project manual contract documents and technical

The City of Austin is committed to compliance with the Americans with Disabilities Act. Reasonable modifications and equal access to communications will be provided upon request.

CITY OF AUSTIN Public Works Department

PROJECT MANUAL

Contract Documents and Technical Specifications

VOLUME 2 of 4

CONFORMED

HORNSBY BEND BIOSOLIDS MANAGEMENT PLANT SIDE STREAM TREATMENT PLANT RELIEF PROJECT

C.I.P. PROJECT NUMBER: 3164.048 SOLICITATION NUMBER: CLMC713

It is the policy of the City of Austin to involve certified Minority Owned Business Enterprises (MBEs) and Woman Owned Business Enterprises (WBEs) in City contracting. MBE and WBE goals for this solicitation are contained in Volume 2 (or 3), M/WBE Participation for Construction Projects.

This project provides insurance to qualified Contractors. Contractors and Subcontractors of any tier shall withhold insurance costs from the bid, thus reducing the bid amount. Please refer to the Supplemental General Conditions, Section 00810, and the Project Safety Manual for specific information regarding this ROCIP.

AUSTIN WATER UTILITY

CITY OF AUSTIN Public Works Department

505 Barton Springs Rd #1300, Austin, TX 78704

AUGUST 27, 2018

TBPE No. F-882

CONFORMED DOCUMENT FOR CONSTRUCTION.

The addenda issued during the bidding period are

unified in this document. If discrepancies between this

conformed set and the bidding set are found, the

bidding set with the original addenda shall govern.

Original sealed by Leonard H.

Allen, 8/15/2018, State of Texas PE# 111050.

THIS PAGE INTENTIONALLY LEFT BLANK

August 13, 2018 9080B11

CITY OF AUSTIN PUBLIC WORKS DEPARTMENT

CIP 3164.048


CONTRACTING REQUIREMENTS AND GENERAL REQUIREMENTS

CIVIL

SECTION NUMBERS:

DIVISION 00 DIVISION 01

02050 02240 02260 02300

02318 07900 08110 08332 08522 08710

08800 09110 09250 09910 SP1

SP403S

TBPE No. F-882

Original sealed by Leonard H. Allen, 08/15/2018, State

of Texas PE# 111050.

August 13, 2018 9080B11

CIVIL

SECTION NUMBERS:

SERIES 100 SERIES 200 SERIES 300 SERIES 400 SERIES 500 SERIES 600

700S 06611 09523 09960 10400 11225

11312E 11312J 11312K 11312Q

11352 11353B 11376E 11378A 11635 13446 14612 15052 15061 15062 15075 15076 15110 15111 15112

15114 15115 15116 15118 15120 15121 15211 15230 15244 15245 15270 15286 15294 15956 15958

TBPE No. F-882

Original sealed by Thomas M. Wessling,

08/15/2018, State of Texas

PE# 116151.

August 13, 2018 9080B11

STRUCTURAL

SECTION NUMBERS:

SP401S SP403S SP406S SP410S SP411S SP416S 03055 03071

03072 03102 03150 03154 03366 03600 03920

03926 03931 05120 05140 05190 05500 13122

HVAC

SECTION NUMBERS:

15082 15084 15282 15732

15740 15762 15812 15820

15830 15852 15936 15954

TBPE No. F-882

Original sealed by Kwasi Duose,


PE# 100650.

Original sealed by Seok Min Kim,


PE# 106107.

August 15, 2018 9080B11


CIP 3164.048



CIVIL

SECTION NUMBERS:

01096 02084

02240 02620

7908 CAMERON ROAD, AUSTIN TEXAS, 78754

REG. NO. F-003572

Original sealed by Michael C. Meriwether,

8/15/2018. State of Texas PE# 58563.

March 1, 2019 - CONFORMED 9080B11


CIP 3164.048 HORNSBY BEND BIOSOLIDS MANAGEMENT PLANT


ELECTRICAL, INSTRUMENTATION AND CONTROL

SECTION NUMBERS:

13390 15170 16120 16140 16150 16200 16250 16300 16350 16450 16500 16524

16540 16550 16600 16800 17100 17200 17302 17305 17380 17502 17600

Original sealed by Vigain Harutunian, 08/14/2018, State

of Texas PE# 87736.

Original sealed by Shant Harutunian, 08/14/2018, State

of Texas PE# 87735.

Original sealed by K. A. Harutunian, 08/14/2018, State

of Texas PE# 59181.

HARUTUNIAN ENGINEERING INCORPORATED (HEI) Engineering and Environmental Consultants 305 East Huntland Drive, Suite 500 Austin, Texas 78752 (512) 454-2788 FAX (512) 454-6434TBPE Firm Registration No. F-2408

Bidding Requirements, Contract Forms and Conditions of the Contract

Table of Contents

Rev. Date 09/17/18 Table of Contents Page 1 of 7

Document Number

Date Title

VOLUME 1 09/17/18 Table of Contents AD2 BIDDING REQUIREMENTS, CONTRACT FORMS, & CONDITIONS OF THE CONTRACT 00020 07/11/18 Invitation for Bids AD1,AD4,AD5 00100 09/17/18 Instructions to Bidders AD2 00220 03/30/18 Geotechnical Data 00300L 06/29/18 Bid Form-Lump Sum 00400 03/30/18 Statement of Bidder’s Experience 00405 03/30/18 Certificate of Non-Suspension or Debarment 00410 06/29/18 Statement of Bidder’s Safety Experience 00425A 03/30/18 Insurance Cost Form 00425B 06/29/18 Rolling Owner Controlled Insurance Program Information 00440 07/11/18 Affidavit - Prohibited Activities 00475 03/30/18 Nonresident Bidder Provisions 00500 06/29/18 Agreement (SAMPLE) 00610 03/30/18 Performance Bond 00620 03/30/18 Payment Bond 00630 03/30/18 Non-Discrimination and Non-Retaliation Certificate 00631 03/30/18 Title VI Assurances Appendix A 00632 03/30/18 Title VI Assurances Appendix E 00650 07/30/12 Certificate of Insurance 00670 03/01/17 Sales Tax Exemption Certificate 00680 03/30/18 Non-Use of Asbestos Affidavit (Prior to Construction) 00681 03/30/18 Non-Use of Asbestos Affidavit (After Construction) 00700 09/17/18 General Conditions AD2 00810 03/30/18 Supplemental General Conditions 00819 06/10/05 Security Requirements SP1070 09/16/14 Facility Security Procedures for Contractors 00830 09/12/18 Wage Rates and Payroll Reporting AD2 00830BC 09/12/18 Wage Rates Building Construction Trades AD2 00830HH 09/12/18 Wage Rates Highway Heavy AD2 00900 03/30/18 Addendum (SAMPLE)


Table of Contents


SPECIFICATIONS Division 1 - General Requirements 01010 03/30/18 Summary of Work 01020 03/30/18 Allowances 01025 09/17/18 Measurement and Payment 01030 03/30/18 Alternates 01050 10/19/15 Grades Lines & Levels 01095 07/21/03 Reference Standards and Definitions 01096 05/06/11 Stormwater Pollution Prevention Plan (SWPPP) 01116 03/01/19 Contract Document Language 01140 03/01/19 Work Restrictions 01200 08/09/12 Project Meetings 01292 03/01/19 Schedule of Values 01300 06/29/18 Submittals 01310 03/01/19 Schedules and Reports 01322 03/01/19 Web Based Construction Management 01352 06/29/18 Sustainable Construction Requirements 01353 08/09/12 Construction Equipment Emissions Reduction Plan 01380 08/09/12 Construction Photography & Videos 01400 03/01/19 Quality Control Services 01410 03/01/19 Regulatory Requirements 01455 03/01/19 Special Tests and Inspections 01500 08/09/12 Temporary Facilities 01505 06/29/18 Construction and Demolition Waste Management 01510 06/29/18 Construction Indoor Air Quality Management Plan 01550 08/09/12 Public Safety and Convenience 01600 03/01/19 Materials and Equipment 01610 03/01/19 Project Design Criteria 01612 03/01/19 Seismic Design Criteria 01614 03/01/19 Wind Design Criteria 01650 03/01/19 Facility Startup/Commissioning 01670 03/01/19 Training 01700 03/01/19 Contract Closeout 01730 03/01/19 Operation and Maintenance Data 01759 03/01/19 Water Leakage Test for Concrete Structures 01783 03/01/19 Warranties and Bonds 01900 03/12/12 Prohibition of Asbestos Containing Materials 01900a 06/05/06 Statement of Non-Inclusion of Asbestos Containing Material

(E/A Prior to Design) 01900b 06/05/06 Statement of Non-Inclusion of Asbestos Containing Material

(E/A After Design)


Table of Contents


City Standard Technical Specifications Series 100 - Earthwork 102S 08/20/07 Clearing and Grubbing 111S 09/26/12 Excavation 130S 09/26/12 Borrow

Series 200 - Subgrade and Base Constructions

210S 02/24/10 Flexible Base 220S 02/24/10 Sprinkling for Dust Control 230S 08/20/07 Rolling (Flat Wheel) 232S 08/20/07 Rolling (Pneumatic Tire) 234S 08/20/07 Rolling (Tamping) 236S 08/20/07 Proof Rolling

Series 300 - Street Surface Courses 301S 08/20/07 Asphalts, Oils, and Emulsions 306S 02/24/10 Prime Coat 307S 02/24/10 Tack Coat 313S 02/24/10 Cleaning and/or Sealing Joints and Cracks (Asphaltic Concrete) 315S 09/26/12 Milling Asphaltic Concrete Pavement and Non-PCC Bases 340S 09/26/12 Hot Mix Asphaltic Concrete Series 400 - Concrete Structures and Miscellaneous Concrete 401S 09/26/12 Structural Excavation and Backfill 402S 11/13/07 Controlled Low Strength Material 403S 09/26/12 Concrete for Structures 405S 11/13/07 Concrete Admixtures 406S 09/26/12 Reinforcing Steel 408S 11/13/07 Concrete Joint Materials 409S 11/13/07 Membrane Curing 410S 09/26/12 Concrete Structures 411S 11/13/07 Surface Finishes for Concrete 416S 11/13/07 Waterstops 430S 11/15/11 P.C. Concrete Curb and Gutter 432S 01/04/10 Portland Cement Concrete Sidewalks 433S 12/09/08 P.C. Concrete Driveways Series 500 - Pipe and Appurtenances 509S 09/26/12 Excavation Safety Systems 510 10/03/13 Pipe 511S 09/26/12 Water Valves 591S 01/04/16 Riprap for Slope Protection


Table of Contents


Series 600 - Environmental Enhancement 601S 11/14/16 Salvaging and Placing Topsoil 604S 01/04/16 Seeding for Erosion Control 605S 06/21/07 Soil Retention Blanket 606S 06/21/07 Fertilizer 610S 09/26/12 Preservation of Trees and Other Vegetation 628S 12/31/13 Sediment Containment Dikes 641S 06/21/07 Stabilized Construction Entrance 642S 09/01/11 Silt Fence Series 700 - Incidental Construction 700S 09/26/12 Mobilization Special Provisions to City Standard Technical Specifications Special Specifications SP1 07/29/15 Special Provision to Measurement and Payments SP111S 09/26/12 Special Provision to Excavation AD2 SP130S 09/26/12 Special Provision to Borrow AD2 SP401S 09/26/12 Special Provision to Structural Excavation and Backfill SP403S 09/26/12 Special Provision to Concrete for Structures SP406S 09/26/12 Special Provision to Reinforcing Steel SP410S 09/26/12 Special Provision to Concrete Structures SP411S 11/13/07 Special Provision to Surface Finishes for Concrete SP416S 11/13/07 Special Provision to Waterstops SP510 10/03/13 Special Provision to Pipe SP511 09/26/12 Special Provision to Water Valves VOLUME 2 DIVISION 2 - SITE CONSTRUCTION 02084 03/01/19 Precast Drainage Structures 02240 03/01/19 Dewatering 02620 03/01/19 Filter Fabric DIVISION 3 - CONCRETE 03055 03/01/19 Adhesive-Bonded Reinforcing Bars and All Thread Rods in

Concrete 03071 03/01/19 Epoxies 03072 03/01/19 Epoxy Resin/Portland Cement Bonding Agent 03154 03/01/19 Hydrophilic Rubber Waterstop 03600 03/01/19 Grouting 03920 08/15/18 Concrete Resurfacing AD2 03926 08/15/18 Structural Concrete Repair AD2 03931 08/15/18 Epoxy Injection System AD2


Table of Contents


DIVISION 5 - METALS 05140 03/01/19 Structural Aluminum 05190 03/01/19 Mechanical Anchoring and Fastening to Concrete and Masonry 05500 03/01/19 Metal Fabrications AD2 DIVISION 6 - WOOD AND PLASTICS 06611 03/01/19 Fiberglass Reinforced Plastic Fabrications DIVISION 7 - THERMAL AND MOISTURE PROTECTION 07900 03/01/19 Joint Sealants DIVISION 8 - DOORS AND WINDOWS 08110 03/01/19 Hollow Metal Doors and Frames 08332 03/01/19 Overhead Coiling Doors 08520 03/01/19 Aluminum Windows 08710 03/01/19 Door Hardware 08800 03/01/19 Glazing DIVISION 9 - FINISHES 09110 03/01/19 Non-Load Bearing Wall Framing 09250 03/01/19 Gypsum Board 09523 03/01/19 Acoustical Panels AD2 09910 03/01/19 Painting 09960 03/01/19 High-Performance Coatings DIVISION 10 - SPECIALTIES 10400 03/01/19 Signage DIVISION 11 - EQUIPMENT 11225 03/01/19 Portable Anoxic Submersible Mixers 11312E 03/01/19 Horizontal Screw Centrifugal Pumps 11312J 03/01/19 Submersible Vortex Sump Pumps 11312K 03/01/19 Submersible Medium Capacity Centrifugal Pumps 11312Q 03/01/19 Horizontal Chopper Centrifugal Pumps 11352 03/01/19 Circular Primary Clarifier Equipment AD2 11353B 03/01/19 Circular Secondary Clarifier Equipment AD2 11376E 03/01/19 Multi-Stage Centrifugal Blower Systems AD2 11378A 03/01/19 Membrane Disk Fine Bubble Diffused Aeration System 11510 03/01/19 Safety Equipment 11635 03/01/19 Automatic Samplers DIVISION 12 - FURNISHINGS 12310 03/01/19 Manufactured Metal Casework DIVISION 13 - SPECIAL CONSTRUCTION 13122 03/01/19 Metal Building System AD2 13390 03/01/19 Packaged Control Systems


Table of Contents


13446 03/01/19 Manual Actuators 13447 03/01/19 Electric Actuators AD2 DIVISION 14 - CONVEYING EQUIPMENT 14612 03/01/19 Davit Cranes DIVISION 15 - MECHANICAL 15050 03/01/19 Common Work Results for Mechanical Equipment 15052 03/01/19 Common Work Results for General Piping AD2 15061 03/01/19 Pipe Supports 15062 03/01/19 Preformed Channel Pipe Support System 15075 03/01/19 Equipment Identification 15076 03/01/19 Pipe Identification 15082 03/01/19 Piping Insulation AD2 15084 03/01/19 Ductwork Insulation 15110 03/01/19 Common Work Results for Valves 15111 03/01/19 Ball Valves 15112 03/01/19 Butterfly Valves for Air Service AD2 15114 03/01/19 Check Valves 15115 03/01/19 Gate, Globe, and Angle Valves 15116 03/01/19 Plug Valves 15117 03/01/19 Specialty Valves 15119 03/01/19 Air Vacuum Relief Valves 15120 03/01/19 Piping Specialties AD2 15121 03/01/19 Pipe Couplings 15170 03/01/19 Electrical Motor, Induction, 600 Volts and Below 15245 03/01/19 Drain, Waste, and Vent Piping 15282 03/01/19 Copper Tube: Seamless, ASTM B280 15286 03/01/19 Stainless Steel Pipe and Tubing 15294 03/01/19 Rubber Hose 15400 03/01/19 Plumbing Fixtures and Equipment AD2 15732 03/01/19 Air Conditioning Units 15740 03/01/19 Heat Pumps 15762 03/01/19 Heating Units 15772 03/01/19 Process Piping and Equipment Heat Tracing AD2 15812 03/01/19 Metal Ducts 15820 03/01/19 Ductwork Accessories 15830 03/01/19 Fans 15852 03/01/19 Louvers 15936 03/01/19 Instrumentation and Control Devices for HVAC 15954 03/01/19 Testing, Adjusting, and Balancing for HVAC 15958 03/01/19 Mechanical Equipment Testing DIVISION 16 - ELECTRICAL 16120 03/01/19 480 Volt Motor Control Centers 16140 03/01/19 Switchboards 16150 03/01/19 Raceways, Fittings and Supports 16200 03/01/19 Wiring (600 Volts and Below) 16250 03/01/19 Boxes and Cabinets 16300 03/01/19 Wiring Devices 16350 03/01/19 Lighting 16450 03/01/19 600 Volts and Below Dry Type Transformers 16500 03/01/19 Panelboards


Table of Contents


16524 03/01/19 480 Volt Automatic Transfer Switches 16540 03/01/19 Field Control Stations and Field Control Panels 16550 03/01/19 Grounding 16600 03/01/19 Disconnect Switches and Enclosures 16800 03/01/19 Calibration, Testing and Settings DIVISION 17 - INSTRUMENTATION AND CONTROLS 17100 03/01/19 Process Instrumentation and Control Systems (PICS) 17101 03/01/19 Specific Control Strategies 17200 03/01/19 Instrumentation and Control Cabinets and Associated

Equipment 17302 03/01/19 Flow Measurement: Magnetic Flowmeters 17305 03/01/19 Flow Measurement: Thermal Mass 17315 03/01/19 Parshall Flume - Primary Flow Element 17380 03/01/19 Field Instrumentation and Sensing Devices 17502 03/01/19 Analyzers - Oxidation Reduction Potential 17600 03/01/19 Distributed Control System AD3 VOL. 3 of 4 03/01/17 MBE/WBE Procurement Program Package VOL. 4 of 4 06/2018 ROCIP Project Safety Manual 08/2018 Drawings

END

AD2 Addendum No. 2 - October 4, 2018 AD1 Addendum No. 1 - September 26, 2018 AD4 Addendum No. 4 - October 5, 2018 AD5 Addendum No. 5 - October 5, 2018 AD3 Addendum No. 3 - October 4, 2018

March 1, 2019 - CONFORMED 02084-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/02084 (CONFORMED)

SECTION 02084

PRECAST DRAINAGE STRUCTURES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Onsite utility structures: 1. Precast concrete manholes.

B. Related sections: 1. Section 02318 - Trenching. 2. Section 03300 - Cast-in-Place Concrete. 3. Section 05500 - Metal Fabrications. 4. Section 07900 - Joint Sealants. 5. Section 09960 - High-Performance Coatings

1.02 REFERENCES

A. ASTM International (ASTM): 1. C 361 - Standard Specification for Reinforced Concrete Low-Head Pressure

Pipe. 2. C 478 - Standard Specification for Precast Reinforced Concrete Manhole

Sections. 3. C 857 - Standard Practice for Minimum Structural Design Loading for

Underground Precast Concrete Utility Structures. 4. C 858 - Standard Specification for Underground Precast Concrete Utility

Structures.

1.03 SYSTEM DESCRIPTION

A. Performance requirements: 1. Manholes and appurtenances: Manholes and appurtenances shall be

watertight and free from infiltration or exfiltration.

1.04 SUBMITTALS

A. Shop drawings: Submit shop drawings for precast utility structures.

PART 2 PRODUCTS

2.01 MANUFACTURED UNITS

A. Precast concrete manholes: 1. Construct precast concrete manholes in accordance with design, size, shape,

form, details, and at locations indicated on the Drawings and specified. 2. Construct manholes of precast eccentric or concentric manhole units in

accordance with the requirements indicated on the Drawings and specified.


3. Provide precast, cylinder units, taper sections, and eccentric flat top sections meeting strength requirements in accordance with ASTM C 478.

4. Base design and manufacture to A-16 (HS 20-44) loading in accordance with ASTM C 857.

5. Construct precast manhole sections of Class D concrete as specified in Section 03300 to form and dimensions indicated on the Drawings.

6. Coat the interior of concrete manholes for corrosion resistance as specified in Section 09960.

2.02 ACCESSORIES

A. Precast concrete manholes: 1. Joint sealant: Use precast concrete joint sealant as specified in Section 07900. 2. Manhole frames and cover sets: Type, size, and quality as specified in

Section 05500 or as indicated on the Drawings. 3. Piping penetrations through cylinder units:

a. Install Kor-N-Seal, or equivalent, rubber gasket boots with steel clamps. b. Piping connections to the manhole bases shall be as indicated on the

Drawings.

PART 3 EXECUTION

3.01 INSTALLATION

A. Standpipes for irrigation or drainage pipes: 1. Excavation and backfill: As specified in Section 02318.

B. Concrete manholes: 1. Excavation and backfill: As specified in Section 02318. 2. Precast concrete manholes:

a. Manhole bases: 1) Form and place concrete on undisturbed soil and/or on aggregate

base course compacted to 95 percent of maximum density. 2) Form that portion of base above invert elevation of sewer pipe to

provide smooth channel section as indicated on the Drawings. 3) Check forms for accuracy of dimensions and relative smoothness

prior to placing concrete for base. Channels shall vary uniformly in size and shape from inlet to outlet if required.

4) Construct of Class A concrete as specified in Section 03300 to form and dimensions indicated on the Drawings.

5) Place base concrete as monolith. b. Manhole sections:

1) Set each manhole section plumb. 2) Use sections of various heights and adjustment rings to bring top of

manhole ring and cover to required elevation. c. Joints:

1) Seal joints with precast concrete joint sealant as specified in Section 07900 unless otherwise indicated on the Drawings.

2) Clean joints with brush and prime.


3) Apply precast concrete joint sealant as follows, except where instructions differ from manufacturer's printed instructions. Where these instructions differ from manufacturer's instructions, install precast concrete joint sealant in accordance with manufacturer's written instructions: a) Remove silicon treated protective paper from one side of

preformed rope and lay preformed rope, paper side up, on cleaned joint surface. Press surface firmly end-to-end around entire joint, making minimum 1-inch laps where necessary.

b) Remove protective paper from preformed rope and lower next section into place.

4) Seal joints watertight. d. Manhole frame and cover sets:

1) Install manhole frames and cover sets at locations indicated on the Drawings.

2) Setting: a) Set manhole frames and covers at elevations and requirements

indicated on the Drawings. (1) Where no paving exists, set manhole cover 6 inches above

surrounding grade. b) Where structure is outside limits of traveled shoulder but not in

roadside ditch, place structure 1/10 foot or more above existing ground surface.

c) Where cover is in existing pavement or in traveled way of existing road shoulder, place cover flush with existing surface.

d) Where manhole cover falls in existing roadside ditch or right of way, place manhole cover approximately 1-1/2 feet above existing ground surface.

e) Set manhole frames at required grade and securely attach to top of precast manhole shaft unit or on adjustment rings, using cement mortar.

f) Setting covers: (1) After frames are securely set in place in accordance with

requirements specified, install covers and perform necessary cleaning and scraping of foreign materials from frames and covers as required to accomplish and to assure proper fit.

(2) Any frame and cover which creates noise when passed over by traffic shall be replaced.

3.02 FIELD QUALITY CONTROL

A. Tests: 1. Sewer manholes: Vacuum test all sanitary sewer manholes. Use following

vacuum test procedures and requirements: a. After completion of the manhole barrels but prior to backfilling and grade

ring installation, seal all openings in the manhole with plugs and a rubber ring "donut" type plug inserted inside the opening of the cone.

b. Attach a small vacuum pump to a hose connected to the plug and apply 4 pounds per square inch of vacuum. 1) Allow vacuum to stabilize at 3.5 pounds per square inch for 1 minute,

then begin the test.


2) The manhole must maintain vacuum such that no greater than 0.5 pounds per square inch of vacuum is lost during the specified test period.

c. The specified test period is as follows: Manhole Depth (Feet) Minimum Test Period (Minutes)

0-5 4.5

5-10 5.5

10-15 6.0

Greater than 15 6.5 d. Patch as required and retest manholes that fail the test. e. Provide a vacuum regulator on the vacuum pump such that no greater

than 4 pounds per square inch can be applied to the manhole during the test.

f. Repair all manholes that do not meet the leakage test, or are unsatisfactory from visual inspection. 1) Retest after repair is completed.

END OF SECTION


SECTION 02240

DEWATERING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Installation and maintenance of dewatering systems. 2. Disposal of water entering excavation or other parts of the work.

B. Related sections: 1. Section 0403S - Concrete for Structures. 2. Section 03600 - Grouting.

1.02 REFERENCES

A. National Electrical Manufacturers Association (NEMA): 1. 250 – Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS

A. NEMA Type 4X enclosure in accordance with NEMA 250.


A. Design requirements: 1. Keep excavations reasonably free from water. Draw down static groundwater

level to minimum of 3 feet below anticipated bottom of excavations before the excavation reaches bottom elevation.

2. Dewatering design analysis. Include following: a. Evaluation of anticipated subsurface conditions. b. Required well spacing. c. Diameter of wells. d. Depth to screen, screen height, and mesh size. e. Backfill and filter pack. f. Pump size. g. Drawdown duration. h. Drawdown and steady state flow rates. i. Plans for de-silting of groundwater before discharge. j. Expected settlements.

3. Include water drawdown curves in dewatering calculations. 4. Coordinate dewatering design with excavation and shoring design. Excavation

and shoring design shall consider changes in groundwater conditions and associated earth pressures.

5. Do not place concrete or masonry foundations or concrete slabs in water. Do not allow water to rise over these elements until concrete or mortar has set for at least 24 hours.


6. Maintain operation of dewatering system until complete structure -- including walls, slabs, beams, struts, and other structural elements -- has been constructed; concrete has attained its specified compressive strength; and backfill has been completed to finished grade.

7. Provide standby power to ensure continuous dewatering in case of power failure.

B. Dewatering shored excavations: 1. Dewater from within shoring. 2. Use impermeable shoring system to minimize lowering of groundwater outside

shoring. 3. Extend impermeable shoring below bottom of excavation sufficient amount to:

a. Minimize lowering of groundwater outside shoring. b. Prevent unstable excavation due to piping and heave.

4. To minimize settlement outside shoring due to dewatering, do not lower groundwater outside shoring more than 1 foot. Provide groundwater recharge if required to maintain this groundwater elevation outside of shoring.

5. Provide monitoring wells located outside shoring for monitoring groundwater elevation.

C. Obtain written permission from Engineer before locating wells, well points, or drain lines for dewatering within the limits of a structure’s foundation.

D. Locate dewatering facilities where they will not interfere with utilities and construction work to be performed by others.

E. Discharge. 1. Discharge water to on-site ponds.

1.05 SUBMITTALS

A. Dewatering plan: 1. Dewatering design analysis. 2. Required permits. 3. Arrangement, location, and depths of dewatering system components. 4. Type and sizes of filters. 5. Identify proposed alignment, support, and protection for discharge pipe.

Identify location of discharge and provide details for that location.

B. Well construction logs. Include: 1. Descriptions of actual materials encountered, categorized in accordance with

Unified Soil Classification System. 2. Construction details. 3. Well development procedures and results. 4. Deviations from original design.

C. Qualifications: 1. Dewatering contractor. 2. Dewatering design engineer. 3. Testing laboratory.


1.06 QUALITY ASSURANCE

A. Dewatering plan and dewatering system analysis: 1. Prepared by a qualified Civil Engineer, licensed in the state where the Project

is located. a. The dewatering design engineer shall have at least 8 years of experience

in designing similar systems.

B. Submit qualifications of Dewatering Contractor, the Dewatering Design Engineer, sampling service, and testing laboratory.

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION

3.01 INSTALLATION

A. During construction, provide and maintain ample means and devices to promptly remove and properly dispose of water entering excavation or other parts of the work, whether water is surface water or underground water.

B. Keep excavations reasonably free of water.

C. Make provisions to maintain continuous dewatering. 1. Provide standby power to maintain dewatering during power outages and

interruptions. 2. Provide 24-hour monitoring by personnel skilled in operation and maintenance

of the system, and capable of providing or obtaining work required to maintain system operation.

D. Intercept and divert precipitation and surface water away from excavations. Use dikes, curb walls, ditches, pipes, sumps, or other means acceptable to Engineer.

E. Disposal of water: 1. Dispose of water from the work in suitable manner without damage to adjacent

property. 2. Do not drain water into work built or under construction. 3. Dispose of water in such manner that it will not be a menace to public health or

safety.

F. Wells, well points, and drain lines for dewatering: 1. Provide after receiving Engineer's written acceptance. 2. Fill dewatering wells, pipes, and french drains to be left in place within

structure foundation limits with Class “C” concrete as specified in Section 03300 or grout as specified in Section 03600.


3.02 CONSTRUCTION

A. Prior to release of groundwater to its static level: Confirm that: 1. All groundwater pressure relief devices for structure are fully operational. 2. Construction of structure is complete and concrete has reached its specified

compressive strength. 3. Backfill of structure is complete.

B. Control release of groundwater to its static level to prevent disturbance of natural foundation soils or compacted backfills and fills and to prevent flotation or movement of structures, pipelines, or other facilities.

END OF SECTION


SECTION 02620

FILTER FABRIC

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Nonwoven filter fabric.

1.02 REFERENCES

A. ASTM International (ASTM): 1. D 4355 - Standard Test Method for Deterioration of Geotextiles by Exposure to

Light, Moisture and Heat in a Xenon Arc Type Apparatus. 2. D 4491 - Standard Test Methods for Water Permeability of Geotextiles by

Permittivity. 3. D 4533 - Standard Test Method for Trapezoid Tearing Strength of Geotextiles. 4. D 4632 - Standard Test Method for Grab Breaking Load and Elongation of

Geotextiles. 5. D 4751 - Standard Test Method for Determining Apparent Opening Size of a

Geotextile. 6. D 5261 - Standard Test Method for Measuring Mass per Unit Area of

Geotextiles. 7. D 6241 - Standard Test Method for the Static Puncture Strength of Geotextiles

and Geotextile-Related Products Using a 50-mm Probe.

1.03 DEFINITIONS

A. Filter fabric: Nonwoven geotextile fabric manufactured from polypropylene fibers.

1.04 SUBMITTALS

A. Product data.

B. Samples.

C. Quality control submittals: 1. Certificates of Compliance. 2. Manufacturer's Instructions.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Storage and protection: 1. Furnish filter fabric in protective covers capable of protecting the fabric from

ultraviolet rays, abrasion, and water.

1.06 PROJECT CONDITIONS

A. Take field measurements to determine the lengths and dimensions of the surfaces to receive the fabric.


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Propex, Geotex 401. 2. Ten Cate Geosynthetics, Mirafi 140N.

2.02 MATERIAL REQUIREMENTS

A. Physical properties: Meet the following minimum requirements:

Property (1) Test Method Unit Requirements (1)

Minimum Weight ASTM D 5261 oz 4.0 Grab Tensile Strength ASTM D 4632 lbs 100 Grab Elongation ASTM D 4632 % 50 Trapezoid Tear Strength ASTM D 4533 lbs 50 CBR Puncture Resistance ASTM D 6241 lbs 300 UV Resistance (strength retained at 500 hrs) ASTM D 4355 % 70 Apparent Opening Size (AOS) ASTM D 4751 US sieve 70 Permittivity ASTM D 4491 sec-1 1.7 Flow Rate ASTM D 4491 gpm/ft2 130 (1) Minimum average roll values.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verification of conditions: Verify that conditions are satisfactory for the installation of filter fabric.

3.02 PREPARATION

A. Surface preparation: 1. During grading operations, take care not to disturb the subgrade. 2. This may require use of lightweight dozers for low strength soils such as

saturated, cohesionless, or low cohesion soils.

B. Prior to placement of fabric: Prepare surface to smooth condition free of debris, depressions, or obstructions that may damage the fabric.

