ 24” WNF & Hub ASME B16.5 300 720 6

151 - 300 ≤ 24” Blind, Bored Blind ASME B16.5 300 300,720 7,8

151 – 300 26” to 40” Ring & Hub AWWA C207, C228 F, SF 6

151 – 300 26” to 40” Blind AWWA C207, C228 F, SF

276 - 300 42” to 48” Blind AWWA C207, C228 F, SF 300

276 - 300 42” to 48” Ring AWWA C207, C228 F, SF 300 Notes: 1) Except when otherwise stated in MWD specifications, or where otherwise shown on MWD drawings, all flange dimensions

shall comply with this table. 2) Flange material shall be per MWD specifications. Use of other material requires submittal of supporting calculations per

ASME Section VIII. 3) For operating pressures greater than listed, or for a flange size and type not listed, a specially engineered flange per ASME

Section VIII shall be used. 4) Specially engineered flanges shall be per ASME Section VIII. Supporting calculations shall be submitted for approval. 5) Flange size 42” and larger shall have 3/8” diameter o-ring per drawing. 6) Hub and WNF flanges shall not be bored. 7) Outside weld shall consist of t bevel weld and 1.4t fillet weld where t = pipe wall thickness. Inside weld shall be per drawings. 8) Does not apply to reducing flanges. Reducing flanges are specially engineered flanges. 9) Hub type flanges are limited to 40”.

Table 3: Flange Thickness1

Size 42" 48" Thickness (in) 2 2.125

Note 1: Table 3 indicates flange thickness for Ring Type Flanges with an operating pressure between 51 psi and 150 psi, all other flange dimensions shall be per AWWA C207 Class D

2. The dimensions for drilling and bolting of flanges for pipe sizes and ratings not shown above shall be as shown on the drawings.

3. The final machining of the contact faces of flanges shall be perpendicular to the centerline axis of the pipe or fitting. Distortion, unevenness, or other irregularities in the contact faces due to welding, stress-relieving, or other cause will not be permitted. The maximum allowable layback for each welded flange shall be 3/4⁰.

4. The gasket surfaces shall have a V-serrated finish of approximately 32 serrations per inch approximately 1/64 inch deep, except O-ring gasket contact surfaces of flanges shall have a smooth face finish of 125 micro inches. The serrations may be either concentric or spiral (phonographic). Flange faces shall be finished to maximum roughness of 250 micro inches before serrating the flange face surfaces.

5. Flanges shall be full thickness, flat faced, and drilled. Flanges shall be spot faced or back-faced parallel to the front face.

6. Welding neck flanges, blind flanges, and slip-on flanges shall be forged steel in accordance with the requirements of ASTM A181, Class 60 or 70, normalized and tempered, or to ASTM A105, normalized and tempered or quenched and tempered. Welding neck flanges shall be bored to match the inside diameter of the adjoining pipe.



7. Gaskets for flanged joints shall be full-faced for flat-faced flanges. Gaskets shall be made of compressed non-asbestos sheet, 1/16” thick. Gaskets shall be furnished in one piece. Gaskets shall be Garlock Blue Guard 3000 or anchor Green Klinger.

8. Sleeve-Type Couplings: Sleeve-type couplings shall be in accordance with the requirements of Section 15060.

9. Stainless steel welding neck flanges and hub flanges shall be forged steel conforming to the requirements of ASTM A182.

10. Welding neck flanges shall be bored to match the inside diameter of adjoining pipe.

11. Plate Flanges and Blind Flanges

a. Carbon steel plate flanges shall be machined from steel plate. Plate material shall be in accordance with ASTM A515 or A516, Grade 65. Plate that is in accordance with ASTM A515 or A516, Grade 70 will be permitted subject to the preheating and interpass temperature requirements specified in this section.

b. Stainless steel plate flanges shall be machined from steel plate that is in accordance with ASTM A240.

c. Plate flanges may be fabricated from segments welded together in accordance with AWWA C207. The plates used shall have sufficient thickness to permit machining so that the finished flange will have the specified thickness with true surfaces free from defects.

d. Plate flanges shall be stress-relieved in accordance with the provisions of the ASME Boiler and Pressure Vessel Code, Section VIII, Unfired Pressure Vessels.

e. Edge rolling of bar stock to form flanges will not be permitted.

f. Blind flanges shall be forged steel conforming to the requirements for welding neck flanges or shall be plate flanges. Flange faces shall be machined flat as specified in this section.

E. Flange Gaskets

1. Flange gaskets shall be compatible with the intended service, in accordance with the specific piping material section of these specifications.

F. Flange Bolting Materials

1. General

a. Threads for bolts and nuts shall be in accordance with ASME B1.1.

b. Threads for bolts 1 inch and less in diameter shall be coarse-thread series and threads for bolts 1.125 inches and greater in diameter shall be the 8-pitch thread series.

c. The fit shall be Class 2 free fit; except that Class 3 medium fit shall be provided in holes tapped for studs.

d. Unless otherwise shown on the drawings, bolts shall have heavy hexagon heads and heavy hexagon nuts.

e. The length of studs and bolts, excluding anchor bolts, shall provide a projection of not less than 0.25 inch nor more than 0.5 inch through the nut when it is drawn tight; however, in exposed locations the projection shall not be more than 0.25 inch.

2. Carbon Steel Fasteners

a. Carbon steel fasteners shall be used only with carbon steel piping subject to a continuously dry environment. Otherwise, stainless steel fasteners shall be used in accordance with Section 15060, “General Mechanical Piping, Stainless Steel Fasteners”.

b. The studs and bolts for flanged connections and joint harnesses shall be machined from steel in accordance with the requirements of ASTM A193, Grade B7, except that the requirements specified herein shall control where at variance with ASTM A193. Studs shall be threaded full length, and each shall be furnished with 2 nuts.

c. Nuts shall be in accordance with the requirements of ASTM A194, Grade 2H, heavy series.

d. Carbon steel bolts installed in holes 1/8 inch or more oversize, as measured on the diameter, shall be provided with hardened steel washers in accordance with the requirements of ASTM F436 at each contact surface.



e. Anti-seize compound shall be used on carbon steel fasteners, and shall be Husk-ITT, Husky 2000; or equal.

3. Stainless Steel Fasteners

a. Except as otherwise specified or shown on the drawings, stainless steel fasteners shall be used with stainless steel, Alloy 20, Hastelloy, Titanium, PVC, and CPVC flanges, and with other piping where the flanges will be immersed in water, intermittently or continuously, or in moist environment installations, or in piping systems used to transport chemicals.

b. Fasteners shall be Type 316 or 316N stainless steel, and shall conform to ASTM A193, Grade B8M, or B8MN for bolting and stud material, and ASTM A194, Grade 8M, or 8MN for nuts.

c. Stainless steel washers shall conform to ASTM F844 except that they shall be punched from steel conforming to ASTM A167, Type 316 or machined from bar stock conforming to ASTM A276, Type 316.

d. Anti-galling compound shall be used on stainless steel fasteners as follows:

(1) Anti-galling compound used for fasteners in LOX, nitrogen injection, oxygen, ozone process/off-gas/vent and contactor maintenance air service shall be Dupont “Krytox”; or equal.

(2) Anti-galling compound used for all other services shall be certified per Section 15060, “General Mechanical Piping”, ASTM A193 for potable water use and shall be Husk-ITT, Lube O’seal; Hercules, Real-Tuff; La Co, Slic-Tite; or equal.

(3) Anti-galling compound shall be applied every time bolts and nuts are assembled.

4. Silicon Bronze Fasteners

a. Silicon bronze fasteners shall be used for flanges constructed of copper or copper-based alloys where the material will be immersed in water, intermittently or continuously, or in a moist environment. Silicon bronze bolts, studs, nuts, and washers shall be of copper-silicon alloy in accordance with ASTM F467 and ASTM F468, Alloys C65100 or C65500. A thread compound to prevent galling will not be required.

5. Fastener assemblies constructed of a combination of silicon bronze nuts and stainless steel bolts or studs shall be used where shown on the drawings or in continuously dry environments.