3.03 INSTALLATION

A. Follow manufacturer's installation instructions and as complimented herein.

B. Place the filter fabric smoothly without folds or wrinkles.

C. Use special care when placing the filter in contact with the soil so that no void spaces occur between the filter and the prepared surface.


D. Overlap the parallel rolls and ends of rolls a minimum of 24 inches and not less than manufacturer's instructions.

E. Do not drag filter fabric across subgrade.

F. Make overlaps at ends of rolls in the direction of the aggregate placement with the previous roll on top.

G. Use lightweight dozers if necessary. Do not allow equipment directly on filter fabric.


A. Inspection: 1. Before covering, the condition of the fabric will be observed by the Engineer to

determine that no holes or rips exist in the fabric. 2. Repair all holes and rips by placing a new layer of fabric extending beyond the

defect in all directions a distance equal to the minimum overlap required for adjacent rolls.

END OF SECTION


SECTION 03055

ADHESIVE-BONDED REINFORCING BARS AND ALL THREAD RODS IN CONCRETE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Bonding reinforcing bars and all thread rods in concrete using adhesives.

B. Related sections: 1. Section 406S - Reinforcing Steel 2. Section 01410 - Regulatory Requirements. 3. Section 01400 - Quality Control Services. 4. Section 01610 - Project Design Criteria 5. Section 01612 - Seismic Design Criteria. 6. Section 05120 - Structural Steel.

1.02 REFERENCES

A. American Concrete Institute (ACI). 1. 355.4 - Qualification of Post-Installed Adhesive Anchors in Concrete and

Commentary.

B. American National Standards Institute (ANSI): 1. Standard B212.15 - Carbide Tipped Masonry Drills and Blanks for Carbide

Tipped Masonry Drills.

C. ASTM international (ASTM): 1. C881 - Standard Specification for Epoxy-Resin-Base Bonding Systems for

Concrete.

D. Concrete Reinforcing Steel Institute (CRSI).

E. ICC Evaluation Service, Inc. (ICC-ES): 1. AC308 - Acceptance Criteria for Post-Installed Adhesive Anchors in Concrete

Elements.

F. Society for Protective Coatings (SSPC): 1. SP-1 - Solvent Cleaning.

1.03 DEFINITIONS

A. Evaluation Report: Report prepared by ICC-ES, or other testing agency acceptable to Engineer and to the Building Official, that documents testing and review of a product to confirm that it complies with the requirements of designated ICC-ES Acceptance Criteria, and to document its acceptance for use under the Building Code specified in Section 01410.


1.04 SUBMITTALS

A. Product Data: Technical data for adhesives, including: 1. Manufacturer's printed installation instructions (MPII). 2. Independent laboratory test results indicating allowable loads in tension and

shear for concrete of the types included in this Work, with load modification factors for temperature, spacing, edge distance, and other installation variables.

3. Handling and storage instructions.

B. Quality control submittals: 1. Special inspection: Detailed step-by-step instructions for the special inspection

procedures required by the building code specified in Section 01410. 2. For each adhesive to be used, Evaluation Report confirming that the product

complies with the requirements of AC308 for both un-cracked and cracked concrete and for use in Seismic Design Categories A through F.

3. Installer qualifications: a. Submit evidence of successful completion of adhesive manufacturer's

installation training program. b. Submit evidence of current certification for installation of inclined and

overhead anchors under sustained tension loading.

C. Inspection and testing reports: 1. Inspections - Field quality control: Reports of inspections and tests.

a. Inspections - Field quality assurance: Reports of special inspections and tests.


A. Qualifications: 1. Installation requirements:

a. Have available at the site, and install anchors in accordance with, the adhesive manufacturer's printed installation instructions.

2. Installer qualifications: a. Demonstrating successful completion of adhesive manufacturer's on-site

training program for installation of adhesive-bonded anchors. b. Holding current certification for installation of adhesive-boonded anchors

by a qualified organization acceptable to the Engineer and to the Building Official. 1) Organizations/certification programs deemed to be qualified are:

a) ACI-CRSI Adhesive Anchor Installer Certification Program. b) Adhesive anchor manufacturer's certification program, subject to

acceptance by the Engineer and the Building Official.


A. Store and protect products as follows, unless more restrictive requirements are recommended by the manufacturer: 1. Store adhesives and adhesive components on pallets or shelving in a covered-

storage area protected from weather. 2. Control temperature to maintain storage within manufacturer's recommended

temperature range.


a. If products have been stored at temperatures outside manufacturer's recommended range, test by methods acceptable to the Engineer to confirm acceptability before installing in the Work.

3. Dispose of products that have passed their expiration date.


A. As specified in Section 01610 and Section 01612.

B. Seismic Design Category (SDC) for structures as specified in Section 01610.

PART 2 PRODUCTS

2.01 GENERAL

A. Like items of materials: Use end products of one manufacturer in order to achieve structural compatibility and singular responsibility.

B. Adhesives shall have a current Evaluation Report documenting testing and compliance with the requirements or ACI 355.4 and of ICC-ES AC308 for use with un-cracked concrete and with cracked concrete in the Seismic Design Category specified.

C. Bond reinforcing bars and all thread rods in concrete using epoxy adhesive unless other adhesives specified are specifically indicated on the Drawings or approved in writing by the Engineer.

2.02 EPOXY ADHESIVE

A. Materials: 1. Meeting the physical requirements of ASTM C881, Type IV, Grade 3, Class B

or C depending on site conditions. 2. 2-component, 100 percent solids, insensitive to moisture. 3. Cure temperature, pot life, and workability: Compatible with intended use and

environmental conditions.

B. Packaging: 1. Disposable, self-contained cartridge system furnished in side-by-side

cartridges designed to fit into a manually or pneumatically operated caulking gun, and with resin and hardener components isolated until mixing through manufacturer's static mixing nozzle. a. Nozzle designed to dispense components in the proper ratio and to

thoroughly blend the components for injection from the nozzle directly into prepared hole.

b. Provide nozzle extensions as required to allow full-depth insertion and filing from the bottom of the hole.

2. Container markings: Include manufacturer's name, product name, batch number, mix ratio by volume, product expiration date, ANSI hazard classification, and appropriate ANSI handling precautions.

C. Manufacturers: One of the following or equal: 1. Hilti, Inc., Tulsa, OK: HIT-RE 500-V3.


2. Powers Fasteners, Inc, Towson MD: Powers Pure110+. 3. Simpson Strong-Tie Company, Inc., Pleasanton, CA: SET-XP.

2.03 ALL THREAD RODS

A. Materials: As specified in Section 05120 for rods, nuts and washers.

2.04 REINFORCING BARS

A. As specified in Section 406S.

PART 3 EXECUTION

3.01 GENERAL

A. Execution of this work is restricted to installers who have personally completed the adhesive manufacturer's on-site training for the products to be installed, and who are personally certified through a qualified certification program described under Quality Assurance and accepted by the Engineer and the Building Official. 1. Do not install holes or adhesive until training is complete.

B. Perform work in strict compliance with the accepted MPII and the following instructions. Where the accepted MPII and the instructions conflict, the MPII shall prevail.

C. Install reinforcing bars and all thread rods to embedment depth, and at spacing and locations indicated on the Drawings. 1. If embedment depth is not indicated, contact Engineer for requirements. 2. Do not install adhesive-bonded all thread rods or reinforcing bars in upwardly

inclined or overhead applications unless accepted in advance by Engineer.

3.02 PREPARATION

A. Do not begin installation of adhesive bonded anchors until: 1. Concrete has achieved an age of at least 21 days after placement. 2. On-site training in installation of adhesive bonded anchors by manufacturer's

technical representative is complete. Do not drill holes in concrete or install adhesive and embeds in holes.

B. Review manufacturer's printed installation instructions (MPII) and "conditions of use" stipulated in the Evaluation Report before beginning work. 1. Bring to the attention of the adhesive manufacturer's technical representative

any discrepancies between these documents, and resolve before proceeding with installation.

C. Install adhesive bonded anchors in full compliance with manufacturer's printed installation instructions using personnel who have successfully completed manufacturer's on-site training for products to be used and who hold certifications specified in this Section.


D. Confirm that adhesive and substrate receiving adhesive are within manufacturer's recommended range for temperature and moisture conditions, and will remain so during the curing time for the product.

3.03 HOLE SIZING AND INSTALLATION

A. Drilling holes: 1. Determine location of reinforcing bars or other obstructions with a

nondestructive indicator device, and mark locations with construction crayon on the surface of the concrete.

2. Do not damage or cut existing reinforcing bars, electrical conduits, or other items embedded in the existing concrete without prior acceptance by Engineer.

B. Hole drilling equipment: 1. Electric or pneumatic rotary impact type with medium or light impact.

a. Installation of anchors in cored holes is not permitted. b. Set drill to "rotation only" mode, or to "rotation plus hammer" mode in

accordance with the manufacturer's installation instructions and the requirements of the Evaluation Report.

c. Where edge distances are less than 2 inches and "rotation plus hammer" mode is permitted, use lighter impact equipment to prevent micro-cracking and concrete spalling during the drilling process.

2. Drill bits: Carbide-tipped in accordance with ANSI B212-15 unless otherwise recommended by the manufacturer or required as a "condition of use" in the Evaluation Report. a. Hollow drill bits with flushing air systems are preferred. Air supplied to

hollow drill bits shall be free of oil, water, or other contaminants that will reduce bond.

C. Hole diameter: As recommended in the manufacturer's installation instructions and the Evaluation Report.

D. Hole depth: As recommended in the manufacturer's installation instructions to provide minimum effective embedment indicated on the Drawings.

E. Obstructions in drill path: 1. If an existing reinforcing bar or other obstruction is hit while drilling a hole,

unless otherwise accepted by Engineer, stop drilling. Prepare and fill the hole with dry-pack mortar. Relocate the hole to miss the obstruction and drill another hole to the required depth. a. Obtain Engineer's acceptance of distance between abandoned and

relocated holes before proceeding with the relocation. b. Allow dry-pack mortar to cure to a strength equal to that of the

surrounding concrete before resuming drilling in the area. c. Epoxy grout may be substituted for dry-pack mortar when accepted by

Engineer. 2. Avoid drilling an excessive number of holes in an area of a structural member,

which would excessively weaken the member and endanger the stability of the structure.


3. When existing reinforcing steel is encountered during drilling and when specifically accepted by Engineer, enlarge the hole by 1/8 inch, core through the existing reinforcing steel at the larger diameter, and resume drilling at original hole diameter using pneumatic rotary impact drill.

4. Bent bar reinforcing bars: Where edge distances are critical, and interference with existing reinforcing steel is likely, if acceptable to Engineer, drill hole at 10 degree (or less) angle from axis of reinforcing bar or all thread rod being installed.

F. Cleaning holes: 1. Insert air nozzle to bottom of hole and blow out loose dust.

a. Use compressed air that is free of oil, water, or other contaminants that will reduce bond.

b. Provide minimum air pressure of 90 pounds per square inch for not less than 4 seconds.

2. Using a stiff bristle brush with diameter that provides contact around the full perimeter of the hole, vigorously brush hole to dislodge compacted drilling dust. a. Insert brush to the bottom of the hole and withdraw using a simultaneous

twisting motion. b. Repeat at least 4 times.

3. Repeat the preceding steps as required to remove drilling dust or other material that will reduce bond, and in the number of cycles required by the MPII and the Evaluation Report.

4. Leave prepared holes clean and dry. 5. Protect prepared and cleaned holes from contamination and moisture until

adhesive is installed. 6. Re-clean and dry previously prepared holes if, in the opinion of the Engineer,

the hole has become contaminated after initial cleaning.

3.04 INSTALLATION OF ADHESIVE AND INSERTS

A. Clean and prepare inserts reinforcing bars and all thread rods: 1. Prepare embedded length of reinforcing bars and all thread rods by cleaning to

bare metal. Inserts shall be free of oil, grease, paint, dirt, mill scale, rust, or other coatings that will reduce bond.

2. Solvent clean prepared reinforcing bars and all thread rods over the embedment length in accordance with SSPC SP-1. Provide an oil and grease free surface for bonding of adhesive to steel.

B. Fill holes with adhesive: 1. Starting at the bottom of the hole, fill hole with adhesive inserting the

reinforcing bar or all thread rod. 2. Fill hole as nozzle is withdrawn without creating air voids. 3. Unless otherwise indicated on the Drawings, fill hole with sufficient adhesive

so that excess adhesive is extruded out of the hole when the reinforcing bar or all thread rod is inserted.

4. Where necessary, seal hole at surface of concrete to prevent loss of adhesive during curing.


C. Installing reinforcing bars and all thread rods: 1. Unless otherwise indicated on the Drawings, install bars and rods

perpendicular to the concrete surface. 2. Insert reinforcing bars and all thread rods into adhesive in accordance with

manufacturer's recommended procedures. 3. Confirm that insert has reached the designated embedment in the concrete,

and that adhesive completely surrounds the embedded portion. 4. Securely brace bars and all thread rods in place to prevent displacement while

the adhesive cures. Bars and rods displaced during curing will be considered damaged and replacement will be required.

5. Clean excess adhesive from the mouth of the hole.

D. Curing and loading. 1. Provide and maintain curing conditions recommended by the adhesive

manufacturer for the period required to fully cure the adhesive at the temperature of the concrete.

2. Do not disturb or load bonded embeds until manufacturer's recommended cure time, based on temperature of the concrete, has elapsed.

3.05 POST-INSTALLATION ACTIVITIES

A. Do not bend bars or all-thread rods after bonding to the concrete, unless accepted in advance by the Engineer.

B. Attachments to all thread rods: 1. After assemblies to be connected are placed, install nuts and washers for

threaded rods as indicated on the Drawings. 2. Draw nuts down tight, using practices specified for "snug tight" installation of

bolts in steel to steel connections.


A. Provide field quality control over the Work of this Section as specified in Section 01400.

B. Do not allow work described in this Section to be performed by individuals who do not hold the specified certifications and who have not completed the specified job site training.

C. Manufacturer's services: 1. Before beginning installation, furnish adhesive manufacturer's technical

representative to conduct on-site training in proper storage and handling of adhesive, drilling and cleaning of holes, and preparation and installation of reinforcing bars and all thread rods. a. Provide notice of scheduled training to Engineer and to Special

Inspector(s) not less than 10 working days before training occurs. Engineer and Special Inspector may attend training sessions.

2. Submit record, signed by the manufacturer's technical representative, listing Contractor's personnel who completed the training. Only qualified personnel who have completed manufacturer's on-site training shall perform installations.

D. Field inspections and testing: 1. Hole drilling and preparation.


2. Results: Submit records of inspections and testing to Engineer by electronic copies within 24 hours after completion.]

3.07 FIELD QUALITY ASSURANCE

A. Provide field quality assurance over the Work of this Section as specified in Section 01400.

B. Special inspections, special tests, and structural observation 1. Frequency of inspections:

a. Unless otherwise indicated on the Drawings or in this Section, provide periodic special inspection as required by the Evaluation Report for the product installed.

b. Provide continuous inspection for the initial installation of each type and size of adhesive bonded reinforcing bar and all thread rod. Subsequent installations of the same anchor may be installed with periodic inspection as defined in subsequent paragraphs.

c. Provide continuous inspection of all drilling, cleaning and bonding activities for bars and rods installed in horizontal an upwardly inclined positions.

2. Preparation: a. Review Drawings and Specifications for the Work to be observed. b. Review adhesive manufacturer's MPII and recommended installation

procedures. c. Review Evaluation Report "Conditions of Use" and "Special Inspection"

requirements. 3. Inspection - Periodic:

a. Initial inspection. Provide an initial inspection for each combination of concrete and reinforcing bar strength or concrete strength and all thread rod material being installed. During initial inspection, observe the following for compliance with the installation requirements. 1) Concrete: Class (minimum specified compressive strength) and

thickness. 2) Environment: Temperature conditions at work area, and moisture

conditions of concrete and drilled hole. 3) Holes: Locations, spacing, and edge distances; verification of drill bit

compliance with requirements; cleaning equipment and procedures; cleanliness of hole. Before adhesive is placed, confirm that depth and preparation of holes conforms to the requirements of the Contract Documents, the MPII, and the "conditions of use" listed in the Evaluation Report.

4) Adhesive: Product manufacturer and name; lot number and expiration date; temperature of product at installation; installation procedure. Note initial set times observed during installation.

5) Reinforcing bars and all thread rods: Material diameter and length; steel grade and/or strength; cleaning and preparation; cleanliness at insertion; minimum effective embedment provided.


b. Subsequent inspections: Subsequent installations of the same reinforcing bars or all thread rods may be performed without the presence of the special inspector, provided that: 1) There is no change in personnel performing the installation, the

general strength and characteristics of the concrete receiving the inserts, or the reinforcing bars and all thread rods being used.

2) For ongoing installations, the special inspector visits the site at least once per day during each day of installation to observe the work for compliance with material requirements and installation procedures.

4. Inspection - Continuous. a. Make observations as described under "Inspection - Periodic, Initial

Inspection" during all drilling, cleaning, and bonding activities for all bars and rods installed.

5. Records of inspections: a. Provide a written record of each inspection using forms acceptable to the

Engineer and to the Building Official. b. Submit electronic copies of inspection reports to Engineer within 24 hours

after completion of inspection.

END OF SECTION


SECTION 03071

EPOXIES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Epoxy. 2. Epoxy gel. 3. Epoxy bonding agent.

B. Related sections: 1. Section 03072 - Epoxy Resin/Portland Cement Bonding Agent.

1.02 REFERENCES

A. ASTM International (ASTM): 1. C 881 – Standard Specification for Epoxy-Resin-Base Systems for Concrete. 2. C 882 – Standard Test Method for Bond Strength of Epoxy-Resin Systems

Used with Concrete by Slant Shear. 3. D 638 - Standard Test Method for Tensile Properties of Plastics. 4. D 695 - Standard Test Method for Compressive Properties of Rigid Plastics.


A. Performance requirements: 1. Provide epoxy materials that are new. 2. Store and use products within shelf life limitations set forth by manufacturer. 3. Perform and conduct work of this Section in neat orderly manner.

1.04 SUBMITTALS

A. Product Data: Submit manufacturer's data completely describing epoxy materials. 1. Submit evidence of conformance to ASTM C 881. Include manufacturer’s

designations of Type Grade, Class, and Color. 2. Submit evidence that materials meet or exceed the specified physical

characteristics.

B. Quality control submittals: 1. Manufacturer's installation instructions.

PART 2 PRODUCTS

2.01 MATERIALS

A. General: Moisture tolerant, water-insensitive, two-component epoxy resin adhesive material containing 100 percent solids, and meeting or exceeding the performance properties specified when tested in accordance with the standards specified.


B. Epoxy: Low viscosity product in accordance with ASTM C 881; Types I, II and V; Grade 1; Class C 1. Manufacturers: One of the following or equal:

a. BASF, Concresive Standard LVI. b. Sika Corporation, Sikadur 35 Hi-Mod LV.

2. Required properties: Table 1: Material Properties – Epoxy. Property Test Method Required Results (“neat”) Tensile Strength (7-day)

ASTM D 638 7,500 pounds per square inch, minimum.

Compressive Strength, (7-day)


Bond Strength (2-day)

ASTM C 882 Concrete shall fail before failure of epoxy.

Notes: Testing results are for materials installed and cured at a temperature between 72 and 78 degrees Fahrenheit for 7 days, unless otherwise noted.

C. Epoxy gel: Non-sagging product in accordance with ASTM C 881, Types I and IV, Grade 3, Class C 1. Manufacturers: One of the following or equal:

a. BASF, Concresive Paste LPL. b. Sika Corporation, Sikadur 31, Hi-Mod Gel.

2. Required properties: Table 2 – Material Properties – Epoxy Gel. Property Test Method Required Results (“neat”) Tensile Strength (7-day)


Compressive Yield Strength (7-day)


Bond Strength (14-day)

ASTM C 882 1,500 pounds per square inch, minimum..


D. Epoxy bonding agent: Non-sagging product in accordance with ASTM C 881, Type II, Grade 1, Class C 1. Manufacturers: One of the following or equal:

a. BASF, Concresive Liquid LPL. b. Sika Chemical Corp., Sikadur 32 Hi-Mod LPL.


2. Required properties. Table 3 – Material Properties – Epoxy Bonding Agent Property Test Method Required Results Tensile Strength (7-day)


Compressive Yield Strength (7-day)


Bond Strength (14-days)

ASTM C 882 1,800 pounds per square inch, minimum. Concrete shall fail before failure of epoxy bonding agent.

Pot Life - Minimum 70 minutes at 77 degrees Fahrenheit or Minimum 90 minutes at 73 degrees Fahrenheit


3. If increased contact time is required for concrete placement, epoxy resin/portland cement bonding agent as specified in Section 03072 may be used instead of epoxy bonding agent.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install and cure epoxy materials in accordance with manufacturer's installation instructions.

B. Epoxy: 1. Apply in accordance with manufacturer's installation instructions.

C. Epoxy gel: 1. Apply in accordance with manufacturer's installation instructions. 2. Use for vertical or overhead work, or where high viscosity epoxy is required. 3. Epoxy gel used for vertical or overhead work may be used for horizontal work.

D. Epoxy bonding agent: 1. Apply in accordance with manufacturer's installation instructions. 2. Bonding agent will not be required for filling form tie holes or for normal

finishing and patching of similar sized small defects.

END OF SECTION


SECTION 03072

EPOXY RESIN/PORTLAND CEMENT BONDING AGENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Epoxy resin/portland cement bonding agent.

1.02 REFERENCES

A. ASTM International (ASTM): 1. C 109 - Standard Test Method for Compressive Strength of Hydraulic Cement

Mortars (Using 2-in. or [50-mm] Cube Specimens). 2. C 348 - Standard Test Method for Flexural Strength of Hydraulic-Cement

Mortars. 3. C 496 - Standard Test Method for Splitting Tensile Strength of Cylindrical

Concrete Specimens. 4. C 882 - Standard Test Method for Bond Strength of Epoxy-Resin Systems

Used With Concrete By Slant Shear.

B. Federal Highway Administration (FHWA): 1. FHWA-RD-86-193 - Highway Concrete Pavement Technology Development

and Testing Volume V: Field Evaluation of SHRP C9206 Test Sites (Bridge Deck Overlays).

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Sika Corporation, Lyndhurst, New Jersey, Sika Armatec 110.

B. Substitutions: The use of other than the specified product will be considered, providing the Contractor requests its use in writing to the Engineer. This request shall be accompanied by: 1. A certificate of compliance from an approved independent testing laboratory

that the proposed substitute product meets or exceeds specified performance criteria, tested in accordance with the specified test standards.

2. Documented proof that the proposed substitute product has a 1-year proven record of performance of bonding portland cement mortar/concrete to hardened portland cement mortar/concrete, confirmed by actual field tests and 5 successful installations that the Engineer can investigate.

2.02 MATERIALS

A. Epoxy resin/portland cement adhesive: 1. Component "A" shall be an epoxy resin/water emulsion containing suitable

viscosity control agents. It shall not contain butyl glycidyl ether. 2. Component "B" shall be primarily a water solution of a polyamine.


3. Component "C" shall be a blend of selected portland cements and sands. 4. The material shall not contain asbestos.

2.03 PERFORMANCE CRITERIA

A. Properties of the mixed epoxy resin/portland cement adhesive: 1. Pot life: 75 to 105 minutes. 2. Contact time: 24 hours. 3. Color: Dark gray.

B. Properties of the cured epoxy resin/portland cement adhesive: 1. Compressive strength in accordance with ASTM C 109:

a. 3 day: 4,500 pounds per square-inch minimum. b. 7 days: 6,500 pounds per square-inch minimum. c. 28 days: 8,500 pounds per square-inch minimum.

2. Splitting tensile strength in accordance with ASTM C 496: a. 28 days: 600 pounds per square-inch minimum.

3. Flexural strength: a. 1,100 pounds per square-inch minimum in accordance with ASTM C 348.

4. Bond strength in accordance with ASTM C 882 modified at 14 days: a. 0 hours open time: 2,800 pounds per square-inch minimum. b. 24 hours open time: 2,600 pounds per square-inch minimum.

5. The epoxy resin/portland cement adhesive shall not produce a vapor barrier. 6. Material must be proven to prevent corrosion of reinforcing steel when tested

under the procedures as set forth by the FHWA Program Report Number FHWA-RD-86-193. Proof shall be in the form of an independent testing laboratory corrosion report showing prevention of corrosion of the reinforcing steel.

PART 3 EXECUTION

3.01 INSTALLATION

A. Mixing the epoxy resin: Shake contents of Component "A" and Component "B." Empty all of both components into a clean, dry mixing pail. Mix thoroughly for 30 seconds with a jiffy paddle on a low-speed with 400 to 600 revolutions per minute drill. Slowly add the entire contents of Component "C" while continuing to mix for a minimum of 3 minutes and until uniform with no lumps. Mix only the quantity that can be applied within its pot life.

B. Placement procedure: 1. Apply to prepared surface with stiff-bristle brush, broom, or "hopper-type"

spray equipment: a. For hand applications: Place fresh plastic concrete/mortar while the

bonding bridge adhesive is wet or dry, up to 24 hours. b. For machine applications: Allow the bonding bridge adhesive to dry for

12 hours minimum.

C. Adhere to all limitations and cautions for the epoxy resin/portland cement adhesive in the manufacturer's current printed literature.


3.02 CLEANING

A. Leave finished work and work area in a neat, clean condition without evidence of spillovers onto adjacent areas.

END OF SECTION


SECTION 03154

HYDROPHILIC RUBBER WATERSTOP

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Hydrophilic rubber waterstop.

1.02 SUBMITTALS

A. General: 1. Submit the following items for each type, style and size of hydrophilic

waterstop to be installed. 2. Product data:

a. Manufacturer’s product data sheets. 1) Include complete physical dimensions, expansion characteristics,

and laboratory test reports indicating that average material properties conform to the requirements specified.

2) Provide data sheets for all materials to be included in the waterstop system.

3. Samples: a. Minimum 6-inch long samples of each type of waterstop to be used if

requested by the Engineer. 4. Manufacturer's installation instructions:

a. Installation instructions and recommended installation details for the complete waterstop system, and for each component used in that system.

PART 2 PRODUCTS

2.01 HYDROPHILIC RUBBER WATERSTOP

A. General: 1. System composed of flexible hydrophilic urethane polymer with preformed

strips, adhesives, paste, fasteners, and other accessories required for a complete and watertight installation. a. To ensure compatibility of materials, a single manufacturer shall provide

all products and accessories for the hydrophilic waterstop system. b. Products incorporating bentonite are not acceptable under this Section. c. Provide waterstop and accessories resistant to degradation under cyclic

wetting and drying

B. Hydrophilic strip waterstop. 1. Pre-formed strips of flexible hydrophilic rubber designed to undergo controlled

expansion when exposed to moisture. a. Strips manufactured to limit expansion in directions parallel to the plane of

the joint, and to direct expansion against confining material perpendicular to that plane.


2. Provide normal or low-expansion pressure as scheduled and as indicated on the Drawings.

3. Manufacturers. One of the following, or equal. a. Hydrophilic strip.

1) Adeka Ultra Seal USA: MC-2010MN. 2) Greenstreak: Hydrotite CJ1020-2K.

b. Low expansion hydrophilic strip. 1) Adeka Ultra Seal USA: KBA-1510FP. 2) Greenstreak: Hydrotite CJ0725-3K

C. Hydrophilic paste waterstop. 1. Single-component gun grade paste of hydrophilic rubber designed to undergo

controlled expansion when exposed to moisture after initial curing. 2. Manufacturers: One of the following, or equal.

a. Adeka Ultra Seal USA: P-201. b. Greenstreak: Leakmaster LV-1

PART 3 EXECUTION

3.01 INSTALLATION

A. Install products in accordance with manufacturer's instructions and recommended details.

B. Prepare concrete joint surfaces: 1. Use wire brushing or scraping to expose an uncontaminated, solid surface. 2. Clean prepared surface with high-pressure air or water to remove residue and

debris. 3. Confirm that prepared surfaces conform to manufacturer’s recommendations

for surface profile and moisture conditions before installing materials.

C. Provide manufacturer’s recommended lap, splice, and corner details for hydrophilic waterstops. 1. Use hydrophilic paste at all corner joints and overlap splices of hydrophilic

strips.

D. Hydrophilic strip waterstop. 1. Install primers and adhesives when recommended by the manufacturer before

setting hydrophilic strips. 2. Keep hydrophilic strip taut during the fastening process. 3. Secure hydrophilic strip in place with concrete nails, screws, or adhesive. 4. Provide installation with no gap between the hydrophilic strip and the concrete

to which it is attached. At rough or irregular surfaces, set hydrophilic strip waterstop strip in a bead of hydrophilic paste. a. Fill all voids and rough areas under the hydrophilic strip with hydrophilic

paste. b. Allow hydrophilic paste to cure in accordance with manufacturer’s

recommendations before encapsulating paste in fresh concrete.


3.02 SCHEDULE

A. At the following joint locations/conditions, use the hydrophilic strip waterstop configuration noted unless otherwise indicated on the Drawings.

B. Concrete construction joints: 1. Under all of the following conditions, use hydrophilic strip waterstop set in a

bed of hydrophilic paste waterstop, and screw strip waterstop to concrete surface: a. Slab or wall thickness is greater than 10 inches. b. Waterstop is placed between 2 rows of steel reinforcement. c. Concrete cover from waterstop to nearest concrete face is at least

4 inches. 2. Under any one of the following conditions, use low-expansion hydrophilic strip

waterstop set in bed of hydrophilic paste waterstop and screw strip to concrete surface: a. Waterstop is placed on 1 side of a single row of steel reinforcement, or b. Concrete cover from waterstop to nearest concrete face is less than

4 inches.

C. Pipe penetrations through concrete: 1. Pipe diameter less than 4 inches: Not allowed. 2. Pipe diameter of 4 to 24 inches: Continuous bead of hydrophilic paste

waterstop, minimum 1/4 inch high by 1/2 inch wide, encircling pipe. 3. Pipe diameter greater than 24 inches: Continuous hydrophilic strip waterstop

around perimeter of pipe, with hydrophilic paste seal at lapped ends of strip.

END OF SECTION


SECTION 03600

GROUTING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Cement grout. 2. Cement mortar. 3. Dry-pack mortar. 4. Epoxy grout. 5. Grout. 6. Non-shrink epoxy grout. 7. Non-shrink grout.

B. Related sections: 1. Section 03071 - Epoxies. 2. Section 03300 - Cast-in-Place Concrete. 3. Section 15050 - Basic Mechanical Materials and Methods.

1.02 REFERENCES

A. ASTM International (ASTM): 1. C 109 - Standard Test Method for Compressive Strength of Hydraulic Cement

Mortars (using 2-inch or [50-millimeter] cube specimens). 2. C 230 - Standard Specification for Flow Table for Use In Tests of Hydraulic

Cement. 3. C 531 - Standard Test Method for Liner Shrinkage and Coefficient of Thermal

Expansion of Chemical-Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes.

4. C 579 - Standard Test Method for Compressive Strength of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings and Polymer Concretes.

5. C 939 - Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method).

6. C 942 - Standard Test Method for Compressive Strength of Grouts for Preplaced-Aggregate Concrete in the Laboratory.

7. C 1107 - Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Non-shrink).

8. C 1181 - Standard Test Methods for Compressive Creep of Chemical-Resistant Polymer Machinery Grouts.

B. International Concrete Repair Institute (ICRI): 1. 310.2R – Selecting and specifying Concrete Surface Preparations for Sealers,

Coatings, Polymer Overlays, and Concrete Repair.


1.03 SUBMITTALS

A. Cement grout: 1. Mix design. 2. Material submittals.

B. Cement mortar: 1. Mix design. 2. Material submittals.

C. Non-shrink epoxy grout: 1. Manufacturer's literature.

D. Non-shrink grout: 1. Manufacturer's literature.


A. Deliver materials to jobsite in their original, unopened packages or containers, clearly labeled with manufacturer's product identification and printed instructions.