G. Liquid Penetrant Checking Compound

1. Products for liquid penetrant inspection shall be water-washable and nonflammable.

2. Penetrant and developer shall be from the same manufacturer and shall be in accordance with ASTM E165.

3. Acceptable Products: Shop Vac Corp., Spotcheck; American Gas and Chemical Co. Ltd., Flaw-Finder, Met-L-Chek; or equal.

2.02 ACCESSORIES

A. Automatic Liquid Drain Traps

1. Liquid drain traps shall be installed as shown on the drawings and specified herein. The liquid drain trap shall be of the float type. Body shall be stainless steel, and valve mechanism shall be stainless steel with hardened working surfaces designed to retain a water seal at all times. An NPT connection shall be provided for a balance pipe. All internal parts are to be renewable and field serviceable. Drain trap shall be as manufactured by Spirax Sarco FA-150; Armstrong 11-LD; or equal.

B. Flexible Connectors

1. Flexible connectors or flanged coupling adapters shall have thrust ties, blocks, or anchors, unless otherwise shown on the drawings.

2. Type FC-1 flexible connectors shall be:

a. Used in water and sludge service

b. Flanged spool-type expansion joints with armored multiple-arched rubber-body design for pressure service

c. Suitable for an operating pressure of 150 psig at 100° F

d. Provided with steel retaining rings, modified for higher pressures



e. Approved products: Thermo Tech, Inc., Flex/Flo/R Style 500; Mercer Rubber Co., Style FC-500; or equal.


a. Used in chemical service.

b. Flanged expansion joints with 3 convolutions of molded polytetrafluoroethylene (PTFE) and ductile iron or carbon steel flanges.

c. Suitable for operating pressure of 100 psig at 100° F.

d. Approved products: Proco Products, Inc., Series 440; Unisource Manufacturing, Inc.; or equal.


a. Used for vibration control at compressors and pumps

b. Stainless steel braided hose with Type 316 or Type 321 stainless steel flanges.

c. Suitable for an operating pressure of 450 psig at 70° F, and 400 psig at 200° F.

d. Acceptable Products: Proco Products, Inc., Unisource Manufacturing, Inc.; or equal.


a. Used in water and sludge service

b. Flanged spool-type expansion joints with steel retaining rings and single-arch rubber body

c. Designed for pressure service suitable for an operating pressure of 100 psig at 100° F

d. Acceptable Products: Mercer Rubber Co., Style 500; General Rubber Corp., Style 1025; Unisource Manufacturing, Inc.; Proco Products, Inc. or equal.


a. Used where shown on the drawings for the subdrain system.

b. Acceptable Products: NDS Flexible Coupling; or equal.


a. Used where shown on the drawings for chemical service.

b. Type 316 or Type 321 stainless steel braided hose with TFE-lining and Type 316 or Type 321 stainless steel flanged ends.

c. Rated for 150 psig at 125° F minimum.

d. Acceptable Products: Unisource Manufacturing, Inc. Model SF-TSC; Proco Products, Inc;; or equal.


a. Used for ozone process/off gas service.

b. Flanged bellows-type expansion joints with Type 316 or 316L stainless steel bellows and Type 316 or 316L stainless steel flanges.

c. Suitable for operating pressure of 100 psig at 200° F.

d. Approved products: American BOA Inc., Model No. FSP; or equal.

C. Sleeve-Type Couplings

1. Sleeve-type couplings shall in accordance with AWWA C219, as modified below.

2. Sleeve-type couplings shall be made of material with same or better chemical and mechanical properties as the pipe on which it is used. ASTM A515 Grade 65 or A516 Grade 65 is acceptable for carbon steel applications. ASTM A240 is acceptable for stainless steel applications.

3. Welding on the middle ring shall be a full-penetration groove weld and shall receive 100 percent radiographic examination.



4. The middle ring of sleeve-type couplings shall be at least the same thickness as the pipe on which it is used. The length of middle rings be shall be as follows:

Pipe Size (Outside Diameter) Length

4.5 inches 4 inches

6.625 inches to 48 inches 7 inches except as otherwise shown on the drawings

49 inches and larger 10 inches

5. Gaskets/seals shall be suitable for use in potable water-supply systems

6. Sleeve-type couplings shall be coated with high-solids epoxy in accordance with Section 09900, “Painting”.

7. Buried sleeve-type couplings shall be further coated to match the pipeline coating. Bond wires shall be AWG No. 4 and shall be installed on all sleeve-type couplings in the field, as shown on the drawings.

8. Acceptable Products: Rockwell; Smith-Blair No. 411; Nappco, Baker Series 200; or equal (without pipe stop, unless otherwise shown on the drawings).

D. Flexible Hose

1. Flexible hoses with connections shall be installed where shown on the drawings and specified herein.

2. Water and air hoses for utility stations shall be:

a. Heavy-duty industrial type, with a minimum operating rating of 200 psig

b. Equipped with quick-disconnect couplings

c. Acceptable Manufacturers: Boston Woven Hose and Rubber Co.; Hewitt Robbins, Inc.; L.A. Rubber Co.; or equal.

E. Pipe Penetration Modular Mechanical Seals

1. The mechanical modular seal shall fill the annular space between a pipe and wall sleeve, preventing groundwater from entering an underground structure. The seal shall consist of mechanically interlocked solid synthetic links and shall form a hydrostatic, watertight seal up to 20 psig with a temperature operating range of -40 to 250°F.

2. Seal components and materials of construction:

a. Seal element shall be EPDM, 1828 psi tensile strength as tested per ASTM D412.

b. Pressure plates shall be a composite plastic or nylon polymer, 27,000 psi tensile strength.

c. Bolts and nuts shall be Type 316 stainless steel.

3. Contractor shall provide pipe OD and sleeve ID to Seal Manufacturer for seal sizing. Seals shall be selected and installed per Manufacturer’s recommendations.

4. Acceptable Manufacturers: PSI Thunderline Link-Seal; APS Innerlynx Modular Mechanical Seal.

F. Insulating Flange Kits

1. Insulating flanges shall be installed as shown on the drawings and per Sections 13984, “Insulating Joints” and 13985, “Pipe Bonding and Test Stations”.

G. Flange Spray Guards

1. Flange spray guards shall be installed where indicated on the drawings.

a. Guards shall be fabricated of teflon-coated fiberglass fabric, with teflon-coated fiberglass tie-down cords.

b. Guards shall be rated for 450° F.

c. Guards shall be UV-stabilized and suitable for outdoor service.

d. Guards shall include a pH indicator to indicate leakage.

e. Acceptable Products: RAMCO SPRA-GARD; or equal

H. Insulating Unions



1. Insulation unions shall be per Section 13984, “Insulating Joints”.

2.03 WELDING

A. General Requirements

1. Welding shall be performed by qualified welders having adequate experience in the methods and materials to be used. Welding and brazing procedures, welders, and operators shall be qualified in accordance with the ASME BPVC, Section IX. Welders or welding operators shall have been qualified for the process involved within the past 6 months, in accordance with ASME BPVC, Section IX, Article QW-322. The Contractor may provide documentation confirming the welder meets the welding continuity requirements per ASME Section IX.

2. Test Specimens

a. The Contractor shall conduct specimen testing of its welders to determine their ability to produce welds that are in compliance with these specifications.

b. Testing shall be made in the presence of the Engineer in accordance with the qualification procedure described herein, using machines and electrodes similar to those that are to be used on the work.

c. The test specimen shall be welded in the same position as that in which the welder is qualifying to work, and the same number of passes shall be used as are specified for the work.

d. In lieu of conducting tests, the Engineer may require that each welder be qualified by a testing agency at the Contractors own expense and approved by the Engineer and using the qualification procedure of ASME BPVC, Section IX.

e. The Engineer may require additional test specimens as the work progresses and may demand the removal of a welder whose work is questionable, regardless of the results of the test welds at the Contractors expense.