B. Store materials in cool dry place and in accordance with manufacturer's recommendations.

C. Handle materials in accordance with the manufacturer's instructions.

PART 2 PRODUCTS


A. Non-shrink epoxy grout: 1. Manufacturers: One of the following or equal:

a. Five Star Products, Inc., Five Star Epoxy Grout. b. BASF Construction Chemicals, Masterflow 648 CP Plus. c. L&M Construction Chemicals, Inc., EPOGROUT.

2. Non-shrink epoxy grout shall be 100 percent solid, premeasured, prepackaged system containing 2-component thermosetting epoxy resin and inert aggregate.

3. Maintain flowable consistency for at least 45 minutes at 70 degrees Fahrenheit.

4. Shrinkage or expansion: Less than 0.0006 inches per inch when tested in accordance with ASTM C 531.

5. Minimum compressive strength: 10,000 pounds per square inch at 24 hours and 14,000 pounds per square inch at 7 days when tested in accordance with ASTM C 579, Method B.

6. Compressive creep: Not exceed 0.0027 inches/per inch when tested under 400 pounds per square inch constant load at 140 degrees Fahrenheit in accordance with ASTM C 1181.

7. Coefficient of thermal expansion: Not exceed 0.000018 inches per inch per degree Fahrenheit when tested in accordance with ASTM C 531, Method B.


B. Non-shrink grout: 1. Manufacturers: One of the following or equal:

a. Five Star Products, Inc, Five Star Grout. b. BASF Construction Chemicals, Masterflow 928. c. L&M Construction Chemicals, Inc., CRYSTEX.

2. In accordance with ASTM C 1107. 3. Preportioned and prepackaged cement-based mixture. 4. Contain no metallic particles such as aluminum powder and no metallic

aggregate such as iron filings. 5. Require only addition of potable water. 6. Water for pre-soaking, mixing, and curing: Potable water. 7. Free from emergence of mixing water from within or presence of water on its

surface. 8. Remain at minimum flowable consistency for at least 45 minutes after mixing

at 45 degrees Fahrenheit to 90 degrees Fahrenheit when tested in accordance with ASTM C 230. a. If at fluid consistency, verify consistency in accordance with ASTM C 939.

9. Dimensional stability (height change): a. In accordance with ASTM C 1107, volume-adjusting Grade B or C at

45 degrees Fahrenheit to 90 degrees Fahrenheit. b. Have 90 percent or greater bearing area under bases.

10. Have minimum compressive strengths at 45 degrees Fahrenheit to 90 degrees Fahrenheit in accordance with ASTM C 1107 for various periods from time of placement, including 5,000 pounds per square inch at 28 days when tested in accordance with ASTM C 109 as modified by ASTM C 1107.

2.02 MIXES

A. Cement grout: 1. Use same sand-to-cementitious materials ratio for cement grout mix that is

used for concrete mix. 2. Use same materials for cement grout that are used for concrete. 3. Use water-to-cementitious materials ratio that is no more than that specified

for concrete. 4. For spreading over surfaces of construction or cold joints.

B. Cement mortar: 1. Use same sand-to-cementitious materials ratio for cement mortar mix that is

used for concrete mix. 2. Use same materials for cement mortar that are used for concrete. 3. Use water-to-cementitious materials ratio that is no more than that specified

for concrete being repaired. 4. At exposed concrete surfaces not to be painted or submerged in water: Use

sufficient white cement to make color of finished patch match that of surrounding concrete.

C. Dry-pack mortar: 1. Proportions by weight: 1 part portland cement to 2 parts concrete sand.

a. Portland cement: As specified in Section 03300. b. Concrete sand: As specified in Section 03300.


D. Epoxy grout: 1. Consist of mixture of epoxy or epoxy gel and sand.

a. Epoxy: As specified in Section 03071. b. Epoxy gel: As specified in Section 03071. c. Sand: Clean, bagged, graded, and kiln-dried silica sand.

2. Proportioning: a. For horizontal work: Consist of mixture of 1 part epoxy with not more than

2 parts sand. b. For vertical or overhead work: Consist of 1 part epoxy gel with not more

than 2 parts sand.

E. Grout: 1. Mix in proportions by weight: 1 part portland cement to 4 parts concrete sand.

a. Portland cement: As specified in Section 03300. b. Concrete sand: As specified in Section 03300.

F. Non-shrink epoxy grout: 1. Mix in accordance with manufacturer's installation instructions.

G. Non-shrink grout: 1. Mix in accordance with manufacturer's installation instructions such that

resulting mix has flowable consistency and is suitable for placing by pouring.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect concrete surfaces to receive grout or mortar and verify that they are free of ice, frost, dirt, grease, oil, curing compounds, paints, impregnations, and loose material or foreign matter likely to reduce bond or performance of grout or mortar.

3.02 PREPARATION

A. Surface preparation for grouting other baseplates: 1. Remove grease, oil, dirt, dust, curing compounds, laitance, and other

deleterious materials that may affect bond to concrete and bottoms of baseplates.

2. Roughen concrete surfaces in contact with grout to ICRI CSP-6 surface profile or rougher. a. Remove loose or broken concrete.

3. Metal surfaces in contact with grout: Grit blast to white metal surface.

3.03 INSTALLATION

A. Mixing: 1. Cement grout:

a. Use mortar mixer with moving paddles. b. Pre-wet mixer and empty out excess water before beginning mixing.

2. Cement mortar: a. Use mortar mixer with moving paddles. b. Pre-wet mixer and empty out excess water before beginning mixing.


3. Dry-patch mortar: a. Use only enough water so that resulting mortar will crumble to touch after

being formed into ball by hand. 4. Non-shrink epoxy grout:

a. Keep temperature of non-shrink epoxy grout from exceeding manufacturer's recommendations.

5. Non-shrink grout: a. May be drypacked, flowed, or pumped into place. Do not overwork grout. b. Do not retemper by adding more water after grout stiffens.

B. Placement: 1. Cement grout:

a. Exercise care in placing cement grout because it is required to furnish structural strength, impermeable water seal, or both.

b. Do not use cement grout that has not been placed within 30 minutes after mixing.

2. Cement mortar: a. Use mortar mixer with moving paddles. b. Pre-wet mixer and empty out excess water before beginning mixing.

3. Epoxy grouts: a. Wet surfaces with epoxy for horizontal work or epoxy gel for vertical or

overhead work prior to placing epoxy grout. 4. Non-shrink epoxy grout:

a. Mix in complete units. Do not vary ratio of components or add solvent to change consistency of mix.

b. Pour hardener into resin and mix for at least 1 minute and until mixture is uniform in color. Pour epoxy into mortar mixer wheelbarrow and add aggregate. Mix until aggregate is uniformly wetted. Over mixing will cause air entrapment in mix.

5. Non-shrink grout: a. Add non-shrink cement grout to premeasured amount of water that does

not exceed the manufacturer's maximum recommended water content. b. Mix in accordance with manufacturer's instructions to uniform consistency.

C. Curing: 1. Cement based grouts and mortars:

a. Keep continuously wet for minimum of 7 days. Use wet burlap, soaker hose, sun shading, ponding, and in extreme conditions, combination of methods.

b. Maintain above 40 degrees Fahrenheit until it has attained compressive strength of 3,000 pounds per square inch, or above 70 degrees Fahrenheit for minimum of 24 hours to avoid damage from subsequent freezing.

2. Epoxy based grouts: a. Cure grouts in accordance with manufacturers' recommendations.

1) Do not water cure epoxy grouts. b. Do not allow any surface in contact with epoxy grout to fall below

50 degrees Fahrenheit for minimum of 48 hours after placement.

D. Grouting equipment bases, baseplates, soleplates, and skids: As specified in Section 15050.


E. Grouting other baseplates: 1. General:

a. Use non-shrink grout as specified in this Section. b. Baseplate grouting shall take place from one side of baseplate to other in

continuous flow of grout to avoid trapping air in grout. c. Maintain hydrostatic head pressure by keeping level of grout in headbox

above bottom of baseplate. Fill headbox to maximum level and work grout down.

d. Vibrate, rod, or chain non-shrink grout to facilitate grout flow, consolidate grout, and remove trapped air.

2. Forms and headboxes: a. Build forms using material with adequate strength to withstand placement

of grouts. b. Use forms that are rigid and liquidtight. Caulk cracks and joints with

elastomeric sealant. c. Line forms with polyethylene for easy grout release. Coating forms with

2 coats of heavy-duty paste wax is also acceptable. d. Headbox shall be 4 to 6 inches higher than baseplate and shall be located

on one side of baseplate. e. After grout sets, remove forms and trim back grout at 45 degree angle

from bottom edges of baseplate.


A. Non-shrink epoxy grout: 1. Test for 24-hour compressive strength in accordance with ASTM C 579,

Method B.

B. Non-shrink grout: 1. Test for 24-hour compressive strength in accordance with ASTM C 942.

END OF SECTION


SECTION 05140

STRUCTURAL ALUMINUM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Structural aluminum products, including sheet, pipe, extrusions, and associated accessories.

B. Related Sections: 1. Section 05190 - Mechanical Anchoring and Fastening to Concrete and

Masonry. 2. Section 09960 - High-Performance Coatings.

1.02 REFERENCES

A. ASTM International (ASTM): 1. B 209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and

Plate. 2. B 221 - Standard Specification for Aluminum and Aluminum-Alloy Extruded

Bars, Rods, Wire, Profiles, and Tubes. 3. B 308 - Standard Specification for Aluminum-Alloy 6061-T6 Standard

Structural Profiles.

B. American Welding Society (AWS): 1. A5.10 - Specification for Bare Aluminum and Aluminum-Alloy Welding

Electrodes and Rods. 2. D1.2 - Structural Welding Code - Aluminum.

1.03 SUBMITTALS

A. Quality control submittals: 1. Test Reports: Certified copies of mill tests or reports from a recognized

commercial laboratory including chemical and tensile properties of each shipment of structural metal or part thereof having common properties. Tests and analyses shall be made in accordance with applicable ASTM Standards.

2. Welder’s certificates.


A. Qualifications: 1. Perform welding of structural metals with welders who have current AWS

certificate for the type of welding to be performed. 2. Notify Engineer 24 hours minimum before starting shop or field welding. 3. Engineer may check materials, equipment, and qualifications of welders. 4. Remove welders performing unsatisfactory work, or require to requalify. 5. Engineer may use gamma ray, magnetic particle dye penetrant, or other aids

to visual inspection to examine any part of welds or all welds. 6. Contractor shall bear costs of retests on defective welds.


7. Contractor shall bear costs in connection with qualifying welders.

PART 2 PRODUCTS

2.01 MATERIALS

A. Structural sheet aluminum: ASTM B 209, Alloy 6061-T6.

B. Structural aluminum: ASTM B 308, Alloy 6061-T6.

C. Extruded aluminum: ASTM B 221, Alloy 6063-T42.

D. Isolating sleeves and washers: 1. As indicated on the Drawings and as specified in Section 05190.

E. Miscellaneous materials: 1. Furnish supplementary parts necessary to complete each item even where

such work is neither definitely indicated on the Drawings nor specified. 2. Size, form, attachment, and location shall conform to the best of current

practice. 3. Conform to applicable ASTM Standards for materials not otherwise specified.

2.02 FABRICATION

A. Aluminum layout: 1. Center punch hole centers, and punch or scribe cutoff lines, except where

marks would remain on fabricated material. 2. Apply temperature correction where necessary in layout of critical dimensions.

Use a coefficient of expansion of 0.000013 per degree of Fahrenheit.

B. Cutting aluminum: 1. Material 1/2-inch thick or less: Shear, saw, or cut with a router. 2. Material more than 1/2-inch thick: Saw or rout. 3. Make cut edges true and smooth, free from excessive burrs or ragged breaks. 4. Avoid reentrant cuts wherever possible. Where used, fillet by drilling prior to

cutting. 5. Do not flame cut aluminum alloys. 6. Punch or drill rivet or bolt holes to finished size before assembly:

a. Make finished diameter of holes for bolts 1/16-inch maximum larger than nominal bolt diameter.

b. Make holes cylindrical and perpendicular to principal surface. c. Do not permit holes to drift in a manner to distort metal.

C. Aluminum forming and assembly: 1. Do not heat structural aluminum, except as follows:

a. Heat aluminum to 400 degrees Fahrenheit for 30 minutes maximum, to facilitate bending or welding.

b. Heat only when proper temperature controls and supervision can ensure that limitations on temperature and time are observed.

D. Before assembly, remove chips lodged between contacting surfaces.


E. Welding aluminum: 1. Perform welding of aluminum in accordance with AWS D1.2. 2. Weld aluminum in accordance with the following:

a. Preparation: 1) Remove dirt, grease, forming or machining lubricants, and organic

materials from areas to be welded by cleaning with a suitable solvent or by vapor degreasing.

2) Additionally, etch or scratch brush to remove oxide coating just prior to welding when inert gas tungsten arc welding method is used.

3) Oxide coating may not need to be removed if welding is performed by automatic or semi-automatic inert gas shielded metal arc.

4) Suitably prepare edges to assure 100 percent penetration in butt welds by sawing, chipping, machining, or shearing. Do not cut with oxygen.

b. Filler metal: Aluminum alloys conforming to the requirements of AWS A5.10 and AWS classification ER 4043, ER 5654, ER 5554, ER 5183, ER 5356, or ER 5556.

c. Perform welding of structures which are to be anodized using filler alloys which will not discolor when anodized, AWS ER 5654, ER 5554, ER 5183, ER 5356, or ER 5556.

d. Perform welding by using a non-consumable tungsten electrode with filler metal in an inert gas atmosphere (TIG) or using a consumable filler metal electrode in an inert gas atmosphere (MIG).

e. Do not use welding process that requires use of a welding flux. f. Neatly make welded closures. g. Where weld material interferes with fit or is unsightly in appearance, grind

it smooth. h. Make welds full penetration welds unless otherwise indicated on the

Drawings.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verification of conditions: Examine Work in place to verify that it is satisfactory to receive the Work of this Section. If unsatisfactory conditions exist, do not begin this Work until such conditions have been corrected.

3.02 INSTALLATION

A. Install structural aluminum products as indicated on the Drawings and specified.

B. Install structural aluminum products accurately and securely, true to level, plumb, in correct alignment and grade, with all parts bearing or fitting structure or equipment for which intended.

C. Do not cock out of alignment, redrill, reshape, or force fit fabricated items.

D. Place anchor bolts or other anchoring devices accurately and make surfaces which bear against structural items smooth and true to level.


E. Rigidly support and brace structural products needing special alignment to preserve straight, level, even, smooth lines, and keep braced until concrete, grout, or dry pack mortar has hardened for a minimum 48-hour period.

F. Interface with other products: 1. Where aluminum comes in contact with dissimilar metals, use stainless steel

bolts or anchors and separate or isolate the dissimilar metals with isolating sleeves and washers as specified in Section 05190.

2. Coat those parts of aluminum which will be cast into concrete or which will be in contact with concrete, grout, masonry, wood, or other materials that will cause the aluminum to corrode, as specified in Section 09960.

END OF SECTION


SECTION 05190

MECHANICAL ANCHORING AND FASTENING TO CONCRETE AND MASONRY

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Cast-in anchors and fasteners:

a. Anchor bolts. b. Anchor rods.

2. Post-installed steel anchors and fasteners: a. Concrete anchors.

3. Appurtenances for anchoring and fastening:

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01410 - Regulatory Requirements. 3. Section 01400 - Quality Control Services. 4. Section 01610 - Project Design Criteria. 5. Section 03055 - Adhesive-Bonded Reinforcing Bars and All Thread Rods 6. Section 05120 - Structural Steel 7. Section 05500 - Metal Fabrications

1.02 REFERENCES

A. American Concrete Institute (ACI): 1. 355.2 - Qualification of Post-Installed Mechanical Anchors in Concrete &

Commentary.

B. American National Standards Institute (ANSI): 1. B212.15 - Cutting Tools - Carbide-tipped Masonry Drills and Blanks for

Carbide-tipped Masonry Drills.

C. American Welding Society (AWS): 1. D1.1 - Structural Welding Code - Steel. 2. D1.6 - Structural Welding Code - Stainless Steel.

D. ASTM International (ASTM): 1. A53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless. 2. A108 - Standard Specification for Steel Bars, Carbon and Alloy, Cold Finished. 3. A123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron

and Steel Products. 4. A153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware. 5. A240 - Standard Specification for Chromium and Chromium Nickel Stainless

Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications.

6. A308 - Standard Specification for Steel Sheet, Terne (Lead-Tin Alloy) Coated by the Hot-Dip Process.


7. A496 - Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.

8. A563 - Standard Specification for Carbon and Alloy Steel Nuts. 9. B633 - Standard Specification for Electrodeposited Coatings of Zinc on Iron

and Steel. 10. B695 - Standard Specification for Coatings of Zinc Mechanically Deposited on

Iron and Steel. 11. E488 - Standard Test Methods for Strength of Anchors in Concrete Elements. 12. F436 - Standard Specification for Hardened Steel Washers. 13. F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws and

Studs. 14. F594 - Standard Specification for Stainless Steel Nuts. 15. F1554 - Standard Specification for Anchor Bolts, Steel, 36, 55 and 105-ksi

Yield Strength. 16. F2329 - Standard Specification for Zinc Coating, Hot-Dip, Requirements for

Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special Threaded Fasteners.

E. International Code Council Evaluation Service, Inc. (ICC-ES): 1. AC193 - Acceptance Criteria for Mechanical Anchors in Concrete Elements.

1.03 DEFINITIONS

A. Built-in anchor: Headed bolt or assembly installed in position before filling surrounding masonry units with grout.

B. Cast-in anchor: Headed bolt or assembly installed in position before placing plastic concrete around.

C. Overhead installations: Fasteners installed on overhead surfaces where the longitudinal axis of the fastener is more than 60 degrees above a horizontal line so that the fastener resists sustained tension loads.

D. Passivation: Chemical treatment of stainless steel with a mild oxidant for the purpose of enhancing the spontaneous formation of the steel’s protective passive film.

E. Post-installed anchor: Fastener or assembly installed in hardened concrete or finished masonry construction, typically by drilling into the structure and inserting a steel anchor assembly.

F. Terms relating to structures or building environments as used with reference to anchors and fasteners: 1. Corrosive locations: Describes interior and exterior locations as follows:

a. Locations used for delivery, storage, transfer, or containment (including spill containment) of chemicals used for plant treatment processes.

b. Exterior and interior locations at the following treatment structures: 1) Wastewater treatment facilities: Liquids stream:

a) Raw wastewater delivery and holding structures. b) Headworks and grit facilities. c) Primary clarifiers and primary clarifier flow splitting boxes. d) Chlorine contact structures.


2. Wet and moist locations: Describes locations, other than “corrosive locations,” that are submerged, are immediately above liquid containment structures, or are subject to frequent wetting, splashing, or wash down. Includes: a. Exterior portions of buildings and structures. b. Liquid-containing structures:

1) Locations at and below the maximum operating liquid surface elevation.

2) Locations above the maximum operating liquid surface elevation and: a) Below the top of the walls containing the liquid. b) At the inside faces and underside surfaces of a structure

enclosing or spanning over the liquid (including walls, roofs, slabs, beams, or walkways enclosing the open top of the structure).

c. Liquid handling equipment: 1) Bases of pumps and other equipment that handles liquids.

d. Indoor locations exposed to moisture, splashing, or routine wash down during normal operations, including floors with slopes toward drains or gutters.

e. Other locations indicated on the Drawings. 3. Other locations:

a. Interior dry areas where the surfaces are not exposed to moisture or humidity in excess of typical local environmental conditions.

1.04 SUBMITTALS

A. General: 1. Submit as specified in Section 01300. 2. Submit information listed for each type of anchor or fastener to be used.

B. Action submittals: 1. Product data:

a. Cast-in anchors: 1) Manufacturer’s data including catalog cuts showing anchor sizes and

configuration, materials, and finishes. b. Post-installed anchors:

1) For each anchor type, manufacturer’s data including catalog cuts showing anchor sizes and construction, materials and finishes, and load ratings.

2. Samples: a. Samples of each type of anchor, including representative diameters and

lengths, if requested by the Engineer. 3. Certificates:

a. Cast-in anchors: 1) Mill certificates for steel anchors that will be supplied to the site.

b. Post-installed anchors: 1) Manufacturer’s statement or certified test reports demonstrating that

anchors that will be supplied to the site comply with the materials properties specified.

4. Test reports: a. Post-installed anchors: For each anchor type used for the Work:

1) Current ICC-ES Report (ESR) , or equivalent acceptable to the Engineer and the authority having jurisdiction, demonstrating:


a) Acceptance of that anchor for use under the building code specified in Section 01410.

5. Manufacturer’s instructions: a. Requirements for storage and handling. b. Recommended installation procedures including details on drilling, hole

size (diameter and depth), hole cleaning and preparation procedures, anchor insertion, and anchor tightening.

c. Requirements for inspection or observation during installation. 6. Qualification statements:

a. Post-installed anchors: Installer qualifications: 1) Submit list of personnel performing installations and include date of

manufacturer’s training for each.


A. Qualifications: 1. Post installed anchors shall be in accordance with building code specified in

Section 01410. 2. Installers: Post-installed mechanical anchors:

a. Conduct a training session with the manufacturer’s authorized technical representative for the project on-site: 1) Training shall cover the complete installation process for each type of

anchor to be used and shall include, but not be limited to, hole drilling procedures and techniques, hole preparation and cleaning, bolt installation, and bolt proof loading and torquing.

2) Use only trained and qualified personnel for anchor installation. b. Installations shall be performed by trained installers having at least [3]

years of experience performing similar installations with similar types of anchors

B. Special inspection: 1. Provide special inspection of post-installed anchors as specified in this

Section.


A. Deliver post-installed anchors in manufacturer’s standard packaging with labels visible and intact. Include manufacturer’s installation instructions.

B. Handle and store anchors and fasteners in accordance with manufacturer’s recommendations and as required to prevent damage.

C. Protect anchors from weather and moisture until installation.


A. As specified in Section 01610.

B. Seismic Design Category (SDC) for structures is indicated on the Drawings.


PART 2 PRODUCTS


A. General: 1. Furnish threaded fasteners with flat washers and hex nuts fabricated from

materials corresponding to the material used for threaded portion of the anchor. a. Cast-in anchors: Provide flat washers and nuts as listed in the ASTM

standard for the anchor materials specified. b. Post-installed anchors: Provide flat washers and nuts supplied for that

product by the manufacturer of each anchor. 2. Size of anchors and fasteners, including diameter and length or minimum

effective embedment depth: As indicated on the Drawings or as specified in this Section. In the event of conflicts, contact Engineer for clarification.

3. Where anchors and connections are not specifically indicated on the Drawings or specified, their material, size and form shall be equivalent in quality and workmanship to items specified.

B. Materials: 1. Provide and install anchors of materials as in this Section.

2.02 CAST-IN ANCHORS AND FASTENERS

A. Anchor bolts: 1. Description:

a. Straight steel rod having one end with an integrally forged head, and one threaded end. Embedded into concrete with the headed end cast into concrete at the effective embedment depth indicated on the Drawings or specified, and with the threaded end left to project clear of concrete face as required for the connection to be made.

b. Furnish anchor bolts with heavy hex forged head or equivalent acceptable to Engineer. 1) Rods or bars with angle bend for embedment in concrete (i.e., “L” or

“J” shaped anchor bolts) are not permitted in the Work. 2. Materials:

a. Ship anchor bolts with properly fitting nuts attached b. Type 316 stainless steel:

1) Surfaces descaled, pickled, and passivated in accordance with ASTM A308

2) Bolts: ASTM F593, Group 2, Condition CW, coarse threads. 3) Nuts: ASTM F594. Match alloy (group and UNS designation) and

threads of bolts. 4) Washers: Type 316 stainless steel.

c. Galvanized steel: 1) Hot-dip galvanized coating in accordance with ASTM F2329. 2) Bolt: ASTM F1554, Grade 36 heavy hex, coarse thread. 3) Nuts: ASTM A563, Grade A heavy hex, threads to match bolt. 4) Washers: ASTM F436, Type 1.


2.03 POST-INSTALLED ANCHORS AND FASTENERS – ADHESIVE

A. Epoxy bonding of reinforcing bars, all thread rods, and threaded inserts in concrete: As specified in Section 03055.

2.04 POST-INSTALLED ANCHORS AND FASTENERS – MECHANICAL

A. General: 1. Post-installed anchors used for the Work shall hold a current ICC Evaluation

Service Report demonstrating acceptance for use under the building code specified in Section 01410. Reports prepared by other recognized evaluation agencies may be submitted for consideration if acceptable to the Engineer and to the authority having jurisdiction. a. Conditions of use: The acceptance report shall indicate acceptance of the

product for use under the following conditions: 1) In regions of concrete where cracking has occurred or may occur. 2) To resist short-term loads due to wind forces. 3) To resist short-term loading due to seismic forces for the Seismic

Design Category of the structure where the product will be used. 2. Substitutions: When requesting product substitutions, submit calculations,

indicating the diameter, effective embedment depth and spacing of the proposed anchors, and demonstrating that the substituted product will provide load resistance that is equal to or greater than that provided by the anchors listed in this Section. a. Calculations shall be prepared by and shall bear the signature and seal of

a Professional Engineer licensed in the State of Texas. b. Decisions regarding the acceptability of proposed substitutions shall be at

the discretion of the Engineer.

B. Concrete anchors: 1. Description. Post-installed anchor assembly consisting of a threaded stud and

a surrounding wedge expansion sleeve that is forced outward by torquing the center stud to transfer loads from the stud to the concrete through bearing, friction, or both. (Sometimes referred to as “expansion anchors” or “wedge anchors.”) a. Do not use slug-in, lead cinch, and similar systems relying on deformation

of lead alloy or similar materials to develop holding power. 2. Concrete anchors for anchorage to concrete:

a. Acceptance criteria: 1) Concrete anchors shall have a current ICC-ES Report demonstrating

that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short-term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and with ICC-ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Concrete anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.

b. Manufacturers: One of the following or equal: 1) Hilti: Kwik Bolt TZ Expansion Anchor. 2) Powers fasteners: PowerStud+ SD2. 3) Simpson Strong-Tie: Strong Bolt 2 Wedge Anchor.

http://www.strongtie.com/


c. Materials. Integrally threaded stud, wedge, washer, and nut: 1) Stainless steel: Type 316.

a) Type 304 stainless steel acceptable for use at wet and moist locations when accepted in writing by the Engineer.

2) Galvanized: Carbon steel, zinc plated in accordance with ASTM B633, minimum 5 microns (Fe/Zn 5).

C. Flush shells: 1. Description: Post-installed anchor assembly consisting of an internally

threaded mandrel that is forced into a pre-drilled concrete hole with a setting tool until the top of the anchor is flush with the face of the concrete. Once installed, a removable threaded bolt is installed in the mandrel.

2. Flush shell anchors are not permitted in the Work. 3. Sleeve anchors for anchorage to concrete:

a. Acceptance criteria: 1) Sleeve anchors shall have a current ICC-ES Report demonstrating

that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short-term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and with ICC-ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Sleeve anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.

b. Manufacturers: One of the following or equal: 1) Hilti: HSL-3 Heavy Duty Expansion (sleeve) Anchor. 2) Powers fasteners: Power Bolt+ Heavy Duty Sleeve Anchor.

c. Materials: 1) Stainless steel: Not available. 2) Galvanized steel: Carbon steel, zinc plated in accordance with

ASTM B633, minimum 5 microns (Fe/Zn 5).

D. Screw anchors: 1. Description: Post-installed concrete anchor that develops tensile strength from

mechanical interlock provided by creating a helical “key” that is larger than the diameter of the bolt itself along the length of the anchor shaft.

2. Screw anchors for anchorage to concrete: a. Acceptance criteria:

1) Screw anchors shall have a current ICC-ES Report demonstrating that the anchors have been tested and qualified for performance in both cracked and un-cracked concrete, and for short-term loading due to wind and seismic forces for Seismic Design Categories A through F in accordance with ACI 355.2 and ICC ES AC193 (including all mandatory tests and optional tests for seismic tension and shear in cracked concrete).

2) Screw anchor performance in the current ICC-ES Report shall be “Category 1” as defined in ACI 355.2.

b. Manufacturers: Screw anchor: One of the following or equal: 1) Hilti: Hex head: HUS-EZ Screw Anchor.

a) With internally threaded head: HUS-EZ I Hanger Anchor. 2) Powers fasteners: Wedge-Bolt+:

a) With internally threaded head: Vertigo+ Rod Hanging System.


3) Simpson Strong-Tie: Titen HD Screw Anchor: a) With internally threaded head: Titen HD Rod Hanger.

c. Materials: 1) Stainless steel: Not available. 2) Galvanized steel: Carbon steel, zinc plated in accordance with ASTM

B633, minimum 5 microns (Fe/Zn 5); or equal.

2.05 APPURTENANCES FOR ANCHORING AND FASTENING

A. Anchor bolt sleeves: 1. Having inside diameter approximately 2 inches greater than bolt diameter and

minimum 10-bolt diameters long. 2. Plastic sleeves:

a. High-density polyethylene, corrugated sleeve, threaded to provide adjustment of location on the anchor bolt.

b. Manufacturers: One of the following, or equal: 3. Fabricated steel sleeves: Construct as specified in Section 05500:

a. At galvanized carbon steel anchor bolts, provide galvanized carbon steel sleeves.

b. At stainless steel anchor bolts, provide stainless steel sleeves of same Type (304 or 316) as bolt, except that sleeves shall be constructed from low carbon stainless steel for welding (Type 304L or 316L).

B. Isolating sleeves and washers: 1. Manufacturers: One of the following or equal:

a. Central Plastics Company, Shawnee, Oklahoma. b. Corrosion Control Products, PSI Inc., Gardena, CA.

2. Sleeves: Mylar, 1/32-inch thick, 4,000 volts per mil dielectric strength, of proper size to fit bolts and extending half way into both steel washers.

3. One sleeve required for each bolt. 4. Washers: The inside diameter of all washers shall fit over the isolating sleeve,

and both the steel and isolating washers shall have the same inside diameter and outside diameter. a. Proper size to fit bolts. b. Two 1/8-inch thick steel washers for each bolt. c. G3 Phenolic: 2 insulating washers are required for each bolt:

1) Thickness: 1/8 inch. 2) Base material: Glass. 3) Resin: Phenolic. 4) Water absorption: 2 percent. 5) Hardness (Rockwell): 100. 6) Dielectric strength: 450 volts per mil. 7) Compression strength: 50,000 pounds per square inch. 8) Tensile strength: 20,000 pounds per square inch. 9) Maximum operating temperature: 350 degrees Fahrenheit.

C. Coating for repair of galvanized surfaces: 1. Manufacturers: One of the following or approved equal:

a. Galvinox. b. Galvo-Weld.

D. Thread coating: For use with threaded stainless steel fasteners:


1. Manufacturers: One of the following or equal: a. Never Seez Compound Corporation, Never-Seez. b. Oil Research, Inc., WLR No. 111.

PART 3 EXECUTION

3.01 EXAMINATION

A. Examine Work in place to verify that it is satisfactory to receive the Work of this Section. If unsatisfactory conditions exist, do not begin this Work until such conditions have been corrected.

3.02 INSTALLATION: GENERAL

A. Where anchors and fasteners are not specifically indicated on the Drawings or specified, make attachments with materials specified in this Section.

B. Substitution of anchor types: 1. Post-installed anchors may not be used as an alternative to cast-in/built-in

anchors at locations where the latter are indicated on the Drawings. 2. Cast-in/built-in anchors may be used as an alternative to post-installed

mechanical anchors at locations where the latter are indicated on the Drawings.

C. Protect products from damage during installation. Take special care to protect threads and threaded ends.

D. Accurately locate and position anchors and fasteners: 1. Unless otherwise indicated on the Drawings, install anchors perpendicular to

the surfaces from which they project. 2. Install anchors so that at least 2 threads, but not more than 1/2 inch of

threaded rod, projects past the top nut.

E. Interface with other products: 1. Where steel anchors come in contact with dissimilar metals (aluminum,

stainless steel, etc.), use stainless steel anchors and separate or isolate dissimilar metals using isolating sleeves and washers.

2. Prior to installing nuts, coat threads of stainless steel fasteners with thread coating to prevent galling of threads.

3.03 INSTALLATION: CAST-IN ANCHORS

A. General: 1. Accurately locate cast-in and built-in anchors.

a. Provide anchor setting templates to locate anchor bolts and anchor rods. Secure templates to formwork.

b. Brace or tie off embedments as necessary to prevent displacement during placement of plastic concrete or of surrounding masonry construction.

c. Position and tie cast-in and built-in anchors in place before beginning placement of concrete or grout. Do not “stab” anchors into plastic concrete, mortar, or grout.


d. Do not allow cast-in anchors to touch reinforcing steel. Where cast-in anchors are within 1/4 inch of reinforcing steel, isolate the metals by wrapping the anchors with a minimum of 4 wraps of 10-mil polyvinyl chloride tape in area adjacent to reinforcing steel.

2. For anchoring at machinery bases subject to vibration, use 2 nuts, with 1 serving as a locknut.

3. Where anchor bolts or anchor rods are indicated on the Drawings as being for future use, thoroughly coat exposed surfaces that project from concrete or masonry with non-oxidizing wax. Turn nuts down full length of the threads, and neatly wrap the exposed thread and nut with a minimum of 4 wraps of 10-mil waterproof polyvinyl tape.

B. Anchor bolts: 1. Minimum effective embedment: 10-bolt diameters, unless a longer embedment

is indicated on the Drawings. 2. Where indicated on the Drawings, set anchor bolts in plastic, galvanized steel

or stainless steel sleeves to allow for adjustment.

C. Anchor rods: 1. Install as specified for anchor bolts

3.04 INSTALLATION: POST-INSTALLED ADHESIVE ANCHORS

A. Epoxy and acrylic adhesive bonding of reinforcing bars, all thread rods, and internally threaded inserts in concrete: As specified in Section 03055.

3.05 INSTALLATION: POST-INSTALLED MECHANICAL ANCHORS

A. General: 1. Install anchors in accordance with the manufacturer’s instructions, ACI 355.2,

the anchor’s ICC-ES Report. Where conflict exists between the ICC-ES Report and the requirements in this Section, the requirements of the ICC-ES Report shall control.

2. Where anchor manufacturer recommends the use of special tools and/or specific drill bits for installation, provide and use such tools.

3. After anchors have been positioned and inserted into concrete or masonry, do not: a. Remove and reuse/reinstall anchors. b. Loosen or remove bolts or studs.

B. Holes drilled into concrete and masonry: 1. Do not drill holes in concrete or masonry until the material has achieved its

minimum specified compression strength (f’c or f’m). 2. Accurately locate holes:

a. Before drilling holes, use a reinforcing bar locator to identify the position of all reinforcing steel, conduit, and other embedded items within a 6 -inch radius of each proposed hole.

b. If the hole depth exceeds the range of detection for the rebar locator, the Engineer may require radiographs of the area designated for investigation before drilling commences.

3. Exercise care to avoid damaging existing reinforcement and other items embedded in concrete and masonry.


a. If embedments are encountered during drilling, immediately stop work and notify the Engineer. Await Engineer’s instructions before proceeding.

4. Unless otherwise indicated on the Drawings, drill holes perpendicular to the concrete surface into which they are placed.

5. Drill using anchor manufacturer’s recommended equipment and procedures. a. Unless otherwise recommended by the manufacturer, drill in accordance

with the following: 1) Drilling equipment: Electric or pneumatic rotary type with light or

medium impact. Where edge distances are less than 2 inches, use lighter impact equipment to prevent micro-cracking and concrete spalling during drilling process.

2) Drill bits: Carbide-tipped in accordance with ANSI B212-15. Hollow drills with flushing air systems are preferred.

6. Drill holes at manufacture’s recommended diameter and to depth required to provide the effective embedment indicated.

7. Clean and prepare holes as recommended by the manufacturer and as required by the ICC-ES Report for that anchor. a. Unless otherwise recommended by anchor manufacturer, remove dust

and debris using brushes and clean compressed air. b. Repeat cleaning process as required by the manufacturer’s installation

instructions. c. When cleaning holes for stainless steel anchors, use only stainless steel

or non-metallic brushes.

C. Insert and tighten (or torque) anchors in full compliance with the manufacturer’s installation instructions. 1. Once anchor is tightened (torque), do not attempt to loosen or remove its bolt

or stud.

D. Concrete anchors: Minimum effective embedment lengths unless otherwise indicated on the Drawings:

Concrete Anchors

Nominal Diameter

Minimum Effective Embedment Length Minimum Member Thickness In Concrete In Grouted Masonry

3/8 inch 2 1/2 inch 2 5/8 inch 8 inch



3/4 inch 5 inch 5 1/4 inch 12 inch

E. Flush shell anchors: 1. Flush shell anchors are not permitted in the Work. 2. If equipment manufacturer’s installation instructions recommend the use of

flush shell anchors, contact Engineer for instructions before proceeding.


F. Sleeve anchors: 1. Minimum effective embedment lengths unless otherwise indicated on the

Drawings: Sleeve Anchors

Nominal Diameter

Minimum Effective Embedment Length Minimum Member

Thickness In Concrete In Grouted Masonry M8 (1/2 inch) 70 mm (2 3/4 inch) Not accepted 100 mm (8 inch)

M10 (5/8 inch) 76 mm (3 inch) Not accepted 250 mm (10 inch)

M12 (3/4 inch) 80 mm (3 1/4 inch) Not accepted 300 mm (12 inch) 2. Install with the sleeve fully engaged in the base material.

G. Screw anchors: 1. Minimum effective embedment lengths unless otherwise indicated on the

Drawings: Screw Anchors

Nominal Diameter


Thickness In Concrete In Grouted Masonry 3/8 inch 2 1/2 inch 3 1/4 inch 8 inch


5/8 inch 4 inch 5 inch 10 inch

3/4 inch 5 1/2 inch 6 1/4 inch 12 inch 2. Install screw anchors using equipment and methods recommended by the

manufacturer. Continue driving into hole until the washer head is flush against the item being fastened.


H. Undercut concrete anchors: 1. Minimum effective embedment lengths unless otherwise indicated on the

Drawings: Undercut Anchors

Nominal Diameter

(bolt)


Thickness(1) In Concrete In Grouted Masonry M10 (3/8 inch) 100 mm (4 inch) Not accepted 200 mm (8 inch)


M16 (5/8 inch) 190 mm (7 1/2 inch) Not accepted 460 mm (18 inch)


Notes: (1) Thickness indicated is for pre-set units. If through-set units are accepted, obtain

minimum member thickness requirements from the Engineer. 2. Installations of undercut anchors shall not be allowed where edge distances

are less than 12 times the nominal diameter of the anchor stud. 3. Undercut bottom of hole using cutting tools manufactured for this purpose by

the manufacturer of the undercut anchors being placed.


A. Contractor shall provide quality control over the Work of this Section as specified in Section 01400. 1. Expenses associated with work described by the following paragraphs shall be

paid by the Contractor.

B. Post-installed anchors: 1. Review anchor manufacturer’s installation instructions and requirements of the

Evaluation Service Report (hereafter referred to as “installation documents”) for each anchor type and material.

2. Observe hole-drilling and cleaning operations for conformance with the installation documents.

3. Certify in writing to the Engineer that the depth and location of anchor holes, and the torque applied for setting the anchors conforms to the requirements of the installation documents.

3.07 FIELD QUALITY ASSURANCE

A. Owner will provide on-site observation and field quality assurance for the Work of this Section. 1. Expenses associated with work described by the following paragraphs shall be

paid by the Owner.

B. Field inspections and special inspections: 1. Required inspections: Observe construction for conformance to the approved

Contract Documents, the accepted submittals, and manufacturer’s installation instructions for the products used.

2. Record of inspections:


a. Maintain record of each inspection. b. Submit copies to Engineer upon request.

3. Statement of special inspections: At the end of the project, prepare and submit to the Engineer and the authority having jurisdiction inspector’s statement that the Work was constructed in general conformance with the approved Contract Documents, and that deficiencies observed during construction were resolved.

C. Special inspections: Anchors cast into concrete and built into masonry. 1. Provide special inspection during positioning of anchors and placement of

concrete or masonry (including mortar and grout) around the following anchors: a. Anchor bolts. b. Anchor rods.

2. During placement, provide continuous special inspection at each anchor location to verify that the following elements of the installation conform to the requirements of the Contract Documents. a. Anchor:

1) Type and dimensions. 2) Material: Galvanized steel, Type 304 stainless steel, or Type 316

stainless steel as specified in this Section or indicated on the Drawings.

3) Positioning: Spacing, edge distances, effective embedment, and projection beyond the surface of the construction.

4) Reinforcement at anchor: Presence, positioning, and size of additional reinforcement at anchors indicated on the Drawings.

3. Following hardening and curing of the concrete or masonry surrounding the anchors, provide periodic special inspection to observe and confirm the following: a. Base material (concrete or grouted masonry):

1) Solid and dense concrete or grouted masonry material within required distances surrounding anchor.

2) Material encapsulating embedment is dense and well-consolidated.

D. Special Inspections: Post-installed mechanical anchors placed in hardened concrete and in grouted masonry. 1. Provide special inspection during installation of the following anchors:

a. Concrete anchors. b. Sleeve anchors .

2. Unless otherwise noted, provide periodic special inspection during positioning, drilling, placing, and torquing of anchors. a. Provide continuous special inspection for post-installed anchors in

“overhead installations” as defined in this Section. 3. Requirements for periodic special inspection:

a. Verify items listed in the following paragraphs for conformance to the requirements of the Contract Documents and the Evaluation Report for the anchor being used. Observe the initial installation of each type and size of anchor, and subsequent installation of the same anchor at intervals of not more than 4 hours. 1) Any change in the anchors used, in the personnel performing the

installation, or in procedures used to install a given type of anchor shall require a new “initial inspection.”


b. Substrate: Concrete or masonry surfaces receiving the anchor are sound and of a condition that will develop the anchor’s rated strength.

c. Anchor: 1) Manufacturer, type, and dimensions (diameter and length). 2) Material (galvanized, Type 304 stainless steel, or Type 316 stainless

steel). d. Hole:

1) Positioning: Spacing and edge distances. 2) Drill bit type and diameter. 3) Diameter, and depth. 4) Hole cleaned in accordance with manufacturer’s required

procedures. Confirm multiple repetitions of cleaning when recommended by the manufacturer.

5) Anchor’s minimum effective embedment. 6) Anchor tightening/installation torque.

4. Requirements for continuous special inspection: a. The special inspector shall observe all aspects of anchor installation,

except that holes may be drilled in his/her absence provided that he/she confirms the use of acceptable drill bits before drilling, and later confirms the diameter, depth, and cleaning of drilled holes.

E. Field tests: 1. Owner may, at any time, request testing to confirm that materials being

delivered and installed conform to the requirements of the Specifications. a. If such additional testing shows that the materials do not conform to the

specified requirements, the Contractor shall pay the costs of these tests. b. If such additional testing shows that the materials do conform to the

specified requirements, the Owner shall pay the costs of these tests.

3.08 Non-conforming work

A. Remove misaligned or non-performing anchors.

B. Fill empty anchor holes and repair failed anchor locations as specified in Section 03600 using high-strength, non-shrink, non-metallic grout.

C. If more than 10 percent of all tested anchors of a given diameter and type fail to achieve their specified torque or proof load, the Engineer will provide directions for required modifications. Make such modifications, up to and including replacement of all anchors, at no additional cost to the Owner.

3.09 SCHEDULES

A. Stainless steel. Provide and install stainless steel anchors at the following locations: 1. “Corrosive locations” as defined in this Section: Type 316 stainless steel 2. “Wet and moist locations” as defined in this Section: Type 316 stainless steel. 3. “Other locations:”

a. For connecting stainless steel members to concrete or masonry: Type 304 stainless steel.

b. For connecting aluminum members to concrete or masonry. 4. At locations indicated on the Drawings.


B. Galvanized: Provide and install galvanized carbon steel anchors at the following locations: 1. Locations not requiring stainless steel. 2. At locations indicated on the Drawings.]

C. Provide and install anchor materials as scheduled in the following Table. Table – Required Anchoring Materials by Location

Location/Exposure Materials Notes 1. Anchors into concrete and grouted masonry for attachment of carbon steel, including

structural steel and other steel fabrications:

a) Interior dry areas Carbon steel – galvanized

b) Locations with galvanized steel structures or fabrications

Stainless steel – Type 304 or 316 1

c) Exterior and interior wet and moist locations

Stainless steel – Type 316 1

d) Corrosive locations Stainless steel – Type 316 1

2. Anchors into concrete and grouted masonry for attachment of aluminum, stainless steel, or fiber-reinforced plastic (FRP) shapes and fabrications:

a) Interior dry areas Stainless steel – Type 304 or 316 1

b) Exterior and interior wet and moist locations

Stainless steel – Type 316 1

c) Corrosive locations Stainless steel – Type 316 1

3. Anchors for attaching equipment and its appurtenances:

a) All locations Stainless steel – Type 316 (unless Type 304 is specifically indicated in the specifications for the equipment.)

1

Note: (1) Where anchors are in contact with a metal that differs from that of the anchor, provide isolation

sleeves and washers.

END OF SECTION


SECTION 05500

METAL FABRICATIONS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Aluminum grating stair tread. 2. Aluminum stair nosing. 3. Cast iron stop plank grooves. 4. Concrete inserts. 5. Handrails and guardrails. 6. Ladders. 7. Manhole frames and covers. 8. Metal gratings. 9. Metal tread plate. 10. Preformed channel pipe supports. 11. Stairs. 12. Miscellaneous metals. 13. Associated accessories to the above items.

B. Related sections: 1. Section 02084 - Precast Drainage Structures. 2. Section 05190 - Mechanical anchoring and Fastening to Concrete and

Masonry. 3. Section 09960 - High Performance Coatings. 4. Section 15061 - Pipe Supports. 5. Section 15062 - Preformed Channel Pipe Support System.

1.02 REFERENCES

A. Aluminum Association (AA): 1. DAF-45: Designations from Start to Finish.

a. M12-C22-A41.

B. American Association of State Highway and Transportation Officials (AASHTO): 1. Standard Specifications for Highway Bridges.

C. ASTM International (ASTM): 1. A 36 - Standard Specification for Carbon Structural Steel. 2. A 48 - Standard Specification for Gray Iron Castings. 3. A 53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded, and Seamless. 4. A 123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron

and Steel Products. 5. A 240 - Standard Specification for Chromium and Chromium-Nickel Stainless

Steel Plate, Sheet, and Strip for Pressure Vessels for General Applications. 6. A 276 - Standard Specification for Stainless Steel Bars and Shapes.


7. A 307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength.

8. A 325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

9. A 380 - Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems.

10. A 489 - Standard Specification for Carbon Steel Lifting Eyes. 11. A 490 - Standard Specification for Structural Bolts, Alloy Steel, Heat-Treated ,

150 ksi Minimum Tensile Strength. 12. A 500 - Standard Specification for Cold-Formed Welded and Seamless

Carbon Steel Structural Tubing in Rounds and Shapes. 13. A 501 - Standard Specification for Hot-Formed Welded and Seamless Carbon

Steel Structural Tubing. 14. A 635 - Standard Specification for Steel, Sheet and Strip, Heavy-Thickness

Coils, Hot-Rolled, Alloy, Carbon, Structural, High-Strength Low-Alloy, and High-Strength Low-Alloy with Improved Formability, General Requirements for.

15. A 653 - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process.

16. A 992 - Standard Specification for Structural Steel Shapes. 17. B 209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and

Plate. 18. B 221 - Standard Specification for Aluminum and Aluminum-Alloy Extruded

Bars, Rods, Wire, Profiles, and Tubes. 19. B 308 - Standard Specification for Aluminum-Alloy 6061-T6 Standard

Structural Profiles. 20. B 429 - Standard Specification for Aluminum-Alloy Extruded Structural Pipe

and Tube. 21. F 593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws and

Studs.

D. American Welding Society (AWS): 1. A2.4 - Standard Symbols for Welding, Brazing, and Nondestructive

Examination.

E. Occupational Safety and Health Administration (OSHA).

1.03 DEFINITIONS

A. Passivation: Removal of exogenous iron or iron compounds from the surface of a stainless steel by means of chemical dissolution resulting from treatment with an acid solution that removes the surface contamination but does not significantly affect the stainless steel itself.

1.04 SUBMITTALS

A. Product Data: 1. Aluminum grating stair tread. 2. Aluminum stair nosing. 3. Cast iron stop plank grooves. 4. Handrail and guardrail. 5. Manhole frames and covers. 6. Metal grating.


B. Shop drawings: 1. Handrails and guardrails:

a. Including details on connection attachments, gates, kick plates, ladders, and angles.

b. Indicate profiles, sizes, connection attachments, reinforcing, anchorage, size and type of fasteners, and accessories.

c. Include erection drawings, elevations, and details where applicable. d. Indicate welded connections using standard AWS A2.4 welding symbols.

Indicate net weld lengths. 2. Ladders. 3. Metal grating. 4. Metal tread plate. 5. Stairs. 6. Miscellaneous metals.

C. Samples: 1. Guardrails with specified finishes.

D. Quality control submittals: 1. Design data. 2. Test reports:

a. Guardrails: 3 copies of certified tests performed by an independent testing laboratory certifying that guardrails meet current State and OSHA strength requirements.

b. Gratings: 1) Grating manufacturers' calculations showing that gratings will meet

specified design load, stress, and deflection requirements for each size grating for each span.

2) Reports of tests performed.

PART 2 PRODUCTS

2.01 MATERIALS

A. General: Unless otherwise specified or indicated on the Drawings, structural and miscellaneous metals in accordance with the standards of the ASTM, including the following:

Item ASTM

Standard No. Class, Grade

Type or Alloy No. Cast Iron

Cast Iron A 48 Class 40B

Steel Galvanized sheet iron or steel A 653 Coating G90

Coil (plate) A 635 --

Structural plate, bars, rolled shapes, and miscellaneous items (except W shapes).

A 36 --


Item ASTM

Standard No. Class, Grade

Type or Alloy No. Rolled W shapes A 992 Grade 50

Standard bolts, nuts, and washers A 307 --

High strength bolts, nuts, and hardened flat washers

A 325 A 490

--

Eyebolts A 489 Type 1

Tubing, cold-formed A 500 --

Tubing, hot-formed A 501 --

Steel pipe A 53 Grade B

Stainless Steel Plate, sheet, and strip A 240 Type 304* or 316**

Bars and shapes A 276 Type 304* or 316**

Bolts (Type 304) F593 Group 1 Condition CW

Bolts (Type 316) F593 Group 2 Condition CW

Aluminum Flashing sheet aluminum B 209 Alloy 5005-H14,

0.032 inches minimum thickness

Structural sheet aluminum- B 209 Alloy 6061-T6

Structural aluminum B 209 B 308

Alloy 6061-T6

Extruded aluminum B 221 Alloy 6063-T42 * Use Type 304L if material will be welded. ** Use Type 316L if material will be welded.

1. Stainless steels are designated by type or series defined by ASTM. 2. Where stainless steel is welded, use low-carbon stainless steel.


A. Aluminum grating stair tread: 1. Manufacturers: One of the following or equal:

a. IKG Borden Industries, Aluminum Grating Stair Tread with Mebac nosing. b. McNichols Co., Type A-Standard with Corrugated Angle Nosing.

2. Material: Welded aluminum grating tread with non-slip nosing and integral end plates for bolt on attachment to stair stringers

3. Size: a. Tread width: To equal tread spacing plus 1 inch minimum. b. Tread length: Length to suit stringer-to-stringer dimension indicated on the

Drawings. c. Depth: 1-3/4 inches.


4. Bolts: Type 316 stainless steel.

B. Aluminum stair nosing: 1. Manufacturers: One of the following or equal:

a. Wooster Products, Inc., Type 101 Nosing. b. American Safety Tread Co., Inc., Style 801 Nosing.

2. Material: Cast aluminum abrasive nosings with aluminum oxide granules integrally cast into metal, forming permanent, nonslip, long-wearing surface.

3. For installation in cast-in-place stairs. 4. Configuration: 4 inches wide, fabricated with integrally cast stainless steel

anchors at approximately 12-inch centers. Length to extend within 3 inches of stair edge on each side.

C. Cast iron stop plank grooves: 1. Manufacturers: One of the following or equal:

a. Neenah Foundry Company, R-7500 Series, Type A. b. McKinley Iron Works, Type L.

2. Size: 2-inch wide groove opening by 1-1/2 inch deep, unless otherwise indicated on the Drawings.

3. Recess groove with the cast iron surface of the groove set flush with the concrete surface.

D. Concrete inserts: 1. Concrete inserts for supporting pipe and other applications are specified in

Section 15061.

E. Handrails and guardrails: 1. General:

a. Design and fabricate assemblies to conform to current local, State, and OSHA standards and requirements.

b. Coordinate layout of assemblies and post spacings to avoid conflicts with equipment and equipment operators. 1) Indicate on the shop drawings locations of such equipment. 2) Highlight locations where railings cannot be made continuous, and

obtain Engineer’s directions on how to proceed before fabricating or installing railings.

2. Aluminum handrails and guardrails (nonwelded pipe): a. Rails, posts, and fitting-assembly spacers:

1) In accordance with ASTM B 429, 6005, 6063 or 6105, minimum Schedule 40, extruded aluminum pipe of minimum 1.89-inch outside diameter and 0.14-inch wall thickness.

b. Kick plates: 6061 or 6105 aluminum alloy. c. Fastenings and fasteners: As recommended or furnished by the

manufacturer. d. Other parts: 6063 extruded aluminum, or F214 or F514.0 aluminum

castings: 1) Fabrications: In accordance with ASTM B 209 or ASTM B 221

extruded bars: a) Bases: 6061 or 6063 extruded aluminum alloy.

2) Plug screws or blind rivets: Type 305 stainless steel. a) Other parts: Type 300 series stainless steel.


e. Finish of aluminum components: 1) Anodized finish, 0.7 mil thick, applied to exposed surfaces after

cutting. Aluminum Association Specification M12-C22-A41, mechanical finish non specular as fabricated, chemical finish-medium matte, anodic coating-clear Class I Architectural.

2) Pretreat aluminum for cleaning and removing markings before anodizing.

f. Fabrication and assembly: 1) Fabricate posts in single, unspliced pipe length. 2) Perform without welding. 3) Do not epoxy bond the parts. 4) Maximum clear opening between assembled railing components as

indicated on the Drawings. g. Manufacturers: One of the following or equal:

1) Moultrie Manufacturing Company, Wesrail. 2) Golden Railings, Golden, CO, Riveted System. 3) Craneveyor Corporation Enerco Metals, C-V Rail.

h. AD2 3. Handrail gates:

a. Supplied by handrail manufacturer: 1) Of same material, quality, and workmanship as specified for handrail

system in which they will be installed. AD2 2) Of design similar to that of handrail or railing system in which they

will be installed. b. Components: Gate frame, stainless steel self-closing device, hinges, gate

stops, and durable self-locking type latch. Fabricate components in conformance with OSHA minimum strength requirements.

4. Fastenings and fasteners: As recommended or furnished by guardrail manufacturer for use with this system.

F. Ladders: 1. General:

a. Type: Safety type conforming to local, State, and OSHA standards as minimum. Furnish guards for ladder wells.

b. Size: 18 inches wide between side rails of length, size, shape, detail, and location indicated on the Drawings.

2. Aluminum ladders: a. Materials: 6063-T5 aluminum alloy. b. Rungs:

1) 1-inch minimum solid square bar with 1/8-inch grooves in top and deeply serrated on all sides.

2) Capable of withstanding 1,000 pound load without failure. c. Side rails: Minimum 4-inch by 1/2-inch flat bars. d. Finish of aluminum components:

1) Anodized finish, 0.7 mil thick, applied to exposed surfaces after cutting. Aluminum Association Specification M12-C22-A41, mechanical finish non specular as fabricated, chemical finish-medium matte, anodic coating-clear Class I Architectural.

2) Pretreat aluminum for cleaning and removing markings before anodizing.

e. Fabrication:


1) Welded construction, of size, shape, location, and details indicated on the Drawings.

2) For ladders over 20 feet high, furnish standard ladder cages or fall prevention system designed in accordance with State and OSHA requirements.

f. Fall prevention system: Include but not limit to railing, brackets, clamps, 2 sleeves, and 2 belts, satisfying OSHA safe climbing requirements: 1) Manufacturers: One of the following or equal:

a) North Consumer Products, Saf-T-Climb. b) Swager Communications, Climbers Buddy System.

G. Manhole frames and covers: 1. Material: Gray iron castings, in accordance with ASTM A 48, Class 30-B. 2. Type: Heavy-duty traffic type, with combined minimum set weight of

265 pounds. 3. Machine horizontal and vertical bearing surfaces to fit neatly, with easily

removable cover bearing firmly in frame without rocking. 4. Frame:

a. Bottom flange type. b. Approximately 4-1/2 inches frame height. c. Dimensions as indicated on the Drawings.

1) Minimum inside clear dimension may not be smaller than nominal diameter minus 2 inches.

5. Cover: a. Skid-resistant grid pattern design stamped with name of utility service

provided by manhole, such as "ELECTRICAL," "SEWER," "TELEPHONE," or "WATER."

b. Solid type without ventilation holes. 6. Finish: Unpainted.

H. Metal gratings: 1. General:

a. Fabricate grating to cover areas indicated on the Drawings. b. Unless otherwise indicated on the Drawings, grating over an opening shall

cover entire opening. c. Make cutouts in grating where required for equipment access or

protrusion, including valve operators or stems, and gate frames. d. Band ends of grating and edges of cutouts in grating:

1) End banding: 1/4 inch less than height of grating, with top of grating and top edge of banding flush.

2) Cutout banding: Full-height of grating. 3) Use banding of same material as grating. 4) Panel layout: Enable installation and subsequent removal of grating

around protrusions or piping. 5) Openings 6 inches and larger: Lay out grating panels with edges of

2 adjacent panels located on centerline of opening. 6) Openings smaller than 6 inches: Locate opening at edge of single

panel. 7) Where an area requires more than 1 grating section to cover area,

clamp adjacent grating sections together at 1/4-points with fasteners acceptable to Engineer.


8) Fabricate steel grating sections in units weighing not more than 50 pounds each.

9) Fabricate aluminum grating sections in units of weighing not more than 50 pounds each.

10) Gaps between adjacent grating sections shall not be more than the clear spacing between bearing bars.

e. When requested by Engineer, test 1 section of each size grating for each span length involved on the job under full load: 1) Furnish a suitable dial gauge for measuring deflections.

f. Grating shall be aluminum, unless otherwise specified or indicated on the Drawings.

2. Aluminum grating: a. Material for gratings, shelf angles, and rebates: 6061-T6 or

6063-T6 aluminum alloy, except crossbars may be 6063-T5 aluminum alloy.

b. Shelf angle concrete anchors: Type 304 or Type 316 stainless steel. c. Grating rebate rod anchors: 6061-T6 or 6063-T6 aluminum alloy. d. Bar size and spacing: As determined by manufacturer to enable grating to

support design load. e. Design live load: A minimum of 100 pounds per square foot uniform live

load on entire grating area, but not less than the live load indicated on the Drawings for the area where grating is located.

f. Maximum fiber stress for design load: 12,000 pounds per square inch. g. Maximum deflection due to design load: 1/240 of grating clear span. h. Maximum spacing of main grating bars: 1-1/8 inches clear between bars. i. Minimum grating height: 1-1/2 inches. j. Manufacturers: One of the following or equal:

1) IKG Borden Industries, grooved aluminum I-bar. 2) Brodhead Steel Products, Inc., grooved aluminum I-bar.

3. Steel gratings: a. Hot-dip galvanized in accordance with ASTM A 123. b. Bar size and spacing: As determined by the manufacturer to support

design load. c. Design live load: A minimum of 100 pounds per square foot uniform live

load on the entire area of the grating area, but not less than the live load indicated on the Drawings for the area where the grating is located.

d. Maximum fiber stress for design load: 18,000 pounds per square inch. e. Maximum deflection under design load: 1/240 of grating clear span. f. Bar spacing: Maximum of 1-1/8 inches clear between bars. g. Manufacturers: One of the following or equal:

1) IKG Borden Industries, IKG Weldforged. 2) Brodhead Steel Products, Inc., Type 19 W 4

4. Heavy-duty steel grating: a. Heavy-duty type, fabricated from structural steel and designed in

accordance with AASHTO Standard Specifications for Highway Bridges, using H-20 loading.

b. Hot-dip galvanized after fabrication in accordance with ASTM A 123. c. Manufacturers: One of the following or equal:

1) Reliance Steel Products Company, Heavy-Duty Steel Grating. 2) Seidelhuber Metal Products, Inc., equivalent product.

I. Metal tread plate:


1. Plate having a raised figured pattern on 1 surface to provide improved traction.

J. Preformed channel pipe supports: 1. Preformed channel pipe supports for pipe supports and other applications are

specified in Section 15062.

K. Stairs: 1. Aluminum stairs:

a. Stringers: 6061-T6 aluminum alloy. b. Stair treads:

1) Aluminum of same type specified under Aluminum Grating. 2) Of sizes indicated on the Drawings, and 1-3/4 inch minimum depth

with cast abrasive type safety nosings. c. Handrails and guardrails: Aluminum pipe specified under Aluminum

Handrails and Guardrails (Nonwelded Pipe). d. Fasteners: Type 304 or Type 316 stainless steel.

2. Steel stairs: a. Ships ladders shall conform to local, State, and OSHA as minimum. b. Stringers: Structural steel channels or plates. c. Treads: Open type attached to stringers with support angles and clips:

1) Borden, "Welded Tread" with Algrip nosing. d. Railings: Steel pipe, sized as indicated on the Drawings. e. Anchors: Welded or bolted brackets designed for support and anchorage

at top and bottom. f. Finish: Prime paint finish for interior locations

L. Miscellaneous aluminum: 1. Fabricate aluminum products, not covered separately in this Section, in

accordance with the best practices of the trade and field assemble by riveting or bolting.

2. Do not weld or flame cut.

M. Miscellaneous cast iron: 1. General:

a. Tough, gray iron, free from cracks, holes, swells, and cold shuts. b. Quality such that hammer blow will produce indentation on rectangular

edge of casting without flaking metal. c. Before leaving the foundry, clean castings and apply 16-mil dry film

thickness coating of coal-tar epoxy, unless otherwise specified or indicated on the Drawings.

N. Miscellaneous stainless steel: 1. Provide miscellaneous stainless steel items not specified in this Section as

indicated on the Drawings or specified elsewhere. a. Fabricate and install in accordance with the best practices of the trade.

2. Cleaning and passivation: a. Following shop fabrication of stainless steel members, clean and

passivate fabrications. b. Finish requirements: Remove free iron, heat tint oxides, weld scale and

other impurities, and obtain a passive finished surface.


c. Provide quality control testing to verify effectiveness of cleaning agents and procedures and to confirm that finished surfaces are clean and passivated. 1) Conduct sample runs using test specimens with proposed cleaning

agents and procedures as required to avoid adverse effects on surface finishes and base materials.

d. Pre-clean, chemically descale (pickle), and final clean fabrications in accordance with the requirements of ASTM A 380 or A967AD2 to remove deposited contaminants before shipping. 1) Passivation by citric acid treatment is not allowed.

a) If degreasing is required before cleaning to remove scale or iron oxide, cleaning (pickling) treatments with citric acid are permissible; however, these treatments shall be followed by inorganic cleaners such as nitric-hydrofluoric acid.