3. Identification

a. Each welder shall be assigned an identification symbol to identify his or her welding work.

b. Only 0.25- or 0.375-inch low-stress steel stencil stamps shall be used.

c. The welder's symbol shall be stamped 1 inch from the weld.

d. If more than one welder completes a joint, stamped symbols shall move outward from the weld in chronological order; the welder completing the weld shall have the furthest symbol.

e. A complete weld map, with all welders' symbols and joint numbers shall be maintained as part of the Contractors Quality Assurance Program.

B. Preparation

1. Prior to welding, the surfaces of members to be welded shall be deburred, ground smooth and thoroughly cleaned by grinding or abrasive blasting in accordance with SSPC SP-1, SSPC SP-2, SSPC SP-3, SSPC SP-5 or SSPC SP-6, as applicable. The area of cleaning, measured from the welding edge, shall be a distance of no less than 1 inch for scale and rust and no less than 3 inches for oil and grease.

2. Grease and oil shall be removed with an approved solvent in accordance with all local regulatory requirements. The use of gasoline, kerosene, or other petroleum solvent will not be permitted. Grease and oil shall be removed prior to abrasive blasting.

3. Abrasive blasting and other cleaning shall be done prior to tack-welding.

C. Special Joint and Fit-Up Requirements

1. Double-sided butt-weld joints shall be used for pipe and rolled plate sections greater than 24 inches in diameter.

2. Weld-bevels shall be machined or ground to bright metal before welding.

3. The use of heat for straightening or bending of the metal is not permissible.

4. For joint preparation of stainless steel, Alloy 20, Hastelloy and other austenitic or chromium-nickel-alloy steel piping components:



a. Grinding wheels shall be resinoid aluminum-oxide-type and shall be new or shall have been previously used only on stainless steel materials.

b. Brushes shall have stainless steel bristles and shall be new or shall have been previously used only on stainless steel materials.

c. Marking materials, temperature-indicating materials, or anti-spatter compound shall be sulfur-and chloride-free.

d. The use of anti-spatter compounds shall be strictly in accordance with the manufacturers' printed recommendations.

5. Butt-welds on NPS-2 inch diameter pipe or smaller shall be made with the shielded metal arc welding (SMAW) process or the gas tungsten arc-welding (GTAW) process and shall be subject to 100% radiographic examination.

6. Socket-welds are acceptable for NPS-2 inch diameter or smaller, provided that a gap of 1/16 to 0.125 inch is left between the pipe and the bottom of the socket.

7. All welded joints, including socket welds, shall be two passes minimum.

8. Weaving for stick electrodes will not be permitted. The stringer-bead technique shall be mandatory. Quarter-welding and backstepping techniques are acceptable where each layer (360 degrees) is completed before the next layer is started and when starts and stops are staggered alternately with successive beads.

9. Visible defects, flux, scale, and spatter shall be removed from each weld pass prior to making the next weld pass.

D. Welding Process Restrictions

1. Subject to prior approval of the Engineer, gas metal arc-welding (GMAW) of the shielded spray and pulsed-current weld processes, and using materials in accordance with AWS A5.18 and AWS A5.28, are acceptable. Procedure qualification shall include the type of material, joint design, filler-wire designation, shielding gas, welding position, and sequence of application. Short-circuiting GMAW shall not be used.

2. Gas tungsten arc-welding (GTAW) with an internal inert-gas purge shall be used for the root and second pass using materials in accordance with AWS A5.9, AWS A5.18, or AWS A5.28. Carbon dioxide shall not be used as a shielding gas for stainless steel welding. Only nitrogen and argon are acceptable as purging gases for stainless steel.

3. The oxygen-fuel welding (OFW) process shall not be used.

4. Fully automatic submerged arc-welding (SAW) shall be used only with approved electrode wires and fluxes equivalent to F7A2-EM12K, as specified in the welding procedure qualification record. Individual weld layers exceeding 0.375 inch in thickness shall not be deposited.

5. Without prior approval of the Engineer, SMAW shall not be used for the root pass in stainless steel weldment from one side.

6. Covered are-welding electrodes shall be in accordance with AWS A5.5 or AWS A5.1, low hydrogen type, classification No. E70XX.

7. Electrodes in accordance with AWS A5.20 shall be used for flux-corded arc-welding (FCAW), classification E71T-X, low hydrogen. Auxiliary gas shielding is mandatory.

E. Temperature and Heat Treatment Restrictions

1. The minimum metal temperature for welding shall be 50° F, unless a higher value is specified in AWS D1.1.

2. Welds between austenitic and ferritic materials shall have the preheat temperature determined in accordance with the qualified weld procedure requirements and ASME BPVC, Section IX, for ferritic material. Postweld heat treatment, if required by the Engineer, shall not exceed 750° F and shall follow the time periods for stainless steel welding requirements. Interpass temperature shall not exceed 350° F.

3. The preheat temperature shall be determined by temperature-indicating crayons, contact pyrometers, or other suitable devices.

4. Preheating and interpass temperatures shall be maintained for all welding procedures, including rewelding made necessary due to defects, in accordance with the qualified welding procedure.



5. The maximum interpass temperature for austenitic steel and nickel base alloy shall be 350° F.

6. Postweld heat treatment, if required by the Engineer, shall be in accordance with the ASME BPVC and only after all welding for piping work has been completed. In no case shall the postweld heat treatment temperature exceed the tempering temperatures for normalized and tempered materials. Postweld heat treatment for stainless steel welds shall be 750° F for 4 hours, or a full solution annealing at 1900° F followed by a rapid quench. Stainless steel pipes and tubes less than 2.5 inches in diameter do not need postweld heat treatment, unless sensitization during welding is suspected. Welds suspected of sensitization shall be full solution annealed at 1900° F and quench cooled.

7. The minimum hold time for postweld heat treatment shall be one hour for ferritic steels. The heating rate shall be limited to 400° F per hour, maximum, above 600° F of the stress-relief temperature. The cooling rate from the stress-relief temperature shall be 400° to 600° F per hour.

8. Preferably, postweld heat treatment shall be done in a furnace. Stacking of components in the furnace will not be permitted. Localized postweld heat treatment not done in a furnace may be accomplished by electric resistance or induction heating, subject to the following restrictions:

a. A full circumferential band shall be heated to the required temperature.

b. The thermal gradient at the extremities of the heat band shall not exceed 150° F per foot.

c. The heater band shall extend on each side of the joint by 5 times the wall thickness.

9. Calibrated recording instrumentation shall be used to document all stress relief.

F. Attachments

1. Nozzle and coupling attachments shall be as detailed on approved shop drawings. Set-in-type couplings are preferable. Drilled-through set-on-type are acceptable, subject to the following requirements:

a. Prior to installation and after completion of the weld, the area where the coupling is to be installed shall be ultrasonically examined for lamination and other defects.

b. The as-machined button at the base of the coupling shall be a maximum diameter of half the nominal coupling size.

c. A minimum 0.125-inch chamfer shall be provided at the bottom edge of the drilled hole.

d. The root pass and outer weld shall be subjected to liquid-penetrant examination or magnetic-particle examination.

e. Visual inspection shall be performed on both internal and external surfaces.

2. Weldolet, Thredolet, or equal attachments shall be as detailed on approved shop drawings. Set-in-type Weldolet, Thredolet, or equal attachments will be permissible, provided that full-penetration welds on the outside of the pipe are used, in which case, each weld pass shall be tested by liquid-penetrant testing. Set-on-type are subject to the following requirements:

a. Holes in pipe shall be bored to the inside diameter of the Weldolet, with a 0.125-inch chamfer on the inside edge.

b. A minimum 0.125-inch root opening at the lowest point shall be provided to ensure complete penetration.

c. Both root and cover passes shall be inspected by liquid penetrant examination or magnetic particles.

d. Fittings shall be welded out to the first break in contour, or flush with the outer edge of the fitting. Partial weld-out will not be permitted.

2.04 CARBON STEEL WELDING

A. Welding shall be by the unvarying arc welding process that excludes the atmosphere during the process of deposition while the metal is in a molten state. The size and type of electrode to be used and the current and voltage required shall in all cases be subject to the approval of the Engineer. The type of wire and flux to be used for automatic processes shall also be subject to the approval of the Engineer.



B. Rusted or otherwise damaged electrodes shall not be used; violation of this provision shall be sufficient cause for rejection of the work. Used flux from automatic welders shall be sifted free of fines and coarse pieces and shall have mill scale completely removed before reusing.

C. Welds shall be of uniform composition, neat, smooth, full strength, and ductile. Each weld shall be made with a technique that will ensure uniform distribution of load throughout the welded section, with a minimum tendency to produce eccentric stress or distortion in the weld or in the adjacent metal. The maximum height of the weld reinforcement shall be 3/32 inch

D. Where possible for hand butt-welds and other hand welds, but excepting plain 90-degree fillet welds, the edges of the plate shall be prepared so that there will be sufficient angle in the welding grove to prevent side-arcing of the electrode and to permit penetration at the deepest point of the groove. These welds shall be back-chipped from the side of deepest penetration on the reverse side before welding is done on the front side. Each hand pass and each back-chipped welding groove shall be subject to inspection before the ensuing pass is made.

E. For hand welds, no more than 0.125 inch of metal shall be deposited in each pass. Each pass shall be thoroughly cleaned to afford visual inspection. Each pass shall be thoroughly fused into the sides; fillet weld passes shall not be permitted to pile up in the center of the weld. Undercutting is not permissible.

F. When welding is resumed after the normal welding process is interrupted for any reason, special care shall be taken to get full penetration and thorough fusion between the previously deposited weld metal and the weld metal and plates. Where welding is interrupted by faulty machine operation, that portion of the weld shall be removed by chipping before resuming the welding operation, subject to approval of the Engineer.

G. Pipe sections that show irregularities in shape after welding may be rerolled to make them cylindrical. Reforming by hammering will not be permitted. Pipe sections that have abrupt changes in curvature at longitudinal weld seams shall not be reformed unless the welds are subsequently removed and the pipe rewelded following the reforming operation.

H. Following the completion of welding or rewelding made necessary because of defects of bell and spigot areas, welds shall be ground flush with plate surfaces on the spigot exterior and on both interior and exterior surfaces of the bell. Grinding shall extend at least 6 inches from the spigot end and shall extend at least one inch from the bell end onto the unstretched portion of the pipe.

2.05 STAINLESS STEEL WELDING

A. Welding shall be performed by the SMAW, FCAW or GTAW. SMAW process, using direct current and electrodes in accordance with AWS A5.4, Class E316L for stainless to stainless welds; and Class E309L or Class E312 for stainless steel to carbon steel welds. The sequence of the welding and welding procedures shall be in all cases subject to approval by the Engineer.

B. Electrodes for manual welding shall not be larger than 3/16 inch for shop-welding, nor larger than 5/32 inch for field welding. The depth of each pass shall not exceed 0.125 inch. Welding on austenitic stainless steel shall be performed by the SMAW process, using direct current and electrodes in accordance with AWS A5.4 and AWS A5.9; Class E308L for welding Type 304L to Type 304L; Class E316L for welding Type 316L to Type 316L; and Class E309L or Class E312 for welding stainless steel to carbon steel.

C. Welding of Schedule 10S stainless shall be by the GTAW process. Interpass temperature shall not exceed 350° F. Stress relieving shall be required, as directed by the Engineer.

D. Postweld heat-treatment, if required by the Engineer, shall consist of heating the material to a minimum temperature of 1900° F and a maximum temperature of 1950° F, and quenching it in water or cooling rapidly by other means. Where this is not possible, stress relieving shall be done at 750° F, maximum, for 4 hours plus an additional 0.5 hour for each full inch of thickness over 0.5 inch.

E. Each layer of deposited weld metal shall be thoroughly cleaned with a power-driven stainless steel wire brush prior to the deposition of each additional layer of weld metal and also after the final pass.

F. Welds shall be deburred and ground smooth by using grinding wheels. Carborundum or other carbon-bearing wheels shall not be used on stainless steel surfaces.

G. Stainless steel welds shall be pickled and passivated after fabrication in accordance with ASTM A380.



H. Contaminated stainless steel surfaces shall be cleaned in accordance with ASTM A380 and as approved by the Engineer.

2.06 BRAZING

A. Brazing of copper and brass pipe and fittings shall be in accordance with Section 15077, “Copper Tubing and Fittings [C-Pipe]”, and ASME BPVC, Section VIII, Part UB.

2.07 SHOP FINISHES AND CLEANING

A. Shop finishes and cleaning shall be in accordance with the specific piping material section of these specifications.

B. All LOX, oxygen gas, supplemental nitrogen gas, ozone-in-oxygen gas, ozone off-gas/vent, and contactor maintenance air piping, fittings, and associated equipment shall be cleaned, packaged, and labeled in accordance with CGA G-4.1, and delivered to the site free of hydrocarbons.

2.08 SOURCE QUALITY CONTROL

A. The Engineer shall have access to all phases of fabrication for inspection and shall be notified a minimum of 2 weeks prior to start of fabrication. Materials or fabricated parts that are discovered to be defective or that are not in accordance with these specifications shall be subject to rejection at any time of fabrication.

B. Contractor shall establish a Quality Assurance program that ensures compliance to requirements of this specification. The program shall document the all welds are made by qualified welders/operators and that all welds are mapped and have been tested to meet the requirements of this specification.

C. The Engineer will audit the Quality Assurance program to ensure compliance to this specification

D. Nondestructive Examination: Each weldment shall be examined and measured to ensure conformance to these specifications as follows:

1. General a. Weld examination shall include shop fabrication and field welding. b. Nondestructive testing shall be in accordance with ASME Section V and VIII.

c. If the Engineer determines that the method of nondestructive testing specified cannot be used under conditions encountered in the work, an alternate method of inspection will be determined by the Engineer.

d. There shall not be evidence of oxidation in the weld metal.

e. Welds shall be free of cracks, pinholes, porosity, slag, and undercut.

f. Welding that is not acceptable and defective welds shall be chipped out and rewelded, and the affected joints shall be checked again by nondestructive testing for acceptance of the repaired welds.

g. Nozzle and branch connection (including weldolet, sockolet, threadolet, and coupling) root welds shall be backgouged to sound metal and examined by the liquid-penetrant method prior to final welding.

h. All welds shall be 100% visually inspected.

2. Radiography

a. All girth and mitered groove welds are to be tracked and random radiography tested as follows:

(1) The first weld a welder produces shall be radiographed. This radiograph does not count towards a welder’s percentage of welds radiographed.

(2) Thereafter, 5% of the welds each welder producers shall be randomly radiographed as directed by the Engineer.

(3) The acceptance criteria shall be per ASME Section VIII, UW-51.

(4) Progressive sampling for examination will be conducted as described in ASME B31.3 341.3.4

b. Butt-welds on NPS-2 diameter or smaller shall be subject to 100% radiography.



3. Liquid Penetrant Testing

a. All butt welds shall be liquid penetrant tested at the root and cover passes and shall be subject to inspection by the Engineer.

b. The cover pass for all socket welds shall be liquid penetrant tested.

c. All plug welds shall be liquid penetrant tested.

d. When joints are modified to provide tapered transition reinforcement at joint offsets, the weld-metal buildup shall be examined over the full surface of the deposit by liquid-penetrant examination.

e. Welds not tested by the soap and compressed air test shall be tested by the liquid-penetrant inspection method (on all root and final weld passes).

f. Where temporary attachments have been made, the base metal shall be tested by liquid penetrant and shall be inspected for base metal tears.