2) Provide acid descaling (pickling) in accordance with Table A1.1 of Annex A1 of ASTM A 380.

3) After pickling, final cleaning of stainless steel shall conform to Part II of Table A2.1 of Annex A2 of ASTM A 380.

e. After cleaning, inspect using methods specified for “gross inspection” in ASTM A 380.

f. Improperly or poorly cleaned and passivated materials shall not be shipped and will not be accepted at the job site.

O. Miscellaneous structural steel: 1. Provide miscellaneous steel items not specified in this Section as indicated on

the Drawings or specified elsewhere. a. Fabricate and install in accordance with the best practices of the trade.

P. Isolating sleeves and washers: 1. As indicated on the Drawings and as specified in Section 05190.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verification of conditions: 1. Examine work in place to verify that it is satisfactory to receive the work of this

Section. 2. If unsatisfactory conditions exist, do not begin this work until such conditions

have been corrected.

3.02 INSTALLATION

A. General: 1. Install products as indicated on the Drawings, and in accordance with shop

drawings and manufacturer's printed instructions, as applicable except where specified otherwise.

2. Interface between materials: a. Dissimilar metals: Where steel comes in contact with dissimilar metals

(aluminum, stainless steel, etc.), separate or isolate the dissimilar metals. 1) Make application so that the isolating or protective barrier is not

visible in the completed construction.


2) Isolating sleeves and washers: As specified in Section 05190. b. Aluminum in contact with concrete or masonry: Coat aluminum surfaces

as specified in Section 09960. c. Aluminum in contact with concrete or masonry.

B. Aluminum stair nosing: 1. Install stair nosings on treads of concrete stairs, including top tread on upper

concrete slab. 2. Omit stair nosings where concrete is submerged. 3. Cast stair nosings in fresh concrete, flush with tread and riser faces. Install

nosing in center of step approximately 3 inches from each stair edge.

C. Cast iron stop plank grooves: 1. Recess stop plank grooves with cast iron surfaces of groove set flush with

concrete surface.

D. Handrails and guardrails: 1. General:

a. Fasten pipe rails to fittings with Series 300 stainless steel pop rivets or flush set screws.

b. Make pipe cuts clean and straight, free of burrs and nicks, and square and accurate for minimum joint-gap.

c. Drill and countersink holes to proper size, as required for a tight flush fit of screws and other component parts.

d. Space attachment brackets as indicated in the manufacturer's instructions.

2. Aluminum pipe handrails and guardrails: a. During construction, keep exterior surfaces of handrails and guardrails

covered with 0.4 millimeters, minimum, heat shrink polyethylene film. b. Do not remove protective film before handrails and guardrails have been

accepted by Engineer nor before other work in proximity of handrails and guardrails has been completed.

c. Discontinue handrails and guardrails at lighting fixtures. d. Provide 1/8-inch diameter weep hole at base of each post. e. Space posts as indicated on the Drawings. f. Anchor posts into concrete by grouting posts into formed holes in

concrete, into stainless steel sleeves cast in concrete; or bracket mount to face of concrete surfaces as specified and indicated on the Drawings.

g. Space rails as indicated on the Drawings. h. Make adequate provision for expansion and contraction of kick plates and

rails. 1) Make provisions for removable sections where indicated on the

Drawings. i. Make lower rails a single, unspliced length between posts, or continuous. j. Make top rails continuous whenever possible, and attach single, unspliced

lengths to 3 posts minimum. k. Draw up fasteners tight with hand wrench or screw driver. l. Space attachment brackets as indicated on shop drawings or in

manufacturer's installation instructions. m. Completed installation shall have handrails and railings rigid and free of

play at joints and attachments.


n. Protect handrail and guardrail finish from scratches, gouges, dents, stains, and other damage.

o. Replace damaged or disfigured handrails and guardrails with new. p. Shortly before final acceptance of the work, and after removal of

protective polyethylene film, clean handrails and guardrails with mild detergent or with soap and water. 1) After cleaning, thoroughly rinse handrails and guardrails and wipe

with soft cloth. q. Erect guardrail straight, level, plumb, and true to the positions as indicated

on the Drawings. Correct deviations from true line of grade, which are visible to the eye.

3. AD2Handrail gates: a. Install gate to be a vertical plane with the handrail when in the closed

position. b. Install hinges so that each gate can swing 180 degrees from the closed

position to the fully open position. c. Install so that the gates swing to the walkway side of the handrail only. AD2

1) Install gate stops on the stationary railing posts to prohibit gates from swinging in the wrong direction.

d. Install gate frames, hinges, stops, and latches in conformance with OSHA minimum strength requirements.

E. Ladders: 1. Secure to supporting surface with bent plate clips providing minimum 8 inches

between supporting surface and center of rungs. 2. Where exit from ladder is forward over top rung, extend side rails 3 feet

3 inches minimum above landing, and return the rails with a radius bend to the landing.

3. Where exit from ladder is to side, extend ladder 5 feet 6 inches minimum above landing and rigidly secure at top.

4. Erect rail straight, level, plumb, and true to position indicated on the Drawings. a. Correct deviations from true line or grade which are visible to the eye.

F. Manhole frames and covers: 1. Installation: As specified in Section 02084.

G. Metal gratings: 1. General:

a. Allow 1/8-inch maximum clearance between ends of grating and inside face of vertical leg of shelf angles.

b. Horizontal bearing leg of shelf angles shall be 2 inches minimum. c. Install aluminum plate or angles where necessary to fill openings at

changes in elevation and at openings between equipment and grating. d. Install angle stops at ends of grating. e. Installed grating shall not slide out of rebate or off support. f. Weld stops in place, unless otherwise specified or indicated on the

Drawings. g. Top surfaces of grating sections adjacent to each other shall lie in same

plane. 2. Aluminum grating:

a. Aluminum grating: Support on aluminum shelf angles or rebates. 3. Steel grating:


a. Support on hot-dip galvanized structural steel shelf angles or rebates. 4. Heavy-duty steel grating:

a. Support on hot-dip galvanized structural steel rebates embedded and anchored in concrete.

b. Use for roadways, traffic areas, and where indicated on the Drawings.

H. Stairs: 1. General:

a. Install guard railings around stair wells as indicated on the Drawings or specified.

I. Stainless Steel: 1. Welding:

a. Passivate field-welded surfaces: 1) Provide cleaning, pickling and passivating as specified in this

Section. 2) Clean using Derustit Stainless Steel Cleaner, or equal.

END OF SECTION

AD2 Addendum No. 2


SECTION 06611

FIBERGLASS REINFORCED PLASTIC FABRICATIONS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Fiberglass reinforced plastic fabrications including: 1. Weirs and Baffles 2. Parshall flume liners.

B. Related sections: 1. Section 01600 - Product Requirements. 2. Section 01612 - Seismic Design Criteria. 3. Section 01614 - Wind Design Criteria. 4. Section 05190 - Mechanical Anchoring and Fastening to Concrete and

Masonry.

1.02 REFERENCES

A. American Water Works Association (AWWA): 1. F 102 - Matched-Die-Molded, Fiberglass-Reinforced Plastic Weir Plates, Scum

Baffles, and Mounting Brackets.

B. ASTM International (ASTM): 1. D 635 - Standard Test Method for Rate of Burning and/or Extent and Time of

Burning of Plastics in a Horizontal Position. 2. D 638 - Standard Test Method for Tensile Properties of Plastics. 3. D 790 - Standard Test Methods for Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials. 4. D 2583 - Standard Test Method for Indentation of Hardness of Rigid Plastics

by Means of a Barcol Impressor. 5. E 84 - Standard Test Method for Surface Burning Characteristics of Building

Materials.

C. United States, Department of Agriculture (USDA).

D. United States, Department of the Interior: 1. Bureau of Reclamation (USBR):

a. ISO 9826 - Water Measurement Manual, Measurement of Liquid Flow in Open Channel.


A. Parshall flume liner: Provide temporary bracing for liner to assure maintenance of dimensions during shipment. Maintain bracing in place for installation.


PART 2 PRODUCTS

2.01 WEIR PLATES AND BAFFLES

A. Manufacturers: One of the following or equal: 1. F. B. Leopold Company. 2. Warminster Fiberglass Company. 3. LaValley Construction, Biloxi, MS. 4. Specialty Plastics, Inc., Baton Rouge, LA. 5. Fibercast, Sand Springs, OK.

B. Materials: 1. Hand lay-up construction. 2. Minimum corrosion liner:

a. One "C" or Nexus veil as specified for the service environment. b. Remainder 1-1/2 ounce per square foot mat to total minimum thickness of

0.096 inches on surface exposed to the service environment. 3. Ultraviolet stabilizer: Added to the exterior surface coat of fabrications intended

for outside service, in the type and amount recommended by the resin manufacturer.

4. Resin: Premium grade vinyl ester: a. Manufacturers: One of the following or equal: As recommended by the

resin manufacturer for the specific operating environment: 1) Dow Chemical Company, Derakane 411. 2) Ashland Chemical Company, Hetron 922. 3) Reichhold Inc., Reichhold Dion VER 9100. 4) Interplastic Corporation, Interplastic VE 8300.

5. Color: Natural, unless otherwise specified.

C. Fabrication: 1. Baffles: Hand lay-up components to specified shape and dimensions. 2. Weirs:

a. Match die molded. b. Weir plates:

1) Of shape and dimensions specified. 2) Provide 2-3/8 inch diameter holes for adjustment. 3) Resin coat cut edges, and drilled and countersunk holes in fiberglass

reinforced plastic fabrications. c. Furnish fiberglass reinforced plastic butt plates for joints. d. Washers:

1) Of same material as weirs, with surfaces smooth, free of voids, and without dry spots and crazes.

D. Rectangular “flat crested” weirs: 1. Fabrication:

a. Molded to produce uniform, smooth surfaces.

E. Rectangular plate and V-notch weirs: 1. Fabrication:

a. Compression molded in matched metal die molds. Fabrications from plate stock with cut-in edges. ends, or V-notches will not be accepted.


b. Tolerances: 1) Deviation between top elevations of V-notches in a line: Maximum

1/16 inch in 6-foot length of weir plate. 2) Deviations between bottom elevations of V-notches in a line:

Maximum 1/16 inch in 6-foot length of weir plate. 3) Deviations in depth of V-notches in a line:

Maximum 1/16 inch in 6 foot length of weir plate.

F. Accessories: 1. Washers: Of same material as weirs, with surfaces smooth, free of voids, and

without dry spots and crazes. 2. Assembly hardware: Concrete anchors as specified in Section 05190.

2.02 PARSHALL FLUME LINER

A. General: 1. Size(s)/Dimensions: As indicted on the Drawings with interior dimensions in

accordance with USBR/ISO 9826. 2. Performance requirements:

a. Accuracy of flow: Plus or minus 5 percent of rate with plus or minus 0.5 percent of rate repeatability.

b. Chemical exposure: c. Suitable for outdoor use in contact with treated secondary effluent.

B. Manufacturers: One of the following or equal: 1. BIF Industries. 2. F. B. Leopold Company, Inc. 3. Warminster Fiberglass. 4. LaValley Construction. 5. Specialty Plastics, Inc. 6. Fibercast.

C. Parshall flume (concrete): 1. Composition: Sufficient embedded galvanized steel to produce substantial,

self-supporting rigid structure requiring no external supporting structure. 2. Throat with fiberglass reinforced plastic liner installed: 6 inches wide for

measuring flows from 0.05 to 1.75 million gallons per day. 3. Interior dimensions with fiberglass reinforced plastic liner installed: In

accordance with USDA Circular 843.a.

D. Materials: 1. Glass fiber reinforced plastic, having the following properties:

Test Standard Requirement: Tensile strength ASTM D 638 14,000 psi, minimum Flexural strength ASTM D 790 25,000 psi, minimum Flexural modulus ASTM D 790 1,000,000 psi, minimum Indentation hardness (Barcol) ASTM D 2583 40 minimum, average

2. Minimum corrosion liner: a. On interior surface of flume. b. Two "C" or Nexus veils as specified for the service environment.


c. Remainder 1-1/2 ounce per square foot mat to a total minimum thickness of 0.106 inches.

3. Ultraviolet stabilizer: Added to the corrosion liner in the type and amount recommended by the resin manufacturer.

4. Minimum 3/8-inch total thickness. 5. Resin: Premium grade vinyl ester:

a. Manufacturers: One of the following or equal: As recommended by the resin manufacturer for the specific operating environment: 1) Derakane 411. 2) Hetron 922. 3) Reichhold Dion VER 9100. 4) Interplastic VE 8300.

6. Color: Natural.

E. Locking clips: Type 316 stainless steel, integral part of liner, minimum 16 per liner sufficient to assure permanent alignment.

F. Design criteria and chemical exposure: As specified for the application.

G. Fabrication: 1. Fabricated with integral stiffening ribs. 2. One piece, full-length construction for flumes up to 84 inches.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify that conditions are satisfactory for installation of products as specified in Section 01600.

3.02 ERECTION AND INSTALLATION, GENERAL

A. Install products where indicated on the Drawings in accordance with manufacturer's printed instructions.

3.03 WEIRS

A. Carefully install weirs, aligning and leveling to the elevations indicated on the Drawings.

B. Installation tolerances: 1. V-notch weirs. In the completed installation:

a. The variation in elevation between any 2 notches of the weir plate in a tank shall not exceed 1/8 inch.

b. In a round tank, the variation from elevation between any one quadrant of the weir and that of any other quadrant shall not exceed 1/16 inch.

3.04 PARSHALL FLUME

A. Install by grouting into place.

END OF SECTION


SECTION 07900

JOINT SEALANTS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Acrylic-Latex sealant. 2. Precast concrete joint sealant. 3. Silicone sealant. 4. Synthetic rubber sealing compound. 5. Synthetic sponge rubber filler. 6. Related materials.

1.02 REFERENCES

A. American Association of State Highway and Transportation Officials (AASHTO): 1. M 198 - Standard Specification for Joints for Concrete Pipe, Manholes, and

Precast Box Sections Using Preformed Flexible Joint Sealants.

B. ASTM International (ASTM): 1. C920 - Standard Specification for Elastomeric Joint Sealants. 2. C990 – Standard Specification for Joints for Concrete Pipe, Manholes, and

Precast Box Sections Using Preformed Flexible Joint Sealants. 3. C1330 - Standard Specification for Cylindrical Sealant Backing for Use with

Cold Liquid-Applied Sealants. 4. C1521 - Standard Practice for Evaluating Adhesion of Installed

Weatherproofing Sealant Joints. 5. D412 - Standard Test Methods for Vulcanized Rubber and Thermoplastic

Elastomers - Tension. 6. D624 - Standard Test Method for Tear Strength of Conventional Vulcanized

Rubber and Thermoplastic Elastomer.

1.03 SUBMITTALS

A. Product data.

B. Samples, include color selections.

C. Manufacturer's Installation Instructions.

D. Warranty.


A. Manufacturer qualifications: Manufacturer of proposed product for minimum 5 years with satisfactory performance record.


B. Installer qualifications: Manufacturer approved installer of products similar to specified products on minimum 5 projects of similar scope as Project with satisfactory performance record.

1.05 PROJECT/SITE CONDITIONS

A. Environmental requirements: Do not apply sealant on wet or frosty surfaces or when surface temperature is higher than 100 degrees Fahrenheit or lower than recommended by the manufacturer.


A. Deliver, store, and handle products in accordance with manufacturer's recommendations.

B. Code date packages. Do not use material older than manufacturer’s published shelf life. Store materials at temperatures lower than 80 degrees Fahrenheit. Condition materials in accordance with manufacturer’s instructions prior to installation.

1.07 SEQUENCING AND SCHEDULING

A. Caulk joints prior to painting.

1.08 WARRANTY

A. Warrant to correct defective products for minimum 1 year in accordance with manufacturer's standard warranty.

PART 2 PRODUCTS

2.01 SEALANTS

A. General: 1. Provide colors matching materials being sealed. 2. Where compound is not exposed to view in finished work, provide

manufacturer's color which has best performance. 3. Nonsagging sealant for vertical and overhead horizontal joints. 4. Sealants for horizontal joints: Self-leveling pedestrian/traffic grade. 5. Joint cleaner, primer, bond breaker: As recommended by sealant

manufacturer. 6. Sealant backer rod and/or compressible filler made from closed cell

polyethylene, polyethylene jacketed polyurethane foam, or other flexible, nonabsorbent, non-bituminous material recommended by sealant manufacturer to: a. Control joint depth. b. Break bond of sealant at bottom of joint. c. Provide proper shape of sealant bead. d. Serve as expansion joint filler.


2.02 ACRYLIC-LATEX SEALANT

A. Permanently flexible, nonstaining, and nonbleeding latex modified acrylic sealant compound, colors as selected by Engineer from manufacturer's standard options. Manufacturers: One of the following or equal: 1. Tremco, Tremflex 834. 2. Pecora Corp., Number AC-20. 3. Sonneborn, Sonolac.

2.03 PRECAST CONCRETE JOINT SEALANT

A. Preformed, cold-applied, ready-to-use, flexible joint sealant in accordance with ASTM C990 and AASHTO M 198. Manufacturers: One of the following or equal. 1. Henry Corporation, Ram-Nek. 2. Concrete Sealants Division, ConSeal.

2.04 SILICONE SEALANT

A. ASTM C920, Type S, Grade NS, Class 25, single component silicone sealant. Manufacturers: One of the following or equal: 1. Tremco, Proglaze. 2. Pecora Corp., Number 864. 3. Dow Corning, Number 795. 4. General Electric, Number 1200 Series.

2.05 SYNTHETIC RUBBER SEALING COMPOUND

A. Manufacturer: One of the following or equal: 1. Sika Corporation, Sikaflex 2c NS or SL 2. Pacific Polymers, Elastothane 227R.

B. Material: In accordance with ASTM C920 Type M, Grade P (pourable), Class 25 and Type M, Grade NS (non-sag), Class 25; multi-part polyurethane; able to cure at room temperature to firm, highly resilient polymer; able to perform satisfactory when continuously submerged in water or sewage and exposed to direct sunlight in dry condition; with the following properties determined at 75 degrees Fahrenheit and 50 percent relative humidity: 1. Base: Polyurethane rubber. 2. Application time: Minimum 2 hours. 3. Cure time: Maximum 3 days. 4. Tack free time: Maximum 24 hours. 5. Ultimate hardness: Non-sag 25, Pourable/SL 40, within 5 Shore A. 6. Tensile strength: Non-sag 95 pounds per square inch minimum and self-

leveling minimum 170 pounds per square inch when tested in accordance with ASTM D412.

7. Ultimate elongation: Minimum 340 percent when tested in accordance with ASTM D412.

8. Tear resistance: Non-sag 45 pounds per inch minimum and self-leveling minimum 85 pounds per inch when tested in accordance with ASTM D624, Die C.

9. Service temperature range: Minus 25 degrees to 158 degrees Fahrenheit.

C. Color: Gray to match concrete, unless indicated on the Drawings.


2.06 SYNTHETIC SPONGE RUBBER FILLER

A. Closed-cell expanded sponge rubber manufactured from synthetic polymer neoprene base, or resilient polyethylene foam backer rod. In accordance with ASTM C1330, Type O. 1. Manufacturers: One of the following or equal:

a. Presstite, Number 750.3 Ropax Rod Stock.

B. Characteristics: 1. Suitable for application intended. 2. Strength: As necessary for supporting sealing compound during application. 3. Resiliency: Resistance to environmental conditions of installation. 4. Bonding: No bonding to the sealing compound. 5. Structure: Cellular, prevents absorption of water. 6. Compatibility with other materials in joint and acceptance by manufacturer of

sealing compound. 7. Size: Minimum 25 percent greater than nominal joint width.

2.07 RELATED MATERIALS

A. Primer: Nonstaining type, recommended by sealant manufacturer to suit application.

B. Joint cleaner: Noncorrosive, nonstaining, compatible with joint forming materials and as recommended by sealant manufacturer.

C. Bond breaker tape: Pressure-sensitive tape recommended by sealant manufacturer to suit application.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify acceptability of joint dimensions, physical, and environmental conditions.

B. Verify that surfaces are dry, clean, and free of dirt, grease, curing compound, and other residue which might interfere with adhesion of sealants.

3.02 PREPARATION

A. Allow concrete to cure thoroughly before caulking.

B. Synthetic sponge rubber filler: 1. Prepare surfaces designated to receive filler in accordance with

manufacturer's installation instructions. 2. Do not stretch filler beyond its normal length during installation.

C. Caulking: 1. Verify that surfaces are dry, clean, and free of dirt, grease, curing compounds,

and other residue that might interfere with adhesion of sealant. 2. Concrete, masonry, wood, and steel surfaces: Clean and prime in accordance

with manufacturer's instructions prior to caulking.


D. Synthetic rubber sealing compound: 1. Ensure surfaces to which synthetic rubber must bond are dry and free of dust,

dirt, and other foreign residue. 2. Heavy sandblasted caulking groove to sound surface, and prime with

manufacturer's recommended primer for particular surface.

E. For sidewalks, pavements, and similar joints sealed with elastomeric sealants and subject to traffic and other abrasion and indentation exposures, fill joints to depth equal to 75 percent of joint width, but neither more than 5/8 inches deep nor less then 3/8 inches deep.

F. For normal moving building joints sealed with elastomeric sealants not subject to traffic, fill joints to depth equal to 50 percent of joint width, but neither more than 1/2 inch deep nor less than 1/4 inch deep.

G. For joints sealed with acrylic-latex sealants, fill joints to depth in range of 75 percent to 125 percent of joint width.

H. Use joint filler to achieve required joint depths, to allow sealants to perform properly.

I. Prepare surfaces and install synthetic sponge rubber filler in accordance with manufacturer's recommendations.

J. Do not stretch filler beyond normal length during installation.

K. Apply bond breaker when recommended by joint sealer manufacturer.

3.03 INSTALLATION

A. Synthetic sponge rubber filler: Install filler in accordance with manufacturer's installation instructions.

B. Caulking, joints, and sealing: 1. Expansion, contraction, and construction joints. 2. Install pipe and conduit in structures. 3. Caulk doors, windows, louvers, and other items installed in or over concrete

openings inside and out. 4. Use synthetic rubber sealing compound for caulking where indicated on the

Drawings or as specified, except for masonry construction and where specified otherwise.

5. Complete caulking prior to painting. 6. Verify that concrete is thoroughly cured prior to caulking. 7. When filler compressible material is used, use untreated type. 8. Apply caulking with pneumatic caulking gun. 9. Use nozzles of proper shape and size for application intended. 10. Maintain continuous bond between caulking and sides of joint to eliminate

gaps, bubbles, or voids and fill joint in continuous operation without layering of compound.

11. Employ experienced applicators to caulk joints and seams in neat workmanlike manner.

12. To hasten curing of compound when used on wide joints subject to movement, apply heat with infrared lamps or other convenient means.


13. Apply synthetic rubber sealing compound with pneumatic caulking tool or other acceptable method.

3.04 CLEANING

A. Clean surfaces adjacent to sealant as work progresses.

B. Remove excess uncured sealant by soaking and scrubbing with sealant cleaning solvent.

C. Remove excess cured sealant by sanding with Number 80 grit sandpaper.

D. Leave finished work in neat, clean condition.

3.05 SCHEDULE

A. Acrylic latex: 1. Interior joints with movement less than 7.5 percent and not subject to wet

conditions.

B. Silicone: 1. Joints and recesses formed where window, door, louver and vent frames, and

sill adjoin masonry, concrete, stucco, or metal surfaces. 2. Door threshold bedding. 3. Moist or wet locations, including joints around plumbing fixtures. 4. Stainless steel doors and frames, including joints between applied stops and

frames, and around anchor bolts. 5. Plenum joints.

C. Synthetic rubber sealing compound, non-sag Type II: 1. Water-bearing and earth-bearing concrete structures. 2. Joints in masonry, concrete vertical surfaces, and metal-faced panels in

vertical surfaces. 3. Joints between sheet metal flashing and trim. 4. Joints between sheet metal flashing and trim, and vertical wall surfaces. 5. Small voids between materials requiring filling for weathertight performance in

vertical surfaces. 6. Perimeters of frames of doors, windows, louvers, and other openings where

bonding is critical to airtight performance. 7. Expansion and control joints in masonry vertical surfaces.

D. Synthetic rubber sealing compound, self-leveling Type I: 1. Expansion and control joints in masonry, concrete horizontal surfaces, and

metal panels in horizontal surfaces. 2. Small voids between materials requiring filling for weathertight performance in

horizontal surfaces. 3. Pavement joints. 4. Perimeters of frames of doors, windows, louvers, and other openings in

horizontal surfaces where bonding is critical to airtight performance.



A. Adhesion testing: 1. Perform adhesion tests in accordance with ASTM C1521 per the following

criteria: a. Water bearing structures: 1 test per every 1,000 LF of joint sealed. b. Exterior precast concrete wall panels: 1 test per every 2,000 LF of joint

sealed. c. Chemical containment areas: 1 test per every 1,000 LF of joint sealed. d. Building expansion joints: 1 test per every 500 LF of joint sealed. e. All other type of joints except butt glazing joints: 1 test per every 3,000 LF

of joint sealed. f. Manufacturer's authorized factory representative provide written

recommendations for remedial measures on failing tests.

END OF SECTION


SECTION 08110

HOLLOW METAL DOORS AND FRAMES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Steel Fire Resistive Rated and Non-Fire Resistive Rated: 1. Doors. 2. Door frames. 3. Window frames. 4. Combination door frames and window frames with mullions, muntins, and

transom bars.

B. Related sections: 1. Section 01410 - Regulatory Requirements. 2. Section 03600 - Grouting. 3. Section 08710 - Door Hardware. 4. Section 08800 - Glazing. 5. Section 09910 - Painting. 6. Section 09960 - High-Performance Coatings.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. A250.6 - Hardware on Steel Doors (Reinforcement Application). 2. A250.8 - Recommended Specification for Standard Steel Doors and Frames.

B. ASTM International (ASTM): 1. A 653/A653M - Standard Specification for Sheet Steel, Zinc Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process.

2. A 924/A924M - Standard Specification for General Requirements for Steel Sheet, Metallic- Coated by the Hot-Dip Process.

3. A 1008 - Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable.

4. A 1011 – Standard Specification for Steel, Sheet and Strip, Hot Rolled, Carbon, Structural, High Strength Low Alloy, High Strength Low Alloy with Improved Formability, and Ultra High Strength.

5. E 152 - Standard Methods of Fire Tests of Door Assemblies. 6. E 413 - Classification for Rating Sound Insulation. 7. E 1408 - Standard Test Method for Laboratory Measurement of the Sound

Transmission Loss of Door Panels and Door Systems. 8. E 2074 - Standard Test Method for Fire Tests of Door Assemblies, Including

Positive Pressure Testing of Side-Hinged and Pivoted Swinging Door Assemblies.


C. National Association of Architectural Metal Manufacturers (NAAMM)/Hollow Metal Manufacturers Association (HMMA): 1. HMMA 861 - Guide Specifications For Commercial Hollow Metal Doors and

Frames.

D. National Fire Protection Association (NFPA): 1. 80 - Standard for Fire Doors and Other Opening Protectives.

E. Steel Door Institute (SDI): 1. SDI-111 - A Steel Doors and Frame Details. 2. SDI-117 - Manufacturing Tolerances Standard Steel Doors and Frames.

F. Underwriters’ Laboratories, Inc., (UL): 1. UL 10C - Positive Pressure Fire Tests of Door Assemblies.

1.03 SUBMITTALS

A. Product data.

B. Shop drawings: Show the following with references to the Engineer's door marks and hardware groups: 1. Location of door and frame types. 2. Details of fabrication, including core construction, glass lights, louvers,

weatherstripping, and factory finish for each door. 3. Cutouts and reinforcements for hardware. 4. Methods of installation and anchorage to adjacent construction.

C. Certificates documenting: 1. Fire-rated units have been successfully tested in accordance with paragraph

2.06.

D. Manufacturer's instructions: Submit manufacturer's installation instructions.


A. Testing agency qualifications: Approved by ultimate enforcing authority for the Project; regularly engaged in inspection of materials and workmanship at factory.


A. Before delivery, identify type and size of each door and frame in such a way that markings will not damage finish.

B. Preassemble doorframes in shop and deliver to Project site with spreader bar at sill or tie them in pairs to form box.

C. Protect doors and frames with resilient packaging sealed with heat shrunk plastic. Break seal on-site to permit ventilation.

D. Protect doors and frames during shipment and storage to prevent warping, bending, and corrosion.



A. Ensure timely delivery of reviewed hardware schedule and hardware templates such that no delay occurs in the work of the Contract.

PART 2 PRODUCTS

2.01 MATERIALS

A. Sheet steel: ASTM A 1008, commercial quality, level, cold rolled steel, or ASTM A 1011, hot rolled, pickled and oil rolled steel. Galvanize by hot-dip process with zinc-coating conforming to ASTM A 653 and A 924, with a coating weight of not less than 0.60 ounces per square foot (0.30 ounces per square foot per side). Clips, bolts, screws, and rivets: sized as recommended by manufacturer.

B. Primer: Rust- inhibitive metal primer capable of being baked and compatible with finish painting system specified in Section 09910.

C. Touch-up materials: Primer as recommended by manufacturer.

D. Door hardware: As specified in Section 08710.

E. Grout: As specified in Section 03600.

F. Glass and glazing materials: As specified in Section 08800.

2.02 DOOR AND FRAME TYPES

A. Interior doors: ANSI 250.8, Grade III, Model 3 or NAAMM HMMA 810 Type A and NAAMM HMMA 861, flush steel rib-stiffened, minimum 18 gauge face sheets.

B. Exterior doors: ANSI 250.8, Grade III, Model 3, or NAAMM HMMA 810 Type A and NAAMM HMMA 861, flush steel rib-stiffened, minimum 16 gauge face sheets.

C. Interior frames: ANSI 250.8 or NAAMM HMMA 861, fully welded frames, minimum 16 gauge, sizes and shapes as indicated on the Drawings.

D. Exterior frames: ANSI 250.8 or NAAMM HMMA 861, fully welded frames HMMA 861, except minimum 14 gauge sizes and shapes as indicated on the Drawings.

2.03 COMPONENTS

A. Door cores: 1. Stiffeners: Vertical steel ribs formed from minimum 22-gauge plain sheet steel,

spaced at maximum 6 inches apart and securely attached to face sheets by spot welds at maximum 5 inches on center.

2. Core fillers: Insulation, minimum 0.60 pound density noncombustible type, installed in spaces between stiffeners for full height of door; labeled door core material shall conform to requirements of labeling authority.


B. Glazing stops: Minimum 18 gauge sheet steel, mitered, square, or rectangular: 1. Outside of exterior doors: Fixed, integral to doors and frames. 2. Secure side of interior doors: Removable.

C. Removable stop fasteners: Flat head, countersunk, tamperproof, self-tapping sheet metal screws.

D. Louvers: 1. Type: Flush with face, inverted Y blades, with UL approved fusible link type

louvers at fire rated doors. 2. Material: Steel sheet, same type sheet as door material. 3. Blade gauge: Minimum 24. 4. Frame gauge: Minimum 20. 5. Construction: Provide louvers that are welded to frame (except at fusible link

type). 6. Moldings: Secure and detachable type. Locate detachable moldings on room

or non-security side of doors.

E. Louver screens: 1. Use: At exterior door louvers. 2. Location: Locate screens on interior face of louver and secured to louvers in

rigid manner that permits easy removal. 3. Screens: Stainless steel insect screen mesh. 4. Frames: Stainless steel manufacturer's standard type and gauge.

2.04 FABRICATION OF FRAMES

A. Galvanize all frames installed in exterior openings.

B. Frames: Sheet steel, integral type, welded continuous to full depth of frames with minimum 5/8-inch deep stops, unless otherwise indicated on the Drawings.

C. Hardware reinforcement: Minimum 7 gauge at hinges; 12 gauge at strikes, bolts, closers, and other applied hardware.

D. Jamb Anchors: As required for adjacent wall construction, minimum 3 per jamb, unless otherwise indicated on the Drawings;

E. Floor anchors: Fixed type, except where adjustable anchors are indicated on the Drawings, 1 per jamb, with minimum 2 holes for anchorage. Where floor fill occurs, terminate bottom of frames at indicated finished floor level and support by adjustable extension clips resting on and anchored to structural slabs.

F. Anchors at masonry: Adjustable strap and stirrup, minimum 16 gauge corrugated or perforated steel at maximum of 30 inches on center and extending minimum 8 inches into masonry.

G. Anchors at previously placed concrete: Countersink machine screws through the frame into expansion devices spaced at maximum 30 inches on center.

H. Anchors at structural steel framing: Welded or otherwise securely fastened with stainless steel screws.


I. Anchors for fire resistive frames: Conform to requirements of labeling authority having jurisdiction.

J. Masonry angle stiffeners: Factory welded into heads of frames for installation in openings more than 48 inches wide.

K. Mullions, muntins, and transom bars: Minimum 18 gauge, tubular sheet steel matching, and butt-welded to head and jamb members.

L. Removable stops: Fasten at approximately 12 to 16 inches on center.

2.05 FABRICATION OF DOORS

A. Galvanize all doors installed in exterior openings.

B. Reinforce face sheets with steel rib stiffeners, spaced at maximum 6 inches apart, and securely attached to face sheets by spot welds at maximum 5 inches on center.

C. Fill voids between face sheets and stiffeners with fiberglass insulation having a minimum density of 0.8 pounds per cubic foot.

D. Edges: Full weld without visible joints. Bevel striking edge 1/8 inch in 2 inches.

E. Tops and bottoms of doors: Close with continuous recess steel channel of minimum 16 gauge, extending full width of door and spot welded to both faces.

F. Tops and bottoms of exterior doors: Flush closing channels welded to make tops and bottoms waterproof with weep holes for escape of moisture.

G. Hinge reinforcement: 7 gauge.

H. Lock, closer, and flush bolt reinforcement: 12 gauge.

I. Astragals: 1. Install on active leaf of double doors in accordance with UL listing

requirements for fire resistive ratings as indicated on the Drawings, and for exterior pairs of doors.

2. Do not install on doors swinging in pairs with rating of 90 minutes or less in means of egress where both leaves are required to provide building code required exiting widths.

3. Do not provide astragal cutouts for hardware operations.

J. Astragal clearances for fire resistive rated doors: 1. Door bottoms at doors designated to receive non-combustible threshold: Not

to exceed 3/8 inch between threshold and door bottom. 2. Door bottoms where there is no threshold: Maximum clearance between door

and floor not to exceed 1/2 inch. 3. Door bottoms at doors designated to receive combustible floor coverings: Not

to exceed 1/2 inch between floor covering and door bottom. 4. Clearance between door and frame and between meeting edges of pairs of

doors: Not to exceed 1/8 inch.


K. Astragal clearances for non-fire resistive rated doors: Same as fire resistive rated doors, unless otherwise indicated on the Drawings.

L. Glazing: In accordance with fire labeling.

2.06 FABRICATION OF FIRE RATED DOORS AND FRAMES

A. Fabricate to meet requirements of the building code as specified in Section 01410, UL 10C, and ASTM E 2074, except hose stream test shall not be required for opposite swing double egress exit doors and for doors of fire endurance rating of less than 45 minutes with or without approved glass lites.

B. Temperature rise requirements of doors at exit enclosures and exit passageways: Maximum transmitted temperature end point of less than 450 degrees Fahrenheit above ambient at end of 30 minutes when tested in accordance with the building code as specified in Section 01410.

C. Apply approved testing agency labels on fire rated doors and frames.

D. Fabricate oversized fire rated doors in accordance with requirements for ratings indicated on the Drawings.

2.07 HARDWARE PREPARATION

A. Cutout, drill, and reinforce frames and doors for hardware in accordance with hardware templates.

B. Install plaster guards or mortar boxes in back of hardware cutouts in and welded to frames.

C. Prepare fire resistive rated doors for hardware in accordance with requirements of labeling authority.

D. Do not weld hinges to doorframes.

E. Silencers: 1. Drill single leaf doorframe jamb stops for minimum 3 silencers. 2. Drill double-leaf doorframe head stops for minimum 2 silencers. 3. Do not drill doorframes for silencers when weatherstripping is to be installed.

2.08 FINISHING

A. Thoroughly clean surfaces of oil, grease, and other impurities; touch-up abraded galvanizing; and chemically etch.

B. Fill irregularities and sand smooth finish surface. Apply 1 coat of manufacturer's standard rust inhibitive baked-on primer.

C. Finish painting: As specified in Section 09910.


PART 3 EXECUTION

3.01 EXAMINATION

A. Examine reviewed hardware schedules and verify proper coordination of hardware and doors and frames.

B. Examine opening locations and verify the following: 1. Correctness of dimensions, backing, or support conditions. 2. Absence of defects that would adversely affect frame or door installation.

3.02 INSTALLATION

A. Install doors and frames in accordance with approved shop drawings and manufacturer's instructions.

B. Frames: 1. Set accurately in position, plumb, align, and attach securely to structure. 2. Set in place before construction of adjacent masonry or framed walls. 3. Anchor frames to previously placed concrete. 4. Set frames before removing spreader bars. 5. Fully grout frames in masonry as the Work progresses. 6. Grout frames at concrete through keyways provided at head and jambs.

C. Doors: Install at correct openings, ensure smooth swing and proper closure with frame.

D. Fire resistive frames and doors: Install to conform to NFPA 80 for fire resistive rated class as indicated on the Drawings.

E. Door hardware: Install in accordance with Section 08710.

F. Separate or isolate dissimilar metals with neoprene gaskets, sleeves, and washers, or with coatings acceptable to the Engineer.

3.03 TOLERANCES

A. Manufacturing and installation tolerances: As indicated on the Drawings or in conformance to SDI 117 as minimum.

3.04 ADJUSTING AND CLEANING

A. Prime coat touch-up: Immediately after installation, sand smooth and touch-up rust areas, and other areas where primer has been damaged, with prime touch-up paint.

B. Make adjustments as required for correct, proper, and free function and smooth operation without binding of hardware or doors and frames.

C. Protect doors and frames from damage to surface or profile.

END OF SECTION


SECTION 08332

OVERHEAD COILING DOORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Non-fire rated non-insulated and insulated overhead coiling doors.

B. Related sections: 1. Section 01612 - Seismic Design Criteria. 2. Section 01614 - Wind Design Criteria. 3. Section 08710 - Door Hardware. 4. Section 09910 - Painting. 5. Section 09960 - High-Performance Coatings.

1.02 REFERENCES

A. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum). 2. Type 4X enclosure in accordance with NEMA 250. 3. Type 12 enclosure in accordance with NEMA 250. 4. MG 1 – Motors and Generators

B. ASTM International: 1. ASTM A 123 – Standard specification for Zinc (Hot-Dip Galvanized) Coatings

on Iron and Steel Products. 2. ASTM A 653 – Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) by the Hot-Dip Process. 3. ASTM A 666 – Standard specification for Austenitic Stainless Steel Sheet,

Strip, Plate, and Flat Bar. 4. ASTM A 924 – Standard Specification for General Requirements of Steel

Sheet, Metallic-Coated by the Hot-Dip Process (Referenced by ASTM A 653).

1.03 DEFINITIONS

A. NEMA: 1. Type 4X enclosure in accordance with NEMA 250. 2. Type 12 enclosure in accordance with NEMA 250.


A. Design requirements: 1. Compatibility with space and service requirements:

a. Doors and equipment items provided shall be compatible with space limitations specified and indicated on the Drawings.

b. Make modifications to doors and equipment items necessary to conform with space limitations or with utility services specified for rough-in.

c. Provide items complete including all necessary ancillary equipment as may be required for complete and trouble-free operation.


2. Maintenance requirements: For ease of maintenance, provide overhead coiling doors complying with following requirements: a. Provide each door assembly as complete unit produced or supplied by a

single manufacturer, including frames, sections, brackets, operating mechanisms, hardware, except hardware items specified in Section 08710, and all necessary accessories for installation of complete in openings indicated.

b. Unless otherwise specified, all doors of particular type throughout the entire project shall be as manufactured or supplied by a single manufacturer.

1.05 SUBMITTALS

A. Product data: 1. General: Submit data completely describing products, including rough-in

diagrams. 2. Electrical operators: Submit complete manufacturer's data for all components

for electric door operators. Show motor size and characteristics. Show manufacturer's verification that motor has been adequately sized for each size and type of door required. Submit electrical schematic diagrams.

B. Shop drawings: 1. Drawings showing complete installation details, required clearances, relation

to building structure, complete electrical rough-in requirements required for installation of motor operators for doors and for connection of such doors to fire alarm system, referenced to the door mark number.

2. Show location and size of access doors required to perform maintenance on doors and auxiliary equipment.

C. Samples: Submit samples of finishes for finish selection.

D. Quality control submittals: 1. Manufacturer's instructions:

a. Installation instructions for each type and size of door, including manufacturer's data, operating instructions, and maintenance data.

b. Furnish installer copy of diagrams and installation instructions.

E. Contract closeout submittals: 1. Project record documents:

a. Operation and maintenance data: Provide manufacturer's operation and maintenance data for each different type of door specified, complete with manufacturer's list of recommended spare parts and their prices, electrical schematic diagrams, and name and address of nearest maintenance organization approved by door manufacturer.

b. Warranty: Provide manufacturer's standard warranty.


A. Regulatory requirements: 1. Wind loading as specified in Section 01614. 2. Seismic requirements for door anchorage and support systems as specified in

Section 01612. 3. Provide electrical materials in NEMA Type enclosures as specified.



A. Packing, shipping, and storage: Protect doors during shipment and storage to prevent warping, bending, and corrosion.

B. Deliver materials only after proper facilities are available. Provide clean dry surfaces or platform as required and protect from deterioration and foreign matter.


A. Field measurements: Field verify all opening dimensions and clearances prior to fabricating doors. Fitting doors to openings is the responsibility of the Contractor.


A. Inserts and anchorages: Furnish inserts and anchoring devices which must be set into concrete or built into masonry. Provide setting drawings, templates, and directions for installation of anchorage devices. Coordinate delivery with other work to avoid delay to the Contract.

PART 2 PRODUCTS


A. Acceptable Manufacturer: One of the following or equal: 1. Overhead Door Corp., Lewisville, TX 75067. 2. Wayne-Dalton Corp., Mt. Hope, Ohio 44660. 3. The Cookson Company, Inc., Phoenix, Arizona 85043.

B. Aluminum overhead coiling door: 1. Mounting: Face of wall. Location as indicated on the Drawings. 2. Operation: As indicated on the Drawings. 3. Curtain:

a. Exterior Slats: Minimum 18-gauge B & S or heavier aluminum alloy manufacturer's standard, interlocking flat-faced slats with ends of alternate slats fitted with metal end locks to hold curtain in alignment.

b. Bottom bar: Fitted with 2 equal-sized aluminum angles minimum 1/8-inch thick, with lift handle and cylindrical lock with housing capable of receiving cylinder as specified in Section 08710 at either end.

4. Weatherstripping: a. Bottom bar: Manufacturer's standard, provided with a flexible PVC bulb

type astragal to ensure a consistent seal along the floor. Extrusion designed to interlock with door curtain.

b. Door jambs: Manufacturer's standard, wool or nylon pile, vinyl extrusion seals.

c. Hood: Manufacturer's standard neoprene baffle. 5. Guides: steel galvanized In accordance with ASTM A 123, formed of roll

formed steel channels and angles or structural angles of sufficient depth to provide a groove of adequate depth on each jamb to hold curtain firmly in guides under design wind pressure.


6. Brackets: steel galvanized In accordance with ASTM A 123, steel plate with permanently sealed ball bearings designed to enclose ends of coil and provide support for counterbalance pipe at each end.

7. Barrel and counterbalance mechanism: Steel pipe of sufficient size to carry door load with maximum deflection of 0.03 inch per foot of opening width and counterbalanced by helical springs, oil tempered torsion type designed with minimum safety factor of 1.25, and having cast iron barrel plugs that anchor springs to tension shaft and pipe.

8. Hood: Fabricated minimum 0.050-inch thick aluminum, designed to enclose curtain coil and counterbalance mechanism.

9. Galvanized

C. Steel overhead coiling door: 1. Mounting: Face of wall. 2. Operation: As indicated on the Drawings. 3. Curtain:

a. Exterior Slats: Manufacturer’s standard, minimum 20-gauge steel galvanized In accordance with ASTM A 653, interlocking flat-faced slats with ends of alternate slats fitted with metal end locks to hold curtain in alignment.

b. Bottom bar: Steel galvanized In accordance with ASTM A 123, fitted with 2 equal-sized steel angles minimum 1/8-inch thick, with lift handle and cylindrical lock with housing capable of receiving cylinder as specified in Section 08710 at either end and provided with a flexible PVC bulb type astragal to ensure a consistent seal along the floor. Extrusion designed to interlock with door curtain.

c. Weatherstripping: 1) Bottom bar: Manufacturer's standard, provided with a flexible PVC

bulb type astragal to ensure a consistent seal along the floor. Extrusion designed to interlock with door curtain.

2) Door jambs: Manufacturer's standard vinyl extrusion seals, manufacturer's standard.

3) Hood: Manufacturer's standard vinyl air baffle. 4. Guides: Steel galvanized In accordance with ASTM A 123, formed of roll

formed steel channels and angles or structural angles of sufficient depth to provide a groove of adequate depth on each jamb to hold curtain firmly in guides under design wind pressure.

5. Brackets: Steel galvanized In accordance with ASTM A 123, steel plate with permanently sealed ball bearings designed to enclose ends of coil and provide support for counterbalance pipe at each end.

6. Barrel and counterbalance mechanism: Steel pipe of sufficient size to carry door load with maximum deflection of 0.03 inch per foot of opening width and counterbalanced by helical springs, oil tempered torsion type designed with minimum safety factor of 1.25 percent, and having cast iron barrel plugs that anchor springs to tension shaft and pipe.

7. Hood: Manufacturer’s standard, minimum 24-gauge steel galvanized In accordance with ASTM A 653, designed to enclose curtain coil and counterbalance mechanism.


D. Stainless steel overhead coiling door: 1. Operation: As indicated on the Drawings. 2. Curtain:

a. Exterior slats: Minimum manufacturer’s standard, minimum 20-gauge stainless steel In accordance with ASTM A 666, interlocking flat-faced slats with ends of alternate slats fitted with metal end locks to hold curtain in alignment.

b. Bottom bar: Stainless steel In accordance with ASTM A 666, fitted with 2 equal-sized steel angles minimum 1/8-inch thick, with lift handle and cylindrical lock with housing capable of receiving cylinder as specified in Section 08710 at either end.

c. Weatherstripping: 1) Bottom bar: Manufacturer's standard, provided with a flexible PVC

bulb type astragal to ensure a consistent seal along the floor. Extrusion designed to interlock with door curtain.

2) Door jambs: Manufacturer's standard vinyl extrusion seals. 3) Hood or Lintel:

a) Hood: Manufacturer's standard waterproofed canvas baffle. b) Lintel: Manufacturer's standard brush typed.

3. Guides: Steel galvanized In accordance with ASTM A 123, formed of roll formed steel channels and angles or structural angles of sufficient depth to provide a groove of adequate depth on each jamb to hold curtain firmly in guides under design wind pressure.

4. Brackets: Steel galvanized In accordance with ASTM A 123, steel plate with permanently sealed ball bearings designed to enclose ends of coil and provide support for counterbalance pipe at each end.

5. Barrel and counterbalance mechanism: Steel pipe of sufficient size to carry door load with maximum deflection of 0.03 inch per foot of opening width and counterbalanced by helical springs, oil tempered torsion type designed with minimum safety factor of 25 percent safety factor, and having cast iron barrel plugs that anchor springs to tension shaft and pipe.

6. Hood: Minimum manufacturer’s standard, minimum 24-gauge stainless steel In accordance with ASTM A666, designed to enclose curtain coil and counterbalance mechanism.

E. Insulation: 1. Interior slats: material to match exterior slats as specified in previous article,

interlocking flat-faced slats, manufacturer's standard size with ends of alternate slats fitted with metal end locks to hold curtain in alignment.

2. Insulation: CFC-free Polyethylene foam yielding a minimum R-value of 6.20.

F. Door operators: 1. Push-up operator: Unless otherwise indicated on the Drawings, use at doors

less than 56 square feet in area. Provide lift handles at the bottom bar. 2. Chain operator: Unless otherwise indicated on the Drawings, use at doors 56

square feet or larger in area. Provide a continuous hand chain and gearing on coil side of door.

3. Motor operator: Unless otherwise indicated on the Drawings, provide a heavy-duty type motor operator. a. High starting torque type motor having sufficient power to operate the load

at an average speed of 1 foot per second.]


b. Totally enclosed, fan cooled, continuous-duty motor, sized to suit door size (1 horsepower minimum), with Class B insulation.

c. 480 volt, 3-phase operation. d. Controlled by momentary contact 3-button station marked OPEN, CLOSE,

and STOP. As indicated on the Drawings. e. Provide automatic screw-type limit switch to break circuit at termination of

travel. f. Provide gear reducer consisting of high efficiency worm gearing running in

an oil bath and a spring set, solenoid-operated brake designed to hold the load when power is off.

g. Provide emergency hand chain operator which does not affect the time of the limit switch, to operate the load in case of power failure.

h. Operator to have reversing NEMA Size 1 starter having mechanical and electrical interlocks, properly sized 24-volt control transformer, and other controls necessary for proper operation, completely assembled and wired to a terminal strip to facilitate field wiring of the power source, pushbutton stations, and/or other remote devices.

i. Unless otherwise indicated on the Drawings, all electrical material supplied shall be in NEMA Type 12 enclosures for interior locations and in NEMA Type 4X enclosure or NEMA Type 4 enclosures for exterior or wet locations.

j. Provide electronic safety edge to reverse direction of door if obstruction is encountered.

k. Where no safety edge is specified, 2-button constant pressure type pushbutton stations marked OPEN and CLOSE shall be provided in lieu of 3-button station previously indicated.

2.02 ACCESSORIES

A. Fasteners: Sizes and types as recommend by reviewed door manufacturer.

2.03 FINISHES

A. Slats, Hood and Bottom Bar: 1. Stainless steel: Material shall be stainless steel with a No. 4 satin finish.

B. Guides and Bracket Plates: 1. Galvanized steel: manufacturer's standard rust inhibitive prime coat in a flat

black finish.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verification of conditions: Examine openings to receive overhead coiling doors and verify: 1. Dimensions and correctness of backing or support conditions. 2. Absence of defects that would adversely affect installation.

B. Do not start the work until unsatisfactory conditions are corrected.


3.02 PREPARATION

A. Verify dimensions and design for each opening.

B. Coordinate details with other work supporting or adjoining coiling doors.

C. Furnish fastening devices as required to mount doors properly.

3.03 INSTALLATION

A. Install doors in strict accordance with manufacturer's installation instructions, unless specifically otherwise indicated on the Drawings.

B. Install assemblies plumb, square, and level at their proper elevations and in their proper planes.

C. Securely anchor assemblies to interior face of openings, in manner that provides full opening clearance, perfectly aligned and adjusted for smooth operation.

D. Interface with other products: Separate or isolate dissimilar metals with neoprene gaskets, sleeves, or washers, or with an acceptable coating.

3.04 ADJUSTING

A. Verify that door assemblies are securely anchored to structure, guides are perfectly aligned, and doors are adjusted for smooth operation.

B. Upon completion of installation, ensure doors are free from warp, twist, or distortion and are lubricated and properly adjusted to operate freely.

3.05 CLEANING

A. Thoroughly clean surfaces of grease, oil, and other impurities.

B. Replace any damaged or otherwise disfigured doors with new prior to final acceptance.

3.06 DEMONSTRATION

A. Provide Owner's maintenance employees with minimum of 8 hours of maintenance instruction.

3.07 PROTECTION

A. Protect installed doors from damage until final acceptance.

END OF SECTION


SECTION 08520

ALUMINUM WINDOWS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Fixed aluminum windows with hardware.

B. Related sections: 1. Section 01612 - Seismic Design Criteria. 2. Section 01614 - Wind Design Criteria. 3. Section 07900 - Joint Sealants. 4. Section 08800 - Glazing.

1.02 REFERENCES

A. Aluminum Association (AA): 1. 45 - Designation System for Aluminum Finishes. 2. 92 - Care of Aluminum.

B. American Architectural Manufacturer's Association (AAMA). 1. GS-001 - Aluminum Architectural Windows. 2. 101 – North American Fenestration Standard/Specification for Windows,

Doors, and skylights.

C. ASTM International (ASTM): 1. B 221 - Standard Specification for Aluminum and Aluminum-Alloy Extruded

Bars, Rods, Wire, Profiles, and Tubes. 2. C 509 - Standard Specification for Elastomeric Cellular Preformed Gasket and

Sealing Material. 3. C 864 - Standard Specification for Dense Elastomeric Compression Seal

Gaskets, Setting Blocks, and Spacers. 4. E 283 - Standard Test Method for Determining Rate of Air Leakage Through

Exterior Windows Curtain Walls and Doors Under Specified Pressure Differences Across the Specimen.

5. E 330 - Standard Test Method for Structural Performance of Exterior Windows, Doors, Skylights, and Curtain Walls by Uniform Static Air Pressure Difference.

6. E 331 - Standard Test Method for Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure Difference.

7. F 588 - Standard Test Methods for Measuring the Forced Entry Resistance of Window Assemblies, Excluding Glazing Impact.

1.03 PERFORMANCE REQUIREMENTS

A. Comply with testing and performance requirements of AAMA GS-001 and AAMA 101.


B. Air infiltration: Maximum 0.37 cubic feet per minute per foot of operable sash crack length or 0.15 cubic feet per minute per square foot of fixed window area at 6.24 pounds per square foot inward test pressure when tested in accordance with ASTM E 283.

C. Water resistance test: No water infiltration when tested at static air pressure difference of 6.00 pound feet per square foot for fixed and ventilator lights in accordance with ASTM E 331.

D. Uniform load deflection: Maximum 1/175 of span when tested in accordance with ASTM E 330 at static air pressure of 60 pound feet per square foot with ventilators closed and locked and pressure applied first on one side then on other side.

E. Uniform load structural performance: No glass breakage, permanent damage to fasteners, hardware parts, support arms, or actuating mechanism, and damage that would cause the unit to be inoperable when tested in accordance with ASTM E 330 at static air pressure difference of 6.24 pounds per square foot with pressure applied first on one side and then other side.

F. Window component structural performance: In compliance with performance requirements indicated by and when tested in accordance with AAMA GS 001.

G. Forced entry resistance: Minimum Performance Level 10 when tested in accordance with ASTM F 588.

1.04 SUBMITTALS

A. Product data.

B. Shop drawings: Include dimensioned elevations of window openings and sash sizes, complete framing details, glass and glazing details, hardware, and anchorage details to adjacent structure.

C. Samples: Minimum 12 inches in length, illustrating, factory-applied aluminum finishes.

D. Manufacturer's Installation Instructions.


A. Regulatory requirements: Design windows to comply with following requirements: 1. Seismic requirements: As specified in Section 01612. 2. Wind loading: As specified in Section 01614.


A. Identification: Prior to shipping identify each window with type location of each window, using Engineer's window mark, in manner as not to damage surface.

B. Packing: Provide wrapping or strippable coating to protect prefinished aluminum surfaces.

C. Delivery: Delivery materials only after proper facilities are available.


D. Shipping, storage, and protection: Ship and store materials in manner that prevents damage such as warping, bending, stains, discolorations, scratches, abrasions, or soiling.


A. Protect aluminum from damage using protective sleeves, polyethylene sheets, removable coatings, or other suitable means.

B. Remove protective devices only when required to perform work or in absence of damage-producing conditions prior to final acceptance.

PART 2 PRODUCTS

2.01 ALUMINUM WINDOWS

A. Type and manufacturer: AAMA 101, Class F-DW-HC-HC40, one of the following products or equal: 1. Kawneer Co., Visalia, CA, Sealair Model 8225T Isolock. 2. Hope Architectural Products, Jamestown, NY, Model 210T Series.

B. Extrusions: 6063-T5 alloy and temper in accordance with ASTM B 221 Alloy G.S. 10A-T5.

C. Glass: Insulating glass, 1/4- inch thick, as specified in Section 08800.

D. Glazing: Compatible with aluminum, sealants, and sealing materials and compatible with gasketing material: 1. Exterior windows: Dry glazed closed cell elastomeric material in accordance

with ASTM C 509, manufacturer's standard size and shape. 2. Interior windows: ASTM C 864, aluminum glazing bead, snap-in type and

compression wedge of dense elastomer.

2.02 FABRICATION

A. Window framing and vent members: One part framing members with 3/8-inch thermal barrier, 2-1/4-inch overall depth, minimum 0.125-inch thick extrusions.

B. Thermal barrier: 2-part, chemically cured, high-density polyurethane.

C. Ventilator corner attachment: Permanently leakproof; mitered, clipped, epoxied, and staked; or mitered, clipped, and sigma arc welded.

D. Frame corners and meeting rail intersection attachments: Permanently leakproof; coped and tenoned, and forged; or mortised and tenoned, and sigma arc welded.

E. Weep slots: Capable of positive drainage to exterior and protected by snap-in-weep covers or integral drips.

F. Glazing beads: 0.050-inch thick.

G. Glazing rabbets: Minimum 13/16-inch deep by width required for glass.


H. Glazing method: Outside.

I. Finishes: 1. Exposed aluminum: Anodize exposed aluminum surfaces uniformly in

accordance with AA 45, Architectural Class 1 Anodic Coating AA-M12C22A42/44, without gripper marks, color selected by Owner.

2. Concealed aluminum: Same as exposed aluminum surfaces or clear anodized in accordance with Architectural Class II Clear Anodic Coating AA 45 AAM12C22A31.

3. Steel: Mill scale and rust cleaned or ground off, grease and dirt cleaned off, chemically etched and 1 prime coat applied.


A. Exposed fasteners: Type 305 stainless steel, manufacturer's standard.

B. Concealed fasteners: Manufacturer's standard steel with provisions to isolate dissimilar metals, or aluminum: 1. Steel in contact with aluminum: Cadmium plated or Type 305 stainless steel. 2. Steel not in contact with aluminum: Structural or mild steel hot-dip galvanized

after fabrication and touched-up when welded.

C. Coatings for isolating dissimilar metals: Manufacturer's standard bituminous paint.

D. Coatings for isolating aluminum from concrete, metal, wood, or other absorptive material: Manufacturer's standard zinc chromate metal primer.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify wall openings and adjoining work are ready to receive aluminum windows.

B. Examine receiving frames and reviewed hardware schedules to verify coordination with doors.

3.02 INSTALLATION

A. Install aluminum windows in accordance with manufacturer's instructions.

B. Set plumb, square, level, and in exact alignment with other work.

C. Anchor frames to structure securely.

D. Align assemblies plumb and level, free of warp or twist. Maintain assemblies dimensional tolerances, aligning with adjacent work.

E. Install watertight flashings.

F. Lead collected moisture or water to outside as directly as possible.


G. Seal joints between framing and building structure in manner to provide watertight installation as specified in Section 07900.

H. Separate or isolate dissimilar metals and materials with coatings: 1. Apply minimum 2 coats to obtain minimum thickness of 5 mils to isolate

dissimilar metals. 2. Apply minimum 2 coats to obtain minimum thickness of 3 mils to isolate

aluminum from concrete, metal, wood or other absorptive material.

I. Install screens and frames at operable units.

3.03 ADJUSTING

A. After completion of glazing and finish painting, adjust windows and window hardware as required for smooth operation and correct function, and lubricate hardware and moving parts as required.

B. Adjust operable units for smooth, free, and easy operation without binding.

3.04 CLEANING

A. Remove protective material from prefinished aluminum surfaces.

B. Clean in accordance with recommendations of AA 92 and reviewed manufacturer's cleaning instructions using only materials approved by aluminum manufacturer. Where doubt exists, make spot tests.

C. Remove soil or other sources of discoloration.

END OF SECTION


SECTION 08710

DOOR HARDWARE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Door hardware.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 08110 - Hollow Metal Doors and Frames.

1.02 REFERENCES

A. ASTM International (ASTM): 1. E 90 - Standard Test Method for Laboratory Measurement of Airborne Sound

Transmission Loss of Building Partitions and Elements. 2. E 283 - Standard Test Method for Determining the Rate of Air Leakage

Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen.

B. Builders Hardware Manufacturers Association (BHMA): 1. A156.7 - Template Hinge Dimensions. 2. A156.18 - Materials and Finishes.

1.03 SUBMITTALS

A. Product Data.

B. Hardware schedule: Include references to Engineer's hardware group number, door type designations, locations, other pertinent data, and manufacturer names or suitable abbreviation opposite items scheduled.

C. Samples: Include for each different type and manufacturer for review of finish.

D. Construction key distribution list: Submit upon Owner's request.

E. Templates: 1. Furnish hardware templates to fabricators of doors, frames, and other work to

be factory-prepared for hardware. 2. Check shop drawings of other work to confirm that adequate hardware backing

is available.

F. Project record documents: Include corrected hardware schedule.



A. Deliver hardware where directed in unopened packages with items packed separately, complete and ready for installation with necessary fittings, trim, fasteners, and accessories.

B. Provide packages bearing the manufacturers' labels with each item or group of items identified according to the accepted hardware schedule.

1.05 MAINTENANCE

A. Require lockset manufacturers to deliver permanent removable cylinder cores and keys and minimum 2 extractor keys to Owner directly.

B. Extra Materials: 1. All extra screws, fasteners, and all special installation tools furnished with the

hardware shall be turned over to the OWNER at the completion of the job.

1.06 WARRANTY

A. All finish hardware products shall be covered by a 1-year warranty from the date of substantial completion of the project. Exit Devices shall carry a 3-year warranty; Mechanical Door Closers shall carry a 10-year warranty.

B. Supply warranty verification to the OWNER for all products that provide factory warranty.

1.07 SCHEDULING AND SEQUENCING

A. Upon receipt of accepted hardware schedule, coordinate accepted hardware schedule, templates, reinforcing units, and template instructions to door and frame sections.

B. Restrict distribution of construction keys to superintendents and foremen. Maintain record of persons who have received keys on construction distribution list.

PART 2 PRODUCTS

2.01 FASTENERS

A. Types: 1. To concrete, marble, or masonry: Machine screws and flush shells. 2. To wood: Wood screws. 3. On gypsum board or plaster: Screws of sufficient length to provide solid

connection to framing or backing behind gypsum board or plaster. 4. To mineral and hollow core doors: Sex bolts. 5. Of exit devices to doors: Thru-bolts, unless otherwise specified.

B. Screws, exposed: Phillips-head type, full-threaded screws, not combination type.

C. Sizes: Suitable for heavy use.


D. Finish: Stainless steel, unless otherwise required to match material and hardware finish.

2.02 HINGES

A. Manufacturers: One of the following or equal: 1. Stanley. 2. Hager. 3. McKinney. 4. Ives.

B. Material: 1. Interior doors in Electrical and Blower Buildings: Stainless steel. 2. Exterior doors: Stainless steel.

C. Knuckles, number of: Minimum 5.

D. Ball bearings: Concealed with interior self-lubricating bushings.

E. Type for doors with closers: Ball bearing.

F. Material for fire-resistive rated doors: Steel.

G. Pins for interior doors: Non-rising.

H. Pins for exterior doors: Non-removable.

I. Template hinges: BHMA A156.7.

J. Tips: Flat button.

K. Height: As follows, unless otherwise specified: 1. Doors 1-3/8-inch thick: 3-1/2 inches. 2. Doors 1-3/4-inch thick and up to 41 inches wide: 4-1/2 inches. 3. Doors 1-3/4-inch thick and from 41 to 48 inches wide: 4-1/2 inches, extra

heavy. 4. Doors 2 inches thick or over 48 inches wide: 5 inches, extra heavy.