4. Soap and Compressed Air Testing

a. Slip on flanges and joints susceptible to this test shall be tested by the soap and compressed air method.

b. As soon as practicable after completion of the welding of joints that are to be tested by the soap and compressed air test, the Contractor shall subject each joint to a soap test by forcing compressed air, at approximately 15 psi, into each joint. While the joint is under pressure, every portion of every welded seam forming a part of the joint shall be swabbed with a heavy soap solution or an approved, commercial, bubble-producing leak-test fluid and shall be carefully examined for leakage.

c. The Contractor shall provide the apparatus and materials for making the tests, shall drill and tap the necessary holes, and shall plug-weld the holes after testing. The plug welds shall be penetrant tested.

2.09 PIPE SUPPORTS AND ACCESSORIES

A. The Contractor shall provide pipe supports for all piping systems shown on the drawings. All pipe supports shall be hot-dipped galvanized unless otherwise noted.

1. All supports and bracing shown on the drawings are intended only to convey design intent. Support and bracing locations are the responsibility of the Contractor. Not all pipe supports and bracings are shown on the drawings. The absence of pipe supports and bracing on the drawings shall not relieve the Contractor for the responsibility for providing them.

2. Pipe hangers, supports, and restraints design and construction shall be coordinated with all electrical, plumbing, and HVAC hangers and supports to prevent conflicts. Electrical, plumbing, and HVAC supports may be combined with piping supports only where permitted by applicable codes. Refer to Sections 01650, “Pipe, Duct, Cable Tray, Raceway, and Bus Duct Supports and Seismic Bracing “, 15140, “Plumbing and Fire Protection Piping Supports and Anchors “, 15890, “Ductwork and Accessories”, and 16110, “Raceways”, for additional requirements.

B. Design Responsibility

1. The Contractor shall engage the services of an independent registered professional engineer ordinarily engaged in the business of pipe support systems analysis, to analyze system piping and service conditions, and to develop detailed support and seismic restraint systems, specific to the piping material, pipe joints, valves, and piping appurtenances proposed for use.

a. The proposed support system engineer shall have at least 5 years of experience in the analysis and design of similar systems, including the use of commercial and custom pipe supports and in the use of commercial pipe stress software programs. Provide a detailed resume, including references from projects within the past 5 years. The use of support systems engineer shall be subject to the approval of the Engineer.

2. The proposed systems engineer shall attend a conference with the Engineer, scheduled prior to any support systems design.



3. Submit a draft report to the Engineer for approval.

a. After the work is installed, but before it is filled for start-up and testing, the support system design engineer shall inspect the work and shall certify its complete adequacy. Each system shall be inspected and certified in the same way.

b. Submit a report, including all field modifications and including all certificates.

c. The report shall bear the stamp of a professional engineer registered in California and shall be subject to the approval of the Engineer.

4. Prepare for and attend a post-analysis review and presentation, after the Engineer’s review of the report. Revise per the comments and issue as Final Report.

C. Design Requirements

1. The support system design shall include:

a. Criteria by piping system.

b. Summary of Contractor-selected related components including joints, class, valves, appurtenances, etc., and commercial supports and especially including pipe materials.

c. Dead weight and dynamic analysis, including system thermal effects and pressure thrusts. Computer-based software system equivalent to ADLPIPE.

(1) Each system shall be presented in an isometric graphic and shall show the resolved and resultant force and moment systems, as well as all recommended hangers, supports, anchors, restraints, and expansion/flexible joints or expansion loops.

d. All aspects of the analysis and design shall comply with the provisions of ANSI B31.1 and the referenced standards.

e. Support arrangements shall be coordinated to eliminate interference with similar systems to be installed under HVAC, Plumbing, and Electrical; to account for structural expansion joints and to maintain access for both personnel and for the removal of equipment. Support systems shall not include the use of monorail or bridge crane support. Nor shall they rely on the horizontal structural struts.

2. Seismic Restraints

a. Seismic restraints shall be designed and provided to resist pipe movements and loads occurring as a result of an earthquake or other seismic event. Unless otherwise specified, all piping shall have bracing to resist seismic loading caused by forces applied at the individual pipe’s center of gravity. Seismic design requirements shall be in accordance with Sections 01640, “Equipment Anchorage”, and 01650, “Pipe, Duct, Cable Tray, Raceway, and Bus Duct Supports and Seismic Bracing”.

3. All supports and appurtenances shall be of approved standard design, unless otherwise acceptable to the Engineer, and shall be adequate to maintain the supported load in proper position under all operating conditions. Any reference to a specific figure number of a specific manufacturer is for the purpose of establishing a type and quality of product and shall not be considered as proprietary.

4. All items shall be designed with liberal strength and stiffness to support, restrain, and allow expansion of the respective pipes under the maximum combination of peak loading conditions to include pipe weight, liquid weight, liquid movement and pressure forces, thermal expansion and contraction, vibration, insulation, valve weight, fittings, and all probable externally applied forces.

5. All of the equipment specified herein is intended to support, restrain, and allow expansion of the various types of pipe and piping systems shown on the drawings. It shall be the responsibility of the Contractor to develop final details and any details associated with special conditions not already covered to meet the system conditions (in particular system temperatures and pressures) specified in the respective Divisions 2, 11, 13, and 15.

6. Supports shall be sufficiently close together such that the sag of the pipe is within limits that will permit drainage and avoid excessive bending stresses from concentrated loads between supports.



7. Complete design details of the pipe system components shall be submitted for review and approval as specified in Section 15060, “General Mechanical Piping", Submittals. No support shall be installed without the written approval of the Engineer.

8. All pipe and appurtenances connected to equipment shall be supported in such a manner as to prevent any strain being imposed on the equipment. When manufacturers have indicated requirements that piping loads shall not be transmitted to their equipment, submit certification stating that such requirements have been complied with.

9. All pipe and tubing shall be supported as required to prevent significant stresses in the pipe or tubing material, valves, fittings, and other pipe appurtenances, and to support and secure the pipe in the intended position and alignment. All supports shall be designed to adequately secure the pipe against excessive dislocation due to thermal expansion and contraction, internal flow forces, and all probable external forces such as equipment, pipe, and personnel contact. Any structural steel members required to brace any piping from excessive dislocation shall conform to the applicable requirements of Section 05500, “Miscellaneous Metals”, and shall be furnished and installed under Section 15060, “General Mechanical Piping”.

10. Contractor may propose minor adjustments to the piping arrangements in order to simplify the supports, or in order to resolve minor conflicts in the work. Such an adjustment might involve minor change to a pressure pipe centerline elevation so that a single trapeze support may be used. Elevations of drain lines shall not be modified without the permission of the Engineer.

11. Where flexible sleeve, split ring, vibration, or other couplings are required at equipment, tanks, etc., the end opposite to the piece of equipment, tank, etc., shall be rigidly supported to prevent transfer of force systems to the equipment. No fixed or restraining supports shall be installed between a flexible coupling and the piece of equipment.

12. Pipe supports shall not induce point loadings but shall distribute pipe loads evenly along the pipe circumference.

13. Supports shall be provided at changes in direction and elsewhere as shown in the drawings or as specified herein. No piping shall be supported form other piping or from metal stairs, ladders, and walkways, unless specifically directed or authorized by the Engineer.

14. Pipe supports shall be provided to minimize lateral forces through valves, both sides of flexible split ring type couplings and sleeve type couplings, and to minimize all pipe forces on pump housings. Pump housings shall not be utilized to support connecting pipes.

D. Specialty Supports

1. Diffuser Pipe Support Systems

a. Pipe support system shall be designed by the Contractor to resist forces from the flow of water against the diffuser. Design criteria shall be as follows:

(1) Flow of water in conduit.

(2) Concentrations of chemical in flow.

(3) Other pipe support design criteria (seismic, etc.) as specified in this section.

b. Contractor shall submit signed and sealed calculations by a registered professional engineer in the state of California showing full compliance with the requirements of this section.

c. For Hypochlorite diffuser pipe supports, the pipe support system shall be FRP, manufactured/fabricated by Enduro Composites, or equal.

PART 3 EXECUTION

3.01 INSTALLATION

A. Preparation: Before beginning installation, the interior of pipe, fittings, and appurtenances shall be thoroughly cleaned of scale, dirt, and foreign substances. The surfaces of exposed piping shall be kept free of marks and blemishes to provide an appearance and finish to the satisfaction of the Engineer. Provision shall be made to avoid abrasion of surfaces to be exposed.