L. Widths: Sufficient to clear trim projection when door swings 180 degrees, unless otherwise specified.

M. Number per door leaf: As follows, unless otherwise specified: 1. 3 hinges on door to 7 feet, 6 inches in height. 2. 1 additional hinge for each additional 2 feet, 6 inches of height or fraction

thereof.

2.03 LOCKSETS

A. Manufacturers typical: One of the following or equal: 1. Schlage ND Series Rhodes design with removable core cylinders. 2. Sargent, Division of Essex Industries, Inc., Model 10-Line with removable core

cylinders, and Model L levers and roses.


B. Manufacturer for corrosive environments: Suitable for marine use or other severe climate conditions, having only stainless steel or bronze parts. One of the following or equal: 1. Schlage L Series with removable core cylinders, and 06A lever and rose. 2. Sargent, Division of Essex Industries, Inc., Model 8200 with removable core

cylinders, and Model L levers, and Model LN roses.

C. Cylinders: 1. Number of pins: Minimum 6. 2. Cases: Steel, cylindrical. 3. Interior parts: Non-corrosive with non-plastic, non-die-cast, non-aluminum

mechanisms. 4. Accessibility to key-in-knob type cylinders: Not requiring removal of lockset

from door. 5. Plugs: Extruded brass bar material fully round without flattened areas. 6. Cores: Removable.

D. Strikes: 1. Material: Same as lock trim. 2. Lock and latch boxes: Wrought. 3. Lips: Extended, able to protect trim from marring by latch bolt. 4. Cutouts at metal frames: In accordance with ANSI, unless otherwise specified.

E. Levers: Type that returns to within 1/2 inch of door.

F. Backset: 2-3/4 inches.

G. Trim materials: As follows, unless otherwise specified: 1. Typical: Stainless steel. 2. Corrosive environments: Stainless steel.

2.04 CONSTRUCTION KEYING

A. Type: Removable core system.

2.05 PERMANENT KEYING AND KEYS

A. General: 1. Finish Hardware Supplier shall meet with OWNER to finalize keying

requirements and match existing or start a new Restricted and Patented Master Key System for the project.

B. Number of keys: 1. Grand master keys: 4. 2. Keyed alike: 8 keys for each keyed alike group furnished. 3. Keyed different: 2.

C. Identification: 1. Emboss face of each cylinder plug and key with minimum 3-digit visual key

control system. 2. Emboss DO NOT DUPLICATE on keys.


2.06 PUSH/PULL PLATES

A. Manufacturers: One of the following or equal: 1. Ives. 2. Trimco. 3. Rockwood.

B. Pulls: 1. Material: As scheduled. 2. Size: Minimum 8 inches center to center, minimum grip diameter of 3/4 inch,

minimum projection of 2-1/4 inch.

C. Pull plates: 1. Material: As scheduled. 2. Plate size: Minimum 3 by 12 inches by 0.050-inch thick, with beveled edges on

4 sides with pull. 3. Pull size: Minimum 8 inches center to center, minimum grip diameter of

3/4 inch, minimum projection of 2-1/4 inch.

D. Push plates: 1. Material: As scheduled. 2. Size: Minimum 3 by 12 inches by 0.050-inch thick, with beveled edges on

4 sides.

2.07 CLOSERS

A. Manufacturers: 1. Features:

a. Heavy-duty. b. Non-handed and non-sized. c. Adjustable spring power from size 1 through 4.

2. One of the following or equal: a. Sargent, 351 Series. b. LCN, Super Smoothee Model 4041 Series. c. Norton Door Controls, Multi-Size Door Closers Model 7500BF Series.

B. Type: Full rack and pinion type with steel spring and non-gumming, non-freezing hydraulic fluid.

C. Controls: Separate set for regulating sweep speed, latch speed, backcheck and backcheck positioning, or where schedules, spring power.

D. Sizes: As recommended by accepted manufacturer.

E. Covers: Plastic, capable of being spray painted to match adjacent hardware finishes, unless otherwise specified.

F. Narrow frame provisions: Drop plates.

G. Effort to operate: As follows: 1. Exterior: Maximum 8-1/2 pounds. 2. Interior: Maximum 5 pounds. 3. Fire-resistive rated doors: Maximum 15 pounds.


H. Adjust closers in accordance with manufacturer's directions for size of door.

2.08 EXIT DEVICES

A. Lever design: 1. Manufacturers: The following or equal:

a. Von Duprin, Lever Model 06.

B. Rim device, non-fire resistive rated: 1. Manufacturers: One of the following or equal:

a. Von Duprin Inc., Model Series 98. b. Sargent Essex Industries, Model Series 8800.

C. Rim device, fire-resistive rated: 1. Manufacturers: One of the following or equal:

a. Von Duprin Inc., Model Series 98-F. b. Sargent Essex Industries, Model Series 12-8800.

D. Mortise lock device, non-fire-resistive rated: 1. Manufacturers: The following or equal:

a. Von Duprin Inc., Model Series 9875L.

E. Material: As scheduled.

2.09 MISCELLANEOUS DOOR HARDWARE

A. Wall stops: As scheduled. 1. Manufacturers: One of the following or equal:

a. Ives. b. Trimco. c. Rockwood.

B. Floor stops: As scheduled with strike of suitable height to compensate for clearance between door and floor. 1. Manufacturers: One of the following or equal:

a. Ives. b. Trimco. c. Rockwood.

C. Mechanical holders: Foot-operated plunger with instant release by touch of toe and integral spring to keep constant shoe pressure against floor; brass. 1. Manufacturers: The following or equal:

a. Glynn-Johnson.

D. Automatic flush bolts: Mortise, bar with stop-mounted coordinator and strikes; materials as scheduled. 1. Manufacturers: One of the following or equal:

a. Glynn-Johnson. b. Hager Hinge Co.


E. Kick plates: As scheduled, 0.050-inch thick, beveled edges, 10 inches high, 1-1/2 inches narrower than single doors, 1 inch narrower than leaf of door pairs. 1. Manufacturers: One of the following or equal:

a. Ives. b. Trimco.

F. Gasketing systems: As scheduled, self-adhesive silicone seal, continuous at head and jambs, rated for fire and smoke in accordance with ASTM E 283, sound rated in accordance with ASTM E 90. 1. Manufacturers: One of the following or equal:

a. Pemko Mfg. Co. b. National Guard Products Inc. c. Reese.

G. Weatherstripping for exterior doors and smoke, light, and sound seals for interior doors.

H. Thresholds: As scheduled, extruded aluminum, maximum 1/2-inch high, maximum slope of 1 foot in 2 feet. 1. Manufacturers: One of the following or equal:

a. National Guard Products Inc. b. Pemko Mfg. Co.

I. Dustproof strike: As scheduled. 1. Manufacturers: One of the following or equal:

a. Ives. b. Trimco.

J. Coordinator with filler bar: As scheduled, non-handed, series type length as required for door sizes indicated, complete with filer lengths as required, with mounting brackets and carry bars when required for proper operation; steel with manufacturer's standard prime finish capable of receiving painted finish. 1. Manufacturers: One of the following or equal:

a. Glynn-Johnson Coordinators, Model COR Series. b. Ives, Door Co-Ordinator, Model 900 Series.

K. Door bottoms: As scheduled, extruded aluminum with vinyl insert, surface mounted, length equal to door width minus 2 inches, automatic, recessed in bottom of door. 1. Manufacturers: One of the following or equal:

a. Pemko. b. Reese.

L. Astragals: As specified in Sections 08110.

M. Silencers: As scheduled, pneumatic gray rubber. 1. Manufacturers: One of the following or equal:

a. Trimco. b. Ives. c. Rockwood.


2.10 FINISHES

A. Brass and bronze: BHMA A156.18 626 (US26D), satin chrome.

B. Steel: BHMA A156.18 652 (US26D), satin chrome.

C. Stainless steel: BHMA A156.18 630 (US32D), satin stainless steel.

D. Aluminum: BHMA A156.18 628 (US28).

E. Plastic closer covers: Spray paint to match typical door hardware finish.

F. Metal closer covers: Plate covers to match typical door hardware finish.

G. Electromagnetic hold open devices: Manufacturer's standard brushed zinc finish.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect doors and door frames for damage or defects and examine hardware for compatibility with receiving conditions and suitable to intended use.

B. Verify that required wall backing has been installed.

3.02 INSTALLATION

A. Install finish hardware in accordance with manufacturer's templates and instructions.

B. Accurately and properly fit hardware.

C. Securely fasten fixed parts for smooth, trouble-free, non-binding operation.

D. Fit faces of mortise parts snug and flush.

E. Ensure that operating parts move freely and smoothly without binding, sticking, or excessive clearance.

F. Protection: 1. Protect door hardware from damage or marring of finish during construction,

use strippable coatings, removable tapes, or other acceptable means. 2. Ensure door hardware displays no evidence of finish paint after final building

cleanup with exception of prime-coated door hardware installed for finish painting.

G. Latch guard and dead bolts: Install so that bolts automatically engage in keeper, whether activated by closer or by manual pressure.

H. Closers: 1. Mount on opposite sides of corridors or vestibules, except at exterior doors. 2. Mount for 180-degree swing wherever possible.


3. Mount with drop plates at narrow top rail doors. 4. Adjust to operate noiselessly and evenly. 5. Have closer manufacturer regulate closers prior to final acceptance of project.

I. Kick plates: Screw on push side of doors.

J. Gasketing: Mount to provide complete contact between door and frame, finished floor, or both; and weathertight enclosure.

K. Thresholds: 1. Install immediately before inspection for Substantial Completion or protect

from heavy traffic damage during construction. 2. Cope to fit door frame profile and drill to suit required flush bolts and panic

bolts. 3. Unless indicated on the Drawings to be set in grout, set in double bead of

sealant, tightly fit at jambs, and make waterproof. 4. Fasten to concrete slab with 5/16-inch stainless steel flat head countersunk

machine screws and concrete anchors at 8-inch centers.

L. Silencers: Insert into predrilled holes in frames.

3.03 CONSTRUCTION KEYING

A. Insert construction cores in cylinders of exterior doors, and doors requiring security and access for workman, unless otherwise directed by the Engineer.

3.04 ADJUSTING

A. Examine hardware in place for complete and proper installation. Lubricate bearing surfaces for proper function.

B. Replace, rework or otherwise correct defective door hardware, including incorrect hand or function.

3.05 CLEANING

A. Remove protective materials and devices and thoroughly clean exposed surfaces of hardware.

B. Check for surface damage prior to final cleaning for acceptance of project.

3.06 PERMANENT KEYING

A. Remove construction key inserts with extractor key. Insert permanent cylinders with cores.

B. Inspect each lockset to ensure permanent cylinders with cores are operating satisfactorily.

C. Test keys for proper conformance with keying system.


3.07 HARDWARE SCHEDULE

A. Electrical and Blower Building 1. Hinges:

a. H-1: Stanley FBB 199, 4 1/2 inch by 4 1/2 inch, NRP, US32D b. H-2: Stanley FBB 199, 4 1/2 inch by 4 1/2 inch, US32D

2. Locksets: a. L-1: Cylinder as required to suit associated device. b. L-2: Best 93 Series, (entrance function), AB F109, 625

3. Closers: a. C-1: Sargent, En 350-P (parallel arm)

4. Thresholds: a. T-1: Pemko 170A

5. Weatherstripping: a. W-1: Pemko, 303A S b. W-2: By Coiling Door Manufacturer.

6. Silencers: a. Q-1: Ives, SR64

7. Bolts: a. B-1" Ives, FB458, US32D (at inactive leaf).

8. Astragals: a. A-1: Pemko, 355AV, clear anodized (at active leaf).

9. Door Bottoms: a. D-1: Pemko, 216 AV b. D-2: By Coiling Door Manufacturer.

10. Exit Devices: a. E-1: Von Duprin, 9975L, US32D, Mortised type (active leaf only at double

doors). 11. Stops:

a. S-1: Ives, floor to wall bumper as required by field conditions, US32D.

END OF SECTION


SECTION 08800

GLAZING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Glass and glazing.

B. Related sections: 1. Section 01410 - Regulatory Requirements. 2. Section 01614 - Wind Design Criteria. 3. Section 07900 - Joint Sealants. 4. Section 08522 - Horizontal Sliding Aluminum Windows.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. Z97.1 - Safety Glazing Materials Used in Buildings - Safety Performance

Specifications and Methods of Test.

B. ASTM International (ASTM): 1. C 1036 - Standard Specification for Flat Glass. 2. C 1048 - Standard Specification for Heat-Treated Flat Glass - Kind HS, Kind

FT Coated and Uncoated Glass. 3. E 773 - Standard Test Method for Accelerated Weathering of Sealed Insulating

Glass Units.

C. Glass Association of North America (GANA): 1. GANA Glazing Manual.

D. Insulating Glass Certification Council (IGCC): 1. Certified Products Directory.

E. U.S. Consumer Product Safety Commission (CPSC): 1. 16 CFR 1201 - Safety Standard for Architectural Glazing Materials.

1.03 DEFINITIONS

A. Full height windows: Windows meeting the following conditions: 1. Lowest edge is less than 18 inches above floor. 2. Area is greater than 9 square feet. 3. Walking surface is on both sides either of which is within 36 inches of window. 4. Window has no minimum 1-1/2-inch railing or mullion at from 24 to 36 inches

above floor.


1.04 SUBMITTALS

A. Product data.

B. Shop drawings: Locations of glass types and typical glazing details.

C. Samples: As follows: 1. Glazing sealants, 2-inch long beads, for color selection. 2. Glass, 1 square foot of each type specified.

D. Certificates of compliance: Certification that tempered glass in accordance with ANSI Z97.1 and CPSC 16 CFR 1201.

E. Manufacturer's Installation Instructions.

1.05 REGULATORY REQUIREMENTS


B. Wind loading: As specified in Section 01614.

C. Provide glass and glazing that conforms to CPSC 16 CFR, Part 1201, and exit requirements of the building code.


A. Deliver, store, and handle materials in manner to prevent damage.

B. Deliver and store packaged materials in original containers bearing manufacturer's name.

C. Deliver glass affixed with manufacturer's labels showing strength, grade, thickness, type and quality of glass, and for insulating glass, IGCC certification label.

D. Remove labels after installation, inspection, and final acceptance.


A. Perform glazing when ambient air temperature is 40 degrees Fahrenheit or above.

PART 2 PRODUCTS

2.01 GLASS

A. Clear monolithic: ASTM C 1036, Type I, Class 1, Quality q3; minimum 1/4-inch thick. 1. Manufacturers: One of the following or equal:

a. PPG Industries, Inc., Cheswick, PA. b. Guardian Industries Corp., Auburn Hills, MI, Sunguard, Clear.


B. Tinted monolithic: ASTM C 1036, Type I, Class 2, Quality q3; tinted light bronze; minimum 1/4-inch thick. 1. Manufacturers: The following or equal:

a. PPG Industries, Inc., Cheswick, PA, Solarbronze. b. Guardian Industries Corp., Auburn Hills, MI, Sunguard, bronze.

C. Tempered: ASTM C 1048, Kind FT, Condition A, Type I, Class 1 or Class 2 as scheduled below, Quality q3; tempered without visible tong marks when installed; minimum 1/4-inch thick. 1. Manufacturers: The following or equal:

a. PPG Industries, Inc., Cheswick, PA, Herculite. b. Guardian Industries Corp., Auburn Hills, MI, equivalent product.

D. Insulating glass units: IGCC Rating Level CBA when tested in accordance with ASTM E 773 and E 774; hermetically sealed units consisting of minimum 1/4-inch thick, tinted exterior light, minimum 1/4-inch thick, clear interior light, and 1/2-inch wide air space, dehydrated with blended molecular sieve and silica gel desiccant, with metal spacer channel with bent corners and welded splice on one vertical side, and polyisobutylene primary and silicone secondary seals. 1. Manufacturers: The following or equal:

a. PPG Industries, Inc., Cheswick, PA, Twindow. b. Guardian Industries Corp., Auburn Hills, MI, equivalent product.

E. Wired monolithic: ASTM C 1036, Type II, Class 1, Form 1, Quality q8, Mesh m2, minimum 1/4-inch thick.

F. Spandrel monolithic: ASTM C 1048, Kind HS, Condition B, Class 2, Quality q3; tinted to match adjacent tinted glass; minimum 1/4-inch thick. 1. Manufacturers: One of the following or equal:

a. PPG Industries, Inc., Cheswick, PA, Spandrelite. b. Guardian Industries Corp., Auburn Hills, MI, equivalent product.

2.02 GLAZING MATERIALS

A. Setting blocks: Neoprene, 80 to 90 durometer.

B. Spacer blocks: 30 to 40 durometer, thickness equal or greater than insulated window thickness by minimum 6 inches long.

C. Pressure tape: Butyl rubber tape. 1. Manufacturers: One of the following or equal:

a. Tremco Mfg. Co., Tremco 440 Tape. b. 3-M Co., Weatherban 5422.

D. Sealant: Silicone. 1. Manufacturers: One of the following or equal:

a. General Electric Co., Silicone Construction Sealant Series SCS-1200. b. Dow Corning Corp., 999-A, Silicone Building and Glazing Sealant.

E. Glazing gaskets and other materials for exterior openings: 1. Aluminum entrances and storefronts: As specified in Section 08412. 2. Aluminum windows: As specified in Section 08520.


2.03 SOURCE QUALITY CONTROL

A. Allowable bow and warp tolerances: As measured with glass resting on edge upon two 1 inch wide supports: 1. Typical: Maximum 1/8 inch in 48 inches. 2. Tempered glass: Maximum allowed in accordance with ASTM C 1048.

PART 3 EXECUTION

3.01 EXAMINATION

A. Examine openings to receive glass for defects that would affect glass and glazing work.

B. Verify removal of rivets, screws, bolts, welding fillets, or other projections from clearances in glazing rabbets.

3.02 PREPARATION

A. Examine frames receiving glass and ensure surfaces are clean and dry.

B. Remove dust and oil from glass by wiping clean immediately before installation.

C. Verify that sealants are compatible with glazing materials.

3.03 INSTALLATION OF MONOLITHIC GLASS

A. In accordance with GANA Glazing Manual, manufacturer's instructions, and accepted shop drawings by the Engineer.

B. Glaze doors in closed position after hanging and adjustment.

C. Accurately size and cut glass clean for each glazing condition. 1. Do not nip edges.

D. Cut and set glass to full fit and play consistent with expansion and contraction requirements and at exterior for absolute security under maximum high velocity wind and vacuum stresses.

E. Maintain edge clearance at least equal to glass thickness from perimeter of glass to inside of rabbet.

F. Maintain 1/8-inch clearance between faces of glass and adjacent stop or bead.

G. Maintain minimum bite of 3/8 inch.

H. Set glass as required to ensure against optical distortion.


3.04 INSTALLATION OF INSULATED GLASS UNITS

A. In accordance with GANA Glazing Manual, manufacturer's instructions, and accepted shop drawings by the Engineer.

B. Use wet and dry glazing method.

C. Cut glazing tape to length and set against permanent stops to project 1/16 inch above sight line.

D. Place setting blocks at quarter points and no closer than 6 inches from corners.

E. Rest glazing on setting blocks and push against tape for full contact at perimeter of unit.

F. Place glazing gasket.

G. Install removable stop with concealed leg notched to accommodate setting blocks.

H. Align top of gasket with stops.

3.05 INSTALLATION OF GASKETS

A. Gaskets: Install in accordance with manufacturer's instructions.

B. Glazing of interior metal frames: Use pressure or foamed tape and sealant as indicated as required to eliminate rattle and reduce sound transmission.

3.06 SEALANT APPLICATION

A. As specified in Section 07900, unless specifically noted otherwise.

B. Ensure protective coatings have been removed from aluminum surfaces.

C. Where setting blocks and spacer shims are required to be set in sealant, butter with sealant, place into position, and allow to set prior to installation of glass.

D. Neatly tool sealant or compound joints to compress material and improve adhesion. Repair or replace pockets exposed by tooling.

3.07 CLEANING

A. After inspection by Engineer, remove labels and marks from glass in accordance with manufacturer's published recommendations.

B. Clean glass and surrounding surfaces from spatter and blemishes resulting from glazing operations.

C. Clean and polish glass inside and outside.


D. Clean glass with a soft, clean, grit-free cloth and mild soap, detergent, or slightly acidic cleaning solution. 1. Immediately rinse with clean water and remove excess rinse water with a

clean squeegee. 2. Do not use an abrasive cleaner.

E. Remove grease and miscellaneous glazing materials with commercial solvent. Follow with normal wash and rinse. 1. Be careful not to damage joint sealers.

3.08 GLASS AND LOCATION SCHEDULE

A. Exterior locations: Glass as follows, unless otherwise scheduled or indicated on the Drawings: 1. Typical: Insulating, tinted. 2. Non-fire-rated doors: Tinted and tempered. 3. Windows within 48 inches of doors: Insulating, tinted, and tempered.

END OF SECTION


SECTION 09110

NON-LOAD BEARING WALL FRAMING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Light gauge, screwable type, non-load bearing, metal framing systems for interior walls and partitions.

B. Related sections: 1. Section 05120 - Structural Steel. 2. Section 07900 - Joint Sealants.

1.02 REFERENCES

A. ASTM International (ASTM): 1. A653- Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or

Zinc-Iron Alloy-Coated (Galvanized)by the Hot-Dip Process. 2. C645 - Standard Specification for Nonstructural Steel Framing Members. 3. C754 - Standard Specification for Installation of Steel Framing Members to

Receive Screw-Attached Gypsum Panel Products. 4. C954 - Standard Specification for Steel Drilled Screws for the Application of

Gypsum Panel Products or Metal Plaster Bases to Steel Studs from 0.033 in. (0.84mm) to 0.112 in. (2.84mm) in Thickness.

5. C1002 - Standard Specification for Steel Self-Piercing Tapping Screws for the Application of Gypsum Panel Products or Metal Plaster Bases to Wood Studs or Steel Studs.

1.03 SUBMITTAL

A. Product data: Product data for all proposed material for framing system.


A. Keep copies of ASTM C754 on site.


A. Deliver and store materials bearing manufacturers' labels indicating manufacturer and brand names.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Non-load bearing wall framing system: One of the following or equal: 1. National Gypsum Company. 2. United States Gypsum Company.


3. Western Metal Lath Company.

2.02 MATERIALS

A. Studs: ASTM C645, hot-dip galvanized steel, minimum 25 gauge 3-5/8 inches wide, channel shaped, punched for utility access.

B. Runners, typical: ASTM C645, hot-dip galvanized steel, minimum 25 gauge, channel shaped unpunched web, minimum 1-1/4-inch legs, same widths as studs.

C. Furring channels: ASTM C645, minimum 25 gauge hot-dip galvanized steel, roll formed into 7/8-inch deep by 2-3/4-inch wide hat shaped section.

D. Bracing members: ASTM C645, hot-dip galvanized steel shapes.

E. Resilient furring channels: Minimum 26 gauge galvanized steel, 1/2-inch deep.

F. Anchor plates: ASTM A446, hot-dip galvanized steel, minimum 11 gauge by 4-inch wide by stud spacing with flanges adequate for fastening to stud webs.

G. Fasteners: 1. General: ASTM C1002, corrosion resistant, for attachment to metal framing 25

gauge and lighter; ASTM C954 for attachment to metal framing 20 gauge and heavier.

2. Thread and head designs and lengths as recommended by manufacturer for uses and materials involved.

H. Powder actuated fasteners: Type and size suitable for application and as specified in Section 05120.

I. Sealant: Polyurethane, as specified in Section 07900.

PART 3 EXECUTION

3.01 PREPARATION

A. Coordinate installation of bucks, anchors, blocking, and electrical and mechanical construction to be placed in or behind framing.

B. Coordinate erection of system with requirements of door and window frame supports or attachments.

3.02 WALL FRAMING

A. Install metal framing in accordance with ASTM C754.

B. Cut framing members to fit squarely against abutting members. Align stud web openings for installation of utilities. Allow for minimum 1/4-inch clearance between top of stud and top runner web.

C. Do not splice studs.


D. Align runners to configurations indicated on the Drawings.

E. Provide clearance under structural members to prevent stud deflection.

F. Provide extended leg top runners when not possible to provide clearance under structural members. 1. Drill 3/4-inch long vertical slots, slightly larger than fasteners, at stud locations.

G. Place bead of sealant between runners and construction where water may penetrate.

H. Anchor runners to structure at maximum 2 inches from ends and at maximum 24 inches on center.

I. Anchor runners to: 1. Concrete with powder actuated fasteners or concrete stub nails. 2. Steel with bolts or by welding. 3. Wood with screws penetrating into wood at least 1 inch or nails penetrating

into wood at least 1-1/2 inches. 4. Suspended ceiling grid with toggle or molly bolts.

J. Anchor top runners not anchored directly to structure with brace runners at minimum 36 inches on center. 1. Fasten brace runner to top runners at right angles to each other. 2. Bend brace runner ends upward at 45-degree angles. 3. Anchor brace runner ends to structural members.

K. Place bed of sealant between studs and construction where water may penetrate.

L. Seat studs squarely in track with stud webs and flanges abutting bottom runner webs.

M. Install 2 studs at abutting construction and on each side of openings.

N. Fit runners under and above openings. 1. Secure cripples between sill and header, and bottom and top runners at

minimum 16 inches on center, unless otherwise indicated on the Drawings.

O. Install minimum 3 studs at metal framing corners.

P. Space studs at 16 inches on center, unless otherwise indicated on the Drawings.

Q. Fasten studs to runners tightly. 1. Loosely fasten studs to extended leg runners through slotted holes.

R. Fasten studs next to openings at framing intersections and at corners to typical runners with 2 screws on each side.

S. Do not tie framing components together with wire.

T. Make framing system with bracing members.


U. Fasten anchor plates to stud webs where required to support wall-mounted accessories, fixtures, or hardware. 1. Align surfaces of anchor plates flush with stud flanges.

V. Special techniques: 1. Framing components may be fabricated into panels prior to erection. 2. Brace panels with additional bracing members to prevent racking. 3. Prevent local member distortion when handling panels.

3.03 FURRING CHANNEL INSTALLATION

A. Space furring channels at maximum 24 inches on center.

B. Nest end splices with minimum 8-inch overlaps. 1. Secure with 2 fasteners.

C. Attach channels at maximum 24 inches on center through alternate flanges.

3.04 TOLERANCES

A. Vertical alignment of studs: Within 1/8 inch in 10 feet.

B. Horizontal alignment of walls: Within 1/8 inch in 10 feet.

C. Stud spacing: Within 1/8 inch, provided that cumulative error does not exceed requirements of finish materials.

D. Squareness of prefabricated panels: Within 1/8 inch within length of panel.

END OF SECTION


SECTION 09250

GYPSUM BOARD

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Gypsum board and associated accessories.

B. Related sections: 1. Section 09960 - Coatings. 2. Section 09110 - Non-load Bearing Wall Framing.

1.02 REFERENCES

A. ASTM International (ASTM): 1. C 475 - Standard Specification for Joint compounds and Joint Tape for

Finishing Gypsum Board. 2. C 514 - Standard Specification for Nails for the Application of Gypsum

Wallboard. 3. C 557 - Standard Specification for Adhesives for Fastening Gypsum Wallboard

in Wood Framing. 4. C 840 - Standard Specification for Application and Finishing of Gypsum Board. 5. C 919 - Standard Practice for Use of Sealants in Acoustical Applications. 6. C 1002 - Standard Specification for Steel Self-Piercing Tapping Screws for the

Application of Gypsum Panel Products or Metal Plaster Based to Wood Studs or Steel Studs.

7. C 1047 - Standard Specification for Accessories for Gypsum Wallboard and Gypsum Veneer Base.

8. C 1396 - Standard Specification for Gypsum Board. 9. E 84 - Standard Test Method for Surface Burning Characteristics of Building

Materials.

B. Gypsum Association: 1. GA 216 - Application and Finishing of Gypsum Board.

C. Underwriters Laboratories, Inc. (UL).

1.03 SUBMITTALS

A. Product Data: Include manufacturer's instructions for sealing openings, penetrations, and cut edges of water-resistant gypsum board.

B. Samples: Include texture samples on minimum 6 inch square specified materials.


A. Manufacturer qualifications: Provide gypsum board products from single manufacturer or from manufacturers recommended by manufacturer of gypsum board.


B. Regulatory requirements: When indicated, provide UL listed and labeled fire-rated components or by other recognized rating service.

C. Pre-installation conference: Convene with affected entities to review coordination and sequencing of construction to ensure that everything that will be concealed by gypsum board has been installed, and that chases, openings, supplementary framing and blocking have been completed.


A. Store gypsum board under cover, stacked flat, off floor.

B. Store adhesives in dry place, protected against freezing.

1.06 ENVIRONMENTAL REQUIREMENTS

A. Maintain uniform room temperature between 55 and 70 degrees Fahrenheit in cold weather during application of wallboard and joint treatment until joint treatment is completely dry or building is occupied.

B. Provide adequate ventilation.

PART 2 PRODUCTS

2.01 GYPSUM BOARD

A. Regular board: 1. ASTM C 1396; 5/8 inches thick; tapered edge; Type X where required for fire

rating.

2.02 ACCESSORIES

A. Square corner bead reinforcement: One of the following or equal: 1. Dur-A-Bead as manufactured by USG or equal. 2. Wallboard corner bead with 1-1/4 inch flanges by manufactured Gold Bond

National Gypsum Company.

B. Metal casing bead: One of the following or equal: 1. No. 200A Metal Trim manufactured by USG or equal. 2. No. 100 wall board casing manufactured by Gold Bond National Gypsum

Company.

C. Control joints: One of the following or equal: 1. No. 093; as manufactured by USG or equal. 2. 0.093 zinc control joint, manufactured by Gold Bond National Gypsum

Company.

2.03 FASTENERS

A. Screws for metal studs: ASTM C 1002, Type S; self-drilling, self-tapping, bugle head, for use with power driven tool, minimum 1-1/4 inches long or length to suit application.


B. Screws for wood framing: ASTM C 1002, Type W, minimum 1-1/4 inches.

C. Nails: ASTM C 514; minimum 1-1/4 inch long, 12-1/2 gauge, 1/4 inch diameter head.

D. Staples: Type G; 1/2 inch; manufactured by Bostitch or equal.

2.04 LAMINATING ADHESIVES

A. Gypsum board to metal framing: One of the following or equal: 1. Durabond 200 or 300; manufactured by USG. 2. Sta-Smooth setting type compound by Gold Bond National Gypsum Company.

B. Gypsum board to wood framing: ASTM C 557.

C. Gypsum board to gypsum board: One of the following or equal: 1. Durabond 600; manufactured by USG. 2. Gypsum board laminating adhesive, manufactured by Gold Bond National

Gypsum Company.

D. Gypsum board to concrete or masonry: Durabond 500; manufactured by USG or equal.

2.05 ACOUSTICAL SEALANT

A. Type: ASTM C 919; Architecture Sealant, manufactured by USG or equal.

2.06 FINISHING MATERIALS

A. Moisture or water resistant sealant: 1. Manufacturers: One of the following or equal:

a. USG, Sheetrock W/R Sealant. b. Gold Bond National Gypsum Company.

B. Joint compound and tape: ASTM C 475: 1. Manufacturers: One of the following or equal:

a. USG, Sheetrock joint system consisting of Sheetrock Reinforcement Tape and Sheetrock All Purpose Ready Mixed Compound for embedding, fill, and finishing.

b. Sta-Smooth HS tape and Sta-Smooth joint compound by Gold Bond National Gypsum Company.

C. Texturing compound for walls: 1. Manufacturers: One of the following or equal:

a. USG, Spray Texture Finish. b. Perfect Spray EM, orange peel finish, by Gold Bond National Gypsum

Company.