B. Alternative Piping



1. The Contractor shall not install any alternative piping until he has obtained written approval from the Engineer.

2. Any installed piping not approved and subsequently found unsatisfactory shall be removed at the expense of the Contractor.

C. Laying

1. Each piping system shall be installed accurately to the indicated alignment and grade, to the satisfaction of the Engineer, and in accordance with approved shop drawings.

2. The routing of tube or pipe lines may be changed to avoid obstructions only with the prior approval of the Engineer.

3. Contractor shall field-weld stainless steel piping and fittings for LOX, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, and/or ozone off-gas/vent gas only as approved by the Engineer, and in accordance with the approved shop drawings.

D. Threaded Joints

1. Where piping is assembled with threaded joints, unions shall be installed in lateral alignments with mains and on the upstream and downstream sides of equipment, even when the unions are not shown on the drawings.

2. Unions shall be installed in accessible locations.

E. PVC Piping Systems: In PVC piping systems, Designation A or E pipe shall be used where shown on the drawings for miscellaneous short spools adjacent to valves or other equipment.

F. Galvanic Isolation: Galvanic isolation shall be provided between piping of dissimilar materials by means of insulating flanges or insulating unions in accordance with Section 13984, “Insulating Joints”. For purposes of galvanic isolation, piping Designations A, T, and GG are similar carbon steels; piping designations E, O and LL are similar stainless steels; and piping Designations B, C, and Z are similar copper alloys.

G. Embedment

1. Piping of Designations B, C, O and BB shall not be embedded or encased in concrete unless otherwise specified or ordered.

2. Where a portion of piping of Designations B, C, O or BB is shown as embedded or encased in concrete, that portion shall be of an alternative material as listed below, but in all cases subject to the Engineer's approval.

Table 4

Piping Designation as Shown Alternative Material for Embedded

or Encased Portions B or C Z or E

BB R, U, Y, or E * O E

*Choice based on service fluid compatibility with pipe interior

H. Cathodic Protection: Buried pipe with Type D or E coating, as defined in Section 09875, “Pipe Coating Systems (Type B and Type D)”, shall have a supplemental cathodic protection system installed in accordance with Section 13990, “Cathodic Protection System – Galvanic Anode”, and shall have insulating flanges, dielectric unions, or dielectric couplings installed where pipes are above ground or become exposed.

3.02 FIELD WELDING

A. Field welding shall be in accordance with the requirements described in Section 15060, “General Mechanical Piping”, Welding.

3.03 FIELD QUALITY CONTROL

A. Testing of field welding shall be in accordance with the tests described in Section 15060, “General Mechanical Piping”, Source Quality Control.

3.04 PIPING SYSTEM CLEANING

A. Cleaning shall be performed as required during assembly, and prior to pressure testing.



B. The following piping systems shall be cleaned by purging with oil-free, dry, compressed air: oil, fuel, gas, service air, instrument air, and water-free chlorine. Piping for water-free chlorine shall be certified clean by a qualified third party approved by the Engineer.

C. All LOX, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, ozone off-gas/vent gas, and contactor maintenance air piping, fittings, and associated equipment and instrumentation shall be cleaned in accordance with the approved procedure submitted under Section 15060, “General Mechanical Piping, Plans and Procedures”.

1. All piping that is 2 inches in diameter or larger shall be pigged using pre-approved pig material that is acceptable for oxygen cleaned pipe systems. The pig diameter shall be the required diameter for the pipe diameter to be tested.

2. The Contractor shall provide flanged ports on pipes that are 8 inches in diameter or larger. These ports can be used for inserting and removing the pig during the cleaning process. For 6-inch and smaller diameter pipes, ports can be installed, sections of pipe removed, or equipment removed to allow the installation and removal of each pig.

3. Once the pig is inserted into the pipe section a nitrogen source pressure is applied, to push the pig to the destination point. This process shall be repeated and continued until the Engineer is satisfied with the cleanliness level for each section of pipe.

4. Metropolitan will witness final pigged operations for each section of pipe.

5. The Contractor is responsible for supplying the nitrogen source.

6. This operation shall be performed prior to the cleanliness inspection specified in Section 01400, “Inspection of the Work”.

7. On the contactor deck, do not perform the pig cleaning operation from the flowmeter/control valve pair for each of the four chambers to each contactor. These sections of pipe shall be performed as described in Section 01400, “Inspection of the Work”.

D. Piping systems for water service and water treatment chemicals in liquid form shall be flushed out with clean, potable water. Piping shall be dried thoroughly after flushing.

3.05 PRESSURE TESTING OF PROCESS AND SERVICE PIPING

A. Testing of plumbing, drainage and venting systems shall be performed with water or air in accordance with the requirements of the UPC.

B. Pneumatic Pressure Testing of Process and Service Piping

1. The following piping systems shall be tested pneumatically: oil, fuel, gas, service air, instrument air, water-free chlorine, LOX, supplemental nitrogen gas, oxygen gas, ozone-in-oxygen gas, ozone off-gas / vent gas, and contactor maintenance air.

2. Testing for Oil, Fuel, Gas, and Air Piping

a. Prior to testing, precaution shall be taken to isolate or otherwise protect each instrument from pressures that exceed the normal operating pressure of the instrument.

b. Each system shall be tested with soap and compressed air at 150 psi. Every portion of every joint shall be swabbed with a heavy soap solution or with an approved commercial bubble-producing, leak-test fluid and shall be carefully examined for leakage. Joints that exhibit leaks shall be repaired. Repairing and testing shall be repeated as often as necessary to provide a system in which there will be no visible signs of leakage nor a drop in the 150 psig test pressure in 2 hours.

3. Test for Dry Chlorine Service

a. Prior to testing, precaution shall be taken to isolate or otherwise protect each instrument from pressures that exceed the normal operating pressure of the instrument.

b. Cleaning and testing shall be in accordance with CHI 6 and these specifications. Alternatively, connections and valves may be tested for leaks by the use of Nupro Company, Snoop Liquid Leak Detectors, or equal.



4. Test for LOX, Supplemental Nitrogen Gas, Oxygen Gas, Ozone-in-Oxygen Gas, Ozone Off-gas / Vent Gas and Contactor Maintenance Air Piping

a. Prior to testing, precautions shall be taken to protect each instrument from pressures that exceed the rating of the instrument.

b. Test in accordance with the requirements of Section 15060, “General Mechanical Piping”, Testing for Oil, Fuel, Gas, and Air Piping, using oil-free, dry compressed air and bubble-producing test fluid compatible with oxygen/ozone.

c. After completion of testing, re-clean system in accordance with Section 15060, “General Mechanical Piping”, Piping System Cleaning.

5. Test of Polyethylene Pipes and Transition Fittings for Natural Gas Service

a. The polyethylene pipe system for natural gas service shall be pneumatically tested at 50 psig for 2 hours with oil-free, dry air.

C. Hydrostatic Testing of Process and Service Piping

1. Preparation

a. The Contractor shall furnish meters for measuring the water used; all necessary certified backflow prevention devices as appropriate; valves and fittings for making connections to outlets; and hoses, piping, pumps, and other materials required to convey water to the test locations.

b. The Contractor shall provide suitable calibrated tanks or flowmeters for the measurement of leakage, and shall furnish the piping, gauges, pumps, electrical power, labor, and anything else required for filling the pipeline to be tested and for obtaining and maintaining the required water pressure.

c. Prior to the test-filling of process piping, the pipeline shall be backfilled between non-welded joints, flanges, and outlets to restrain the pipeline during hydrostatic testing. Until the hydrostatic test has been accepted by the Engineer, non-welded joints, flanges, and outlets shall be left visible and accessible for inspection except as otherwise directed by the Engineer. The piping shall not be enclosed in a manner that will prevent inspection during the test.

d. Pipelines that do not have valves shall be closed with blind flanges or caps on the ends of the sections to be tested.

e. Pipelines shall be properly braced before tests are conducted. On lines that require thrust blocks, the thrust blocks shall have been placed and the concrete shall have set to the satisfaction of the Engineer before the test is conducted.

f. At the end of the test section of pipeline, the Contractor shall provide adequate anchorage to restrain the pipe during the test. The design of the anchorage shall be submitted for approval. These anchorages shall be removed upon completion of the test.

g. Just prior to hydrostatic testing, the piping shall be cleaned or flushed out with clean water to the satisfaction of the Engineer so that it is free from obstructions, dirt, or other foreign matter.

h. The Contractor shall provide the labor, material, and equipment required to obtain, use, and dispose of the water used for test purposes. The quality of water shall be acceptable to the Engineer.

i. Water used for hydro testing shall be chlorine free, with less than 50 ppm chlorides.

j. After a test section has been filled with water, it shall be allowed to stand under pressure for sufficient time to allow air to escape before testing. Air and vacuum valves or corporation stops shall be installed to remove air from high points of the pipeline.

k. The Contractor shall be responsible for damage to the pipe as a result of pressure imposed during the pipe-filling operations and during testing. At the end of testing, the pipeline shall be restored to a condition satisfactory to the Engineer.



2. Safety

a. A safety valve shall be added to the system to protect equipment from accidental overpressure during the hydrostatic testing of lines and equipment. This valve shall be set at 10 percent above the calculated hydrostatic test pressure.

b. Permanently installed instrumentation shall be removed from the pipe prior to testing. As determined by the Engineer, pumps and other permanently installed equipment that might be damaged during testing shall also be removed or isolated.

3. Test Requirements

a. Hydrostatic test pressures shall be based on the lowest point of the line or section of line being tested.

b. Leakage will not be allowed.

c. Unless stated otherwise the hydrostatic pressures shown in Table 5 shall be applied for duration of at least 2 hours.

Table 5. Hydrostatic Test Pressure

Pipe and Fitting Type Metropolitan Designation Code for Piping

Hydrostatic Test Pressure (psig)

Carbon steel A, H, R, T, U, Y, GG 1.5x Design Pressure Brass pipe and tubing B, Z 1.5x Design Pressure Copper tubing C 1.5x Design Pressure PVC, CPVC (6 inches and smaller) D, DD, BB 150 PVC, CPVC (8 and 10 inches) D, DD 100 PVC, CPVC (12 inches and larger) D, DD 70 Stainless steel pipe and tubing E, O, LL 1.5x Design Pressure Ductile iron F, I 1.5x Design Pressure Alloy 20 JJ 1.5x Design Pressure

d. Regardless of the rate of leakage, detectable leaks shall be stopped. The Contractor shall excavate as necessary, including the removal of backfill already placed, to locate and repair leaks or other defects that may develop during testing. After making the repairs necessary to secure the required water tightness in the pipe or in its appurtenances, the Contractor shall replace the excavated materials, refill the affected reach of pipeline, and then repeat testing until the test results are found to be satisfactory. The Contractor shall be responsible for dewatering necessary as a result of defects.

e. The Contractor shall be responsible for purging all pipe, valves, tanks, and appurtenances after the hydrostatic test is completed. Closed-loop (hydronic) system piping shall be completely dried after testing and shall be kept clean and dry until charged with conditioned cooling/heating water.

END OF SECTION

October 7, 2009 15075-1 1562 (construction contract) (Addendum 2)

SECTION 15075 BRASS PIPE AND FITTINGS [Z-PIPE]

PART 1 GENERAL

1.01 REFERENCES

A. General


2. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition available on the date of Notice Inviting Bids shall be used.


1. ANSI B16.15, Cast Bronze Threaded Fittings, Classes 125 and 250

2. ANSI B120.1, Pipe Threads, General Purpose (Inch)

C. American Society for Testing and Materials (ASTM)

1. ASTM B43, Standard Specification for Seamless Red Brass Pipe, Standard Sizes

2. ASTM B62, Standard Specification for Composition Bronze or Ounce Metal Castings

1.02 SUBMITTALS:

A. Product Data: The Contractor shall submit material specifications and catalog cuts including recommendations for delivery, storage, and handling.

B. Certification: Written certification that all materials and testing are in accordance with the requirements of this section shall be furnished.

PART 2 PRODUCTS

2.01 MATERIALS

A. Unless otherwise specified or shown on the drawings, materials shall conform to the following:

1. Pipe

a. Brass pipe shall be seamless red brass pipe, standard sizes, extra strong, conforming to ASTM B43 temper H58.

b. Threadings; Pipe threads shall be per ANSI B1.20.1.

2. Fittings

a. Fittings for use with brass pipe shall be bronze or brass, 250 psi, screwed in accordance with ASTM B62 and ANSI B16.15.

PART 3 EXECUTION

3.01 INSTALLATION

A. All brass piping and fittings shall be installed as shown on the drawings and in accordance with Section 15060. Brass piping and fittings in buried service shall be wrapped with 20 mills of PVC tape. Wrapping shall be performed after all testing.

3.02 CLEANING

A. Piping shall be cleaned in accordance with Section 15060.

3.03 TESTING

A. Field hydrostatic or pneumatic testing shall be in accordance with Section 15060.

END OF SECTION


SECTION 15077 COPPER TUBING AND FITTINGS [C-PIPE]

PART 1 GENERAL

1.01 REFERENCES

A. General


2. Where a date is given for reference standards, the edition of that date shall be used. Where no date is given for reference standards, the latest edition available on the date of the Notice Inviting Bids shall be used.


1. ANSI B16.18, Cast Copper Alloy Solder Joint Pressure Fittings

2. ANSI B16.22, Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

3. ANSI B16.24, Cast Copper Alloy Pipe Flanges and Flanged Fittings Class 150, 300, 400, 600, 900, 1500, and 2500

4. ANSI B16.26, Cast Copper Alloy Fittings for Flared Copper Tubes

C. American Society for Testing and Materials (ASTM)

1. ASTM B32, Standard Specification for Solder Metal

2. ASTM B42, Standard Specification for Seamless Copper Pipe, Standard Sizes

3. ASTM B43, Standard Specification for Seamless Red Brass Pipe, Standard Sizes

4. ASTM B62, Standard Specification for Composition Bronze or Ounce Metal Castings

5. ASTM B75, Standard Specification for Seamless Copper Tube

6. ASTM B88, Standard Specification for Seamless Copper Water Tube

7. ASTM B813, Standard Specification for Liquid and Paste Fluxes for Soldering of Copper Tube

8. ASTM F467, Standard Specification for Nonferrous Nuts for General Use

9. ASTM F468, Standard Specification for Nonferrous Bolts, Hex Cap Screws, and Studs for General Use

D. American Welding Society Inc. (AWS)

1. AWS A5.8, Specification for Filler Metals for Brazing and Braze Welding

2. AWS A5.31, Specification for Fluxes for Brazing and Braze Welding

E. Compressed Gas Association (CGA)

1. CGA G-4.1, Cleaning Equipment for Oxygen Service

F. International Association of Plumbing and Mechanical Officials (IAPMO)

1. Uniform Plumbing Code (UPC)

1.02 SUBMITTALS

A. Product Data: The Contractor shall submit material specifications and catalog cuts including recommendations for delivery, storage, and handling.

B. Certification: Written certification that all materials, cleaning, and testing are in accordance with the requirements of this section shall be furnished.

C. The Contractor shall submit a field cleaning procedure for all pipes, fittings, and associated equipment that will come into contact with liquid oxygen, supplemental nitrogen gas and oxygen gas. The procedure shall ensure hydrocarbon and welding residue decontamination of the system in accordance with CGA G-4.1, and shall be as approved by the Engineer.

Copper Tubing And Fittings (C-Pipe)

1562 15077-2 October 7, 2009 Addendum 2 (construction contract)

1.03 DELIVERY, STORAGE, AND HANDLING

A. Pipe, fittings, and associated equipment for LOX, oxygen, and supplemental nitrogen gas service shall be handled and stored to maintain packaging integrity and cleanliness.

PART 2 PRODUCTS 2.01 MATERIALS

A. Unless otherwise specified or shown on the drawings, materials shall conform to the following:

1. Copper Tubing

a. Copper tubing shall be seamless cold-drawn tubing conforming to the requirements of ASTM B88, Type K, Temper O60 for buried service and Temper H58 for all other services; provided, that tubing furnished in coils and for use with flared fittings shall be annealed.

b. Tubing furnished in straight lengths shall have drawn temper.

2. Fittings

a. Fittings for copper water tubing 5/8 inch outside diameter or larger shall be wrought copper solder joint type conforming to the material requirements of ASTM B75, No. 120 or 122, and to the design and dimensional requirements of ANSI B16.22.

b. Fittings for copper tubing 1\2 inch outside diameter and smaller shall be cast bronze conforming to the requirements of ANSI B16.26 for 37 degree flared tubing; or shall be double-ferrule, compression-type. Fittings shall have a pressure rating equal or greater than the tubing, and shall be manufactured by Swagelok Companies; Parker Hannifin Corporation; or equal.

c. All unions shall have ground joints.

d. The zinc content of bronze shall not exceed 5 percent and the aluminum content shall not exceed 2 percent.

e. Insulating unions shall be as manufactured by Central Plastics; or equal.

3. Flanges, Flange Gaskets, and Flange Bolting

a. Flanges and flanged fittings shall be cast bronze conforming to ASTM B62 or Type 316 stainless steel.

b. Flanges for plumbing, air, and water service shall be Class 150, flat-faced, full thickness, serrated, and drilled. The dimensions and drilling of flanges not otherwise called for on the drawings or specified shall conform to the requirements of the 150-pound standard of ANSI B16.5. The gasket surfaces shall have a V-serrated finish of approximately 32 serrations per inch approximately 1/64-inch deep; except “O”-ring or rubber-faced gasket contact surfaces of flanges shall have smooth face finishes. The serrations may be either concentric or spiral (phonographic). A Blanchard ground finish on flange faces will not be acceptable.

c. Flange gaskets for plumbing, air, and water service shall be minimum 1/16 inch thick, full-face gaskets made of rubber sheet packing and be Crane Company “CC”; Garlock Style 22; or equal.

d. Flange gaskets for LOX service shall be minimum 1/16 inch thick, expanded PTFE suitable for cryogenic oxygen service. Gaskets shall be W.L. Gore & Associates Inc., or equal.

e. Flange gaskets for supplemental nitrogen gas and oxygen gas service shall be minimum 1/16 inch thick, expanded PTFE. Gaskets shall be W.L. Gore & Associates Inc., or equal.

f. Fasteners for cast bronze flanges shall be as follows:

(1) Flanges in submerged, partially submerged, or moist environment service shall have silicon bronze fasteners in accordance with Section 15060.

(2) Flanges in continuously dry services shall have silicon bronze bolts or studs and stainless steel nuts in accordance with Section 15060.

(3) Anti-galling compound shall be used in accordance with Section 15060.

g. Fasteners for stainless steel flanges shall be as follows:

(1) Fasteners shall be stainless steel in accordance with Section 15060.

(2) Anti-galling compound shall be used in accordance with Section 15060.



4. Brazing

a. Brazing shall be used for LOX, supplemental nitrogen gas and oxygen gas copper tubing.

(1) Brazing material for copper-to-copper or copper-to-bronze joints shall be BAg-1 or BAg-3 in accordance with AWS A5.8.

(2) Brazing material for copper-to-316 stainless steel joints shall be BAg-3, in accordance with AWS A5.8.

(3) Flux shall be Type 3A, in accordance with AWS A5.31.

5. Soldering shall be used for plumbing, air, and water service copper piping.

a. Solder shall be in accordance with ASTM B32, Grade Sb5, 95-5 tin-antimony, or Grade Sn96, 96-4 tin-silver.

b. Soldering flux shall be in accordance with ASTM B813, and shall contain less than 0.2 percent lead.

6. Nipples

a. Nipples shall be extra strong, copper threaded nipples per ASTM B42, No. 120 or 122. For plumbing, air, and water service, nipples may be red brass per ASTM B43 temper O61 when approved by the Engineer.

7. Threaded Joint Compound

a. American National taper pipe threads shall be used on all threaded joints.

b. Joint compound shall be applied to the male threads only, unless otherwise directed.

c. Pipe joint compound shall be Teflon thread sealant such as “Bakerseal” manufactured by Radiator Specialty Company; La-Co Slic-Tite manufactured by Lake Chemical Company; or equal.

d. Joint compound in LOX and oxygen service shall be approved for oxygen compatibility.

PART 3 EXECUTION

3.01 INSTALLATION

A. All copper tubing and fittings shall be installed as shown on the drawings and in accordance with Section 15060.

B. Bends shall be made by the use of fittings or with a bending tool on the proper radius to avoid flattening or kinking of the tubing. Runs of tubing that will be subjected to thermal expansion and contraction, great enough to cause the line to bow or buckle, shall be provided with expansion loops or offsets adequately spaced. Lines shown on the drawings to be parallel shall be held truly parallel by means of an adequate number of supports. No waviness or sagging of lines will be permitted. Tube and fittings shall be cleaned of all impurities before jointing.

C. Copper tubing shall be wrapped with PVC tape where copper tubing passes through sleeves in walls or floors.

D. Stainless steel pipe in accordance with Section 15070 or extra strong seamless copper pipe conforming to the requirements of ASTM B42, No. 120 or 122, shall be substituted for copping tubing wherever tubing lines are required to pass through concrete, unless otherwise shown on the drawings.

E. An insulating flange or union joint shall be provided whenever a junction occurs between dissimilar metals. Insulating joints shall be in accordance with Sections 13984 and 15060. Unions shall be installed in accessible locations. All insulating connections shall be in accordance with the manufacturer's printed instructions.

F. Soldered joints shall be made by mechanics experienced in this class of work. The joint shall be heated so that the heat is uniformly distributed around the entire circumference of the fitting. Heat shall be applied by a propane torch. The use of an oxyacetylene torch will not be allowed. Excess solder shall be removed while it is still in a plastic state. All residual flux shall be removed immediately after the solder has set. The joint shall be allowed to cool undisturbed in still air before water is applied.

G. Brazed joints shall be made by persons experienced in this class of work. The joint shall be heated uniformly around the entire circumference of the fitting. Heat shall be applied by an oxyacetylene torch. The joint shall be allowed to cool undisturbed in still air before water is applied. All residual flux shall be removed immediately after the braze has set. Brazing of copper tubing and fittings shall be in accordance with ASME BPVC, Section VIII, Part UB.

H. For flared fittings, the tube ends shall be flared so that the angle, radius, length, and diameter of the flare conforms to the corresponding dimensions of the flare seat of the fitting. The flare shall be square and concentric with the tube and fitting. Flared tube fittings shall be assembled in accordance with the manufacturer's recommendations.


1562 15077-4 October 7, 2009 Addendum 2 (construction contract)

I. Where hangers or supports are in contact with copper tubing, the portion of the support in direct contact with the copper tubing shall be of insulating material. The insulating material shall be a rigid material of high dielectric properties, such as Bakelite, or a built-up insulation consisting of multiple layers of PVC tape applied to the tubing so as to provide a total thickness of at least 70 mils.

3.02 CLEANING

A. All copper tubing and fittings for LOX, supplemental nitrogen gas and oxygen gas and associated equipment shall be cleaned and packaged in accordance with CGA G-4.1, and the approved procedure to be submitted as specified in this section. All pipe for these services shall be delivered to the site free of hydrocarbons. Piping systems for other service shall be cleaned in accordance with Section 15060.

3.03 TESTING

A. Field hydrostatic and pneumatic testing shall be in accordance with Section 15060.

END OF SECTION

document 00310 bidding sheet

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