D. Texturing compound for exterior ceilings: 1. Manufacturers: One of the following or equal.

a. USG, Duracal Exterior Spray Texture Finish.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install gypsum board systems in accordance with ASTM C 840 and GA 216.

3.02 GYPSUM BOARD INSTALLATION ON WALLS

A. Cut gypsum wallboard by scoring and breaking or by sawing, working from face side.

B. Use boards of maximum practical length to minimize end joints.

C. Apply board with long dimension at right angles to framing or furring members with ends on studs. Attach upper boards first.

D. Bring boards into contact with each other but do not force into place.

E. Do not place butt ends against tapered edges.

F. Stagger end joints. Locate joint on opposite sides of partition on different studs.

G. Do not align joints with edges of openings, except for control joints. Cut board neatly to fit around openings. Locate joints at least 8 inches from openings. Center vertical end joints above openings.

H. Extend board to within 1/4 inch of floor.

I. Install fasteners proceeding from center portion of gypsum board toward edges and ends.

J. On non-fire rated walls, screw board to framing at maximum 12 inches on center in field of board at bearings and along abutting edges. Nail board to framing at maximum 8 inches on center in field at bearings and along edges.

K. On fire rated walls, nail or screw board to framing at maximum 8 inches on center in field of board at bearings and along edges, unless indicated otherwise by UL assembly requirements.

L. Drive fasteners home with maximum 1/32 inch dimple in wall surface. Avoid breaking face paper of wallboard. Remove improperly driven nails.

M. Thoroughly seal openings, penetrations and cut edges of water-resistant wallboard in accordance with manufacturer's recommendations.

N. Double stud partitions: 1. Install strips of gypsum board 12 inches wide and of length to span partition

depth by screwing to webs of opposing studs. 2. Space strips approximately 42 inches on center.

O. Double layer partitions: 1. Install first layer vertically then second layer horizontally. 2. Stagger joints between layers and on opposite sides as far as is practical.


P. Sound control partitions: 1. Apply full running beads of acoustical sealant at perimeter of sound control

partitions. 2. Apply acoustical sealant with air operated equipment. 3. Inspect joints to receive sealant to be sure they are clean, dry and free of dust,

dirt and other foreign matter. 4. Seal around light boxes, outlets, and switches, with continuous bead of

sealant. 5. Remove excess of sealant or smears as construction progresses.

Q. Perimeter relief where non-load bearing gypsum board partitions abut structural decks or ceilings or vertical structural elements: 1. Allow not less than 1/4 inch, nor more than 1/2 inch gap between gypsum

board and structure. 2. Finish edges of board face layer with metal casing bead and caulk space

between casing bead and structure with continuous sealant bead. 3. Attach board to studs not less than 1/2 inch below bottom edge of ceiling track

flanges and to first stud adjacent to vertical tracks. Do not attach boards directly to tracks.

3.03 INSTALLATION OF CONTROL JOINTS

A. Discontinue gypsum board at control joints.

B. In ceiling construction, discontinue gypsum board and framing at control joints.

C. In partitions, discontinue gypsum board and install framing studs on each side of control joints.

D. Position control joints to intersect light fixtures, air diffusers, door openings and other areas of stress concentration.

E. Isolate gypsum board construction at following locations: 1. Where partitions or ceilings of dissimilar construction meet and remain in same

plane. 2. Where wings of "L," "U," and "T" shaped ceiling areas are joined. 3. When expansion or control joints occur in base building construction.

F. Space control joints at following maximum distances: 1. Partitions: 30 feet in either direction. 2. Interior ceilings with perimeter relief: 50 feet in either direction. 3. Interior ceilings without perimeter relief: 30 feet in either direction. 4. Exterior ceilings: 30 feet in either direction.

G. Extend control joints to ceiling from both corners of door frames where control joints are required.

H. Cut end joints square, align to provide neat fit.

I. Staple control joint to board at maximum 6 inches on center in each flange.


3.04 JOINT COMPOUND

A. Mix joint and topping compound in accordance with instructions on package.

B. Apply thin layer of joint compound uniformly approximately 4 inches wide over each joint.

C. Center tape over joint and embed into compound, leaving sufficient joint compound under tape to provide proper bond.

D. Reinforce wall angles and inside corner angles with tape folded to conform to angle and embedded into compound.

E. Apply skim coat of compound immediately after embedding tape.

F. After compound is thoroughly dry, cover tape with coat of joint compound or topping compound. Spread over tape and approximately 3 inches beyond edges of tape. Feathered out edge.

G. After compound is thoroughly dry, cover tape with coat of joint compound or topping compound. Spread over tape and approximately 3 inches beyond edges of previous coat. Feathered out edge.

H. Coat inside corners with minimum of one coat of joint compound or topping compound with edges feathered out.

I. Apply 3 coats of compound to nail and screw head dimples.

J. Conceal flanges of wallboard corner beads with minimum of 2 coats of compound. 1. Apply joint compound for first coat. 2. Apply joint compound or topping compound for second coat.

a. Feathered out second coat approximately 9 inches on both sides of exposed metal nose of corner bead.

K. Clean excess compound from board surface.

L. Sand coats as necessary after each application of compound has dried. 1. Leave board uniformly smooth ready to receive texturing, to extent that after

painting, board shows no distinguishable difference in appearance between taped and untaped surfaces.

3.05 TOLERANCES

A. Offsets between planes of board faces: Maximum 1/16 inch.

B. Flatness: Maximum 1/8 inch in 96 inches.

C. Variation from plumb: Maximum 1/8 inch in 96 inches.

END OF SECTION


SECTION 09523

ACOUSTICAL PANELS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Acoustical panels and accessories: 1. Wood fiber panels, and associated materials and accessories. 2. Acoustical wall and ceiling panels.

1.02 REFERENCES

A. ASTM International (ASTM): 1. C 514 - Standard Specification for Nails for the Application of Gypsum Board. 2. C 645 - Standard Specification for Nonstructural Steel Framing Members. 3. C 1002 - Standard Specification for Application and Finishing of Gypsum

Board. 4. E 1264 – Standard Classification for Acoustical Ceiling Products.


A. Performance requirements: Noise Reduction Coefficient (NRC) of minimum 85, minimum sound absorption coefficient of 2 by 8 foot panels mounted on 1-1/2 inch furring with insulation at following octave band center frequencies: 1. 125 hertz: 0.24. 2. 250 hertz: 0.57. 3. 500 hertz: 1.17. 4. 1,000 hertz: 0.87. 5. 2,000 hertz: 0.93. 6. 4,000 hertz: 0.87.

1.04 SUBMITTALS

A. Product data: Include sound absorption data, cutting and fabrication, and installation details for panel systems.

B. Shop drawings: Include panel layout and mounting details: 1. Indicate panel layout; show locations of mechanical grills, lighting, access

panels, sprinkler heads, and other items affecting ceiling installation.

C. Test reports: Results of sound absorption coefficient testing by independent acoustical laboratory.

D. Manufacturer's installation instructions: Including installation instructions for suspended grid system and adhesives.

E. Samples: 1. Submit full range of manufacturer's standard colors for color selection.


2. Submit 12 inches square samples for each type and size acoustical unit required.

3. Submit sample of suspension system; 12 inches long.


A. Store wood fiber panels in dry place. 1. Wrap panels with moisture-proof material. 2. Lay flat on pallets. 3. Allow for air circulation under cover. 4. Store within areas in which panels will be applied for minimum 24 hours prior

to installation.

1.06 SITE CONDITIONS

A. Deliver panels when building is closed in and in cold seasons, heated.

PART 2 PRODUCTS

2.01 ACOUSTICAL WALL PANELS

A. Manufacturer: One of the following or equal: 1. Sound Sorb by Acoustic Systems, Austin, Texas. 2. Eckoustic Functional Panels by Eckel Industries, Inc. Cambridge, MA.

B. Metal Facing: 0.032 inches minimum; coated aluminum, ribbed to provide impact resistance.

C. Perforation ratio: Not less than 23 percent.

D. Panel size: 18 by 96 inches.

E. Absorber: 1. Fiberglass or mineral wool wrapped in heat-sealed polyvinyl chloride film for

outdoor applications or polyethylene sheet for indoor applications. 2. Polyvinyl chloride film thickness 2 mils, polyethylene thickness 1.5 mils. 3. Perforation ratio 10 percent within 2 percent both sides. 4. Blanket; semi rigid, not less than 2 inch, density of approximately 1.5 pounds

per cubic foot.

F. Perforated metal facing shall be furred out on metals channels by 2 inches.

G. Mounting brackets: Minimum 4; Type 316 stainless steel.

H. Adsorption factors:

Frequency Band 125 250 500 1000 2000 4000 NRC Wall Panel 0.34 1.11 1.48 1.15 0.74 0.56 1.10


2.02 AD2

2.02 PANELS

A. Manufacturer and type: In accordance with ASTM E 1264, Class 25, noncombustible, with maximum 0.5 percent linear expansion due to humidity; One of the following or equal: 1. Tectum, Inc., Newark, OH, Tectum Wall Panels. 2. Cornell Corp., PetriCal Acoustical Panels.

B. Fabrication: 1-inch thick by 24 or 30 inches wide by 6 or 8 feet long panels with long-strand wood fibers and cement binder bonded and molded under controlled heat and pressure; long edges beveled; finished with factory-applied white latex paint.

C. Metal trim: 2-1/2 inch by 1 inch by 1/8-inch anodized aluminum angles; color as selected by Engineer.

D. Furring: One of the following or equal: 1. Douglas fir, nominal 2 by 4 inch, preservative treated. 2. Studs: ASTM C 645, hot dipped galvanized steel, minimum 20 gauge, channel

shaped, 1-5/8 inches wide.

E. Insulation: 2-1/2-inch thick, 0.75 pound per cubic foot density, fiberglass batts without vapor barrier.

F. Fasteners: 1. Furring to concrete or masonry: Acceptable concrete anchors or concrete

nails. 2. Screws, panels to metal: ASTM C 1002, Type S; self-drilling, self-tapping,

bugle head, for use with power driven tool, minimum 1-1/4 inches long or length to suit application.

3. Screws, panels to wood: ASTM C 1002, Type W, minimum 1-1/4 inches, hot-dip galvanized.

4. Nails, panels to wood: ASTM C 514; minimum 1-1/4-inch long, 12-1/2 gauge, 1/4-inch diameter head.

5. Trim to panels: Aluminum nails.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install acoustical panels in accordance with manufacturer's instructions.

B. Anchor furring to concrete or masonry walls securely. 1. Anchor horizontally at 12 inches above floor, at 24 inches on center, at ceiling,

and vertically at ends.

C. Install insulation between furring. 1. Hold in place until installation of panels.

D. Place panels vertically on walls, perpendicular to direction of furring, with maximum 1/16-inch space between panels.


E. Paint nail or screw head white. 1. Nail or screw panels to furring in manufacturer's recommended pattern. 2. Countersink nails or screws 1/16 inch.

F. Do not cover columns and beams with panels. 1. Hold panels back 2 inches from columns.

G. When panels require field cutting, make sharp and perpendicular cuts using jigs.

H. Make neat cutouts for pipes, supports, and other projections from wall. 1. Install metal trim around perimeter of panels. 2. Fasten trim to edge furring with aluminum nails. 3. Miter corners.

3.02 SCHEDULE

A. Install wall panels as scheduled below: Coverage

Location Wall Panels Ceiling Panels Total Treated Area

Blower Building Blower Room

200 square feet minimum

--- 200 square feet

Notes: (1) (None)

END OF SECTION

AD2 Addendum No. 2


SECTION 09910

PAINTING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Field applied paints and coatings for normal exposures. 2. Painting Accessories.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01770 - Closeout Procedures.

1.02 DEFINITIONS

A. Paints: Manufacturer's best ready-mixed coatings, except when field catalyzed, with fully ground pigments having soft paste consistency and capable of being readily and uniformly dispersed to complete homogeneous mixture, having good flowing and brushing properties, and capable of drying or curing free of streaks or sags.

B. Volatile Organic Compound (VOC): Content of air polluting hydrocarbons in uncured coating product measured in units of grams per liter or pounds per gallon.

1.03 SUBMITTALS

A. General: Submit as specified in Section 01300.

B. Shop drawings: Include schedule of where and for what use coating materials are proposed in accordance with requirements for Product Data.

C. Product data: Include description of physical properties of coatings including solids content and ingredient analysis, VOC content, temperature resistance, typical exposures and limitations, and manufacturer's standard color chips.

D. Samples: Include 8-inch square draw-downs or brush-outs of topcoat finish when requested. Identify each sample as to finish, formula, color name and number and sheen name and gloss units.

E. Manufacturer's instructions: Submit in accordance with requirements for Product Data. Include: 1. Special requirements for transportation and storage. 2. Mixing instructions. 3. Shelf life. 4. Pot life of material. 5. Precautions for applications free of defects. 6. Surface preparation. 7. Method of application.


8. Recommended number of coats. 9. Recommended thickness of each coat. 10. Recommended total thickness. 11. Drying time of each coat, including prime coat. 12. Required prime coat. 13. Compatible and non-compatible prime coats. 14. Recommended thinners, when recommended. 15. Limits of ambient conditions during and after application. 16. Time allowed between coats. 17. Required protection from sun, wind and other conditions. 18. Touch-up requirements and limitations. 19. Material Safety Data Sheet.


A. Products: First line or best grade.

B. Materials for each paint system: By single manufacturer.

C. Applicator qualifications: Applicator of products similar to specified products with minimum 3 years’ experience.

D. Regulatory requirements: Comply with by using paints that do not exceed governing agency's VOC limits or do not contain lead.

E. Field samples: 1. Paint 1 complete surface of each color scheme to show colors, finish texture,

materials, and workmanship. 2. Obtain approval before painting other surfaces.

1.05 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle products as specified in Section 01600.

B. Remove unspecified and unapproved paints from Project site immediately.

C. Deliver containers with labels identifying: 1. Manufacturer's name. 2. Brand name. 3. Product type. 4. Batch number. 5. Date of manufacturer. 6. Expiration date or shelf life. 7. Color. 8. Mixing and reducing instructions.

D. Store coatings in well-ventilated facility that provides protection from the sun weather, and fire hazards. 1. Maintain ambient storage temperature between 45 and 90 degrees

Fahrenheit, unless otherwise recommended by the manufacturer.

E. Take precautions to prevent fire and spontaneous combustion.


1.06 ENVIRONMENTAL CONDITIONS

A. Surface moisture contents: Do not paint surfaces that exceed manufacturer specified moisture contents, or when not specified by the manufacturer, the following moisture contents: 1. Plaster and gypsum wallboard: 12 percent. 2. Masonry, concrete and concrete block: 12 percent. 3. Interior located wood: 15 percent. 4. Concrete floors: 7 percent.

B. Do not paint or coat: 1. Under dusty conditions. 2. When light on surfaces measures less than 15 foot-candles. 3. When ambient or surface temperature is less than 50 degrees Fahrenheit or

unless manufacturer allow a lower temperature. 4. When relative humidity is higher than 85 percent, unless manufacturer allows

a higher relative humidity. 5. When surface temperature is less than 5 degrees Fahrenheit above dew point. 6. When surface temperature exceeds the manufacturer's recommendation. 7. When ambient temperature exceeds 90 degrees Fahrenheit, unless

manufacturer allows a higher temperature. 8. Apply clear finishes at minimum 65 degrees Fahrenheit.

C. Provide fans, heating devices, or other means recommended by coating manufacturer to prevent formation of condensate or dew on surface of substrate, coating between coats and within curing time following application of last coat.

D. Provide adequate continuous ventilation and sufficient heating facilities to maintain minimum 50 degrees Fahrenheit for 24 hours before, during and 48 hours after application of finishes.

1.07 PROTECTION

A. Protect adjacent surfaces from paint and damage. Repair damage resulting from inadequate or unsuitable protection.

B. Furnish sufficient drop cloths, shields, and protective equipment to prevent spray or droppings from fouling surfaces not being painted and in particular, surfaces within storage and preparation area.

C. Place cotton waste, cloths, and material that may constitute fire hazard in closed metal containers and remove daily from site.

D. Remove electrical plates, surface hardware, fittings and fastenings, prior to painting operations. 1. Carefully store, clean and replace on completion of painting in each area. 2. Do not use solvent or degreasers to clean hardware that may remove

permanent lacquer finish.

1.08 EXTRA MATERIALS

A. Extra materials: Deliver as specified in Section 01770. Include minimum 1 gallon of each type and color of coating applied:


1. When manufacturer packages material in gallon cans, deliver unopened labeled cans as comes from factory.

2. When manufacturer does not package material in gallon cans, deliver material in new gallon containers, properly sealed and identified with typed labels indicating brand, type, and color.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Paints: One of the following or equal: 1. Carboline: Carboline, St. Louis, MO. 2. ICI/Devoe: ICI/Devoe/AkzoNobel, Strongsville, OH. 3. Rustoleum: Rustoleum Corp., Sommerset, NJ. 4. S/W: Sherwin-Williams Co., Cleveland, OH. 5. Tnemec: Tnemec Co., Kansas City, MO.

B. Submit requests for substitutions as specified in Section 01600: 1. Include certified ingredient analyses. 2. Provide colors that match specified colors.

2.02 PAINTS, INTERIOR EXPOSURE

A. Latex, semi-gloss: One of following or equal: 1. Carboline: Carbocrylic 3359MC. 2. ICI/Devoe:

a. Dulux Ultra 1407. b. Dulux Lifemaster 9200N.

3. S/W: Promar 200, B77W3402D.

B. Urethane varnish, clear: One of following or equal: 1. ICI/Devoe: Woodpride 1802 Clear Interior Water-based Varnish. 2. S/W: Wood Classics Waterborne Polyurethane Varnish Gloss Clear A68V91. 3. Rustoleum: Varathane Exterior Liquid Plastic.

C. Oil: The following or equal: 1. Watco Danish Oil.

PART 3 EXECUTION

3.01 INSPECTION

A. Thoroughly examine surfaces scheduled to be painted before starting work.

B. Start painting when unsatisfactory conditions have been corrected.

3.02 SURFACE PREPARATION

A. Prepare surfaces in accordance with paint manufacturer's instructions or when none, the following: 1. Gypsum wallboard:


a. Remove contamination and prime to show defects. b. Repair and prime defects.

3.03 APPLICATION

A. Apply each coat at proper consistency.

B. Tint each coat of paint slightly darker than preceding coat.

C. Sand lightly between coats to achieve required finish.

D. Do not apply finishes on surfaces that are not sufficiently dry.

E. Allow each coat of finish to dry before following coat is applied, unless directed otherwise by manufacturer.

F. Where clear finishes are required ensure tint fillers match wood. 1. Work fillers well into grain before set. 2. Wipe excess from surface.

G. Backprime exterior woodwork, which is to receive paint finish, with exterior primer paint.

H. Backprime interior woodwork, which is to receive paint or enamel finish, with enamel undercoat paint.

I. Backprime interior and exterior woodwork, which is to receive stain or varnish finish, with gloss varnish reduced 25 percent with mineral spirits.

J. Prime top and bottom edges of wood and metal doors with enamel undercoat when they are to be painted.

K. Prime top and bottom edges of wood doors with gloss varnish when they are to receive stain or clear finish.

3.04 SURFACES NOT REQUIRING FINISHING

A. Stainless steel, brass, bronze, copper, monel, chromium, anodized aluminum: Specially finished articles such as porcelain enamel, plastic coated fabrics, and baked enamel.

B. Finished products such as ceramic tile, windows, glass, brick, resilient flooring, acoustical tiles, board and metal tees; other architectural features, such as finish hardware, furnished in aluminum, bronze or plated ferrous metal, prefinished panels, or other items that are installed prefinished.

C. Items completely finished at factory, such as preformed metal roof and wall panels, aluminum frames, toilet compartments, sound control panels, acoustical tiles, shower compartments, folding partition, and flagpole.


3.05 CLEANING

A. As work proceeds and upon completion, promptly remove paint where spilled, splashed, or spattered.

B. During progress of work, keep premises free from unnecessary accumulation of tools, equipment, surplus materials, and debris.

C. Upon completion of work, leave premises neat and clean.

3.06 INTERIOR PAINT SCHEDULE

A. Gypsum board: 2 coats of following finish paints: 1. Latex, semi-gloss:

a. Walls and partitions.

END OF SECTION


SECTION 09960

HIGH-PERFORMANCE COATINGS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Field applied coatings.

B. Related sections: 1. Section 01140 – Work Restrictions. 2. Section 01200 – Project Meetings. 3. Section 01300 – Submittals. 4. Section 01352 – Alteration Project Procedures. 5. Section 01600 – Product Requirements. 6. Section 01770 – Closeout Procedures. 7. Section 15075 – Equipment Identification. 8. Section 15150 - Raceways, Fittings and Supports

1.02 REFERENCES

A. ASTM International (ASTM): 1. D 16 – Standard Terminology for Paint, Related Coatings, Materials, and

Applications. 2. D 4541 – Standard Test Method for Pull-off Strength of Coatings Using

Portable Adhesion Testers.

B. NACE International (NACE): 1. SP0178 – Design, Fabrication, and Surface Finish Practices for Tanks and

Vessels to Be Lined for Immersion Service. 2. SP0188-06 – Discontinuity (Holiday) Testing of Protective Coatings.

C. National Association of Pipe Fabricators (NAPF): 1. 500-03 – Surface Preparation Standard for Ductile Iron Pipe and Fittings

Receiving Special External Coatings and/or Special Internal Linings.

D. NSF International (NSF): 1. 61 – Drinking Water System Components – Health Effects.

E. Society for Protective Coatings (SSPC): 1. SP COM – Surface Preparation Commentary for Steel and Concrete

Substrates. 2. SP-1 – Solvent Cleaning. 3. SP-2 – Hand Tool Cleaning. 4. SP-3 – Power Tool Cleaning. 5. SP-5 – White Metal Blast Cleaning. 6. SP-6 – Commercial Blast Cleaning. 7. SP-7 – Brush-Off Blast Cleaning. 8. SP-10 – Near-White Blast Cleaning.


F. U.S. Environment Protection Agency (EPA): 1. Method 24 – Surface Coatings.

1.03 DEFINITIONS

A. Submerged metal: Steel or iron surfaces below tops of channel or structure walls which will contain water even when above expected water level.

B. Submerged concrete and masonry surfaces: Surfaces which are or will be: 1. Underwater. 2. In structures which normally contain water. 3. Below tops of walls of water containing structures.

C. Exposed surface: Any metal or concrete surface, indoors or outdoors that is exposed to view.

D. Dry film thickness (DFT): Thickness of fully cured coating, measured in mils.

E. Volatile organic compound (VOC): Content of air polluting hydrocarbons in uncured coating product measured in units of grams per liter or pounds per gallon, as determined by EPA Method 24.

F. Ferrous: Cast iron, ductile iron, wrought iron, and all steel alloys except stainless steel.

G. Where SSPC surface preparation standards are specified or implied for ductile iron pipe or fittings, the equivalent NAPF surface preparation standard shall be substituted for the SSPC standard.


A. Coating materials shall be especially adapted for use in wastewater treatment plants.

B. Coating materials used in contact with potable water supply systems shall be certified to NSF 61.

1.05 SUBMITTALS

A. General: Submit as specified in Section 01300.

B. Shop drawings: 1. Schedule of proposed coating materials. 2. Schedule of surfaces to be coated with each coating material.

C. Product Data: Include description of physical properties of coatings including solids content and ingredient analysis, VOC content, temperature resistance, typical exposures and limitations, and Manufacturer's standard color chips: 1. Regulatory requirements: Submit data concerning the following:

a. Volatile organic compound limitations. b. Coatings containing lead compounds and PCBs. c. Abrasives and abrasive blast cleaning techniques, and disposal. d. NSF certification of coatings for use in potable water supply systems.


D. Samples: Include 8-inch square drawdowns or brush-outs of topcoat finish when requested. Identify each sample as to finish, formula, color name and number and sheen name and gloss units.

E. Certificates: Submit in accordance with requirements for Product Data.

F. Manufacturer's Instructions: Include the following: 1. Special requirements for transportation and storage. 2. Mixing instructions. 3. Shelf life. 4. Pot life of material. 5. Precautions for applications free of defects. 6. Surface preparation. 7. Method of application. 8. Recommended number of coats. 9. Recommended dry film thickness (DFT) of each coat. 10. Recommended total dry film thickness (DFT). 11. Drying time of each coat, including prime coat. 12. Required prime coat. 13. Compatible and non-compatible prime coats. 14. Recommended thinners, when recommended. 15. Limits of ambient conditions during and after application. 16. Time allowed between coats (minimum and maximum). 17. Required protection from sun, wind, and other conditions. 18. Touch-up requirements and limitations. 19. Minimum adhesion of each system submitted in accordance with

ASTM D 4541.

G. Manufacturer's Representative’s Field Reports.

H. Operations and Maintenance Data: Submit as specified in Section 01770. 1. Reports on visits to project site to view and approve surface preparation of

structures to be coated. 2. Reports on visits to project site to observe and approve coating application

procedures. 3. Reports on visits to coating plants to observe and approve surface preparation

and coating application on items that are “shop coated.”

I. Quality Assurance Submittals: 1. Quality Assurance plan. 2. Qualifications of coating applicator including List of Similar Projects.

J. Certifications: 1. Submit notarized certificate that:

a. All paints and coatings to be used on this project comply with current federal, state, and local VOC regulations.


A. Applicator qualifications: 1. Minimum of 5 years experience applying specified type or types of coatings

under conditions similar to those of the Work:


a. Provide qualifications of applicator and references listing 5 similar projects completed in the past 2 years.

2. Manufacturer approved applicator when Manufacturer has approved applicator program.

3. Approved and licensed by polymorphic polyester resin Manufacturer to apply polymorphic polyester resin coating system.

4. Approved and licensed by elastomeric polyurethane (100 percent solids) Manufacturer to apply 100 percent solids elastomeric polyurethane system.

5. Applicator of off-site application of coal tar epoxy shall have successfully applied coal tar epoxy on similar surfaces in material, size, and complexity as on the Project.

B. Regulatory requirements: Comply with governing agencies regulations by using coatings that do not exceed permissible volatile organic compound limits and do not contain lead: 1. Do not use coal tar epoxy in contact with drinking water or exposed to

ultraviolet radiation.

C. Certification: Certify that applicable pigments are resistant to discoloration or deterioration when exposed to hydrogen sulfide and other sewage gases and product data designates coating as suitable for wastewater service.

D. Field samples: 1. Prepare and coat a minimum 100 square foot area between corners or limits

such as control or construction joints of each system. 2. Approved field sample may be part of Work. 3. Obtain approval before painting other surfaces.

E. Pre-installation conference: Conduct as specified in Section 01200.

F. Compatibility of coatings: Use products by same Manufacturer for prime coats, intermediate coats, and finish coats on same surface, unless specified otherwise.

G. Services of coating Manufacturer’s representative: Arrange for coating Manufacturer’s representative to attend pre-installation conferences. Make periodic visits to the project site to provide consultation and inspection services during surface preparation and application of coatings, and to make visits to coating plants to observe and approve surface preparation procedures and coating application of items to be “shop primed and coated”.

1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle products as specified in Section 01600.

B. Remove unspecified and unapproved paints from Project site immediately.

C. Deliver new unopened containers with labels identifying the Manufacturer's name, brand name, product type, batch number, date of Manufacturer, expiration date or shelf life, color, and mixing and reducing instructions. 1. Do not deliver materials aged more than 12 months from manufacturing date.


D. Store coatings in well-ventilated facility that provides protection from the sun weather, and fire hazards. Maintain ambient storage temperature between 45 and 90 degrees Fahrenheit, unless otherwise recommended by the Manufacturer.

E. Take precautions to prevent fire and spontaneous combustion.


A. Surface moisture contents: Do not coat surfaces that exceed Manufacturer specified moisture contents, or when not specified by the Manufacturer, the following moisture contents: 1. Plaster and gypsum wallboard: 12 percent. 2. Masonry, concrete, and concrete block: 12 percent. 3. Interior located wood: 15 percent. 4. Concrete floors: 7 percent.

B. Do not apply coatings: 1. Under dusty conditions or adverse environmental conditions, unless tenting,

covers, or other such protection is provided for structures to be coated. 2. When light on surfaces measures less than 15 foot-candles. 3. When ambient or surface temperature is less than 55 degrees Fahrenheit

unless Manufacturer allows a lower temperature. 4. When relative humidity is higher than 85 percent. 5. When surface temperature is less than 5 degrees Fahrenheit above dew point. 6. When surface temperature exceeds the Manufacturer's recommendation. 7. When ambient temperature exceeds 90 degrees Fahrenheit, unless

Manufacturer allows a higher temperature. 8. Apply clear finishes at minimum 65 degrees Fahrenheit.

C. Provide fans, heating devices, dehumidifiers, or other means recommended by coating MANUFACTURER to prevent formation of condensate or dew on surface of substrate, coating between coats and within curing time following application of last coat.

D. Provide adequate continuous ventilation and sufficient heating facilities to maintain minimum 55 degrees Fahrenheit for 24 hours before, during and 48 hours after application of finishes.

E. Dehumidification and heating for coating of wet wells, and high humidity enclosed spaces: 1. Provide dehumidification and heating of interior spaces in which surface

preparation, coating application, or curing is in progress according to the following schedule: a. October 1 to April 30: Provide continuous dehumidification and heating as

required to maintain the tanks within environmental ranges as specified in this Section and as recommended by the coating material Manufacturer. For the purposes of this Section, “continuous” is defined as 24 hours per day and 7 days per week.


b. May 1 to September 30: Provide temporary dehumidification and heating as may be required to maintain the tanks within the specified environmental ranges in the event of adverse weather or other temporary condition. At Contractor’s option and at his sole expense, Contractor may suspend work until such time as acceptable environmental conditions are restored, in lieu of temporary dehumidification and heating. Repair or replace any coating or surface preparation damaged by suspension of work, at Contractor’s sole expense.

2. Equipment requirements: a. Capacity: Provide dehumidification, heating, and air circulation equipment

with minimum capacity to perform the following: 1) Maintain the dew point of the air in the tanks at a temperature at least

5 degrees Fahrenheit less than the temperature of the coldest part of the structure where work is underway.

2) Reduce dew point temperature of the air in the tanks by at least 10 degrees Fahrenheit in 20 minutes.

3) Maintain air temperature in the tanks at 60 degrees minimum. b. Systems:

1) Dehumidification: Provide desiccant or refrigeration drying. Desiccant types shall have a rotary desiccant wheel capable of continuous operation. No Liquid, granular, or loose lithium chloride drying systems will be allowed.

2) Heating: Electric, indirect combustion, or steam coil methods may be used. Direct fired combustion heaters will not be allowed during abrasive blasting, coating application, or coating cure time.

3. Design and submittals: a. Contractor shall prepare dehumidification and heating plan for this project,

including all equipment and operating procedures. b. Suppliers of services and equipment shall have not less than 3 years

experience in similar applications. 1) Supplier: The following or equal:

a) Cargocaire Corporation (Munters) or equal. c. Submit dehumidification and heating plan for Engineer’s review.

4. Monitoring and performance: a. Measure and record relative humidity and temperature of air, and

structure temperature twice daily (beginning and end of work shifts) to verify that proper humidity and temperature levels are achieved inside the work area after the dehumidification equipment is installed and operational. Test results shall be made available to the Engineer upon request.

b. Interior space of the working area and tank(s) shall be sealed and a slight positive pressure maintained as recommended by the supplier of the dehumidification equipment.

c. The filtration system used to remove dust from the air shall be designed so that it does not interfere with the dehumidification equipment’s ability to control the dew point and relative humidity inside the reservoir. 1) The air from the tank, working area, or dust filtration equipment shall

not be recirculated through the dehumidifier during coating application or when solvent vapors are present.



A. Sequence and Schedule: As specified in Section 01352.

1.10 MAINTENANCE

A. Extra materials: Deliver as specified in Section 01770. Include minimum 1 gallon of each type and color of coating applied: 1. When Manufacturer packages material in gallon cans, deliver unopened

labeled cans as comes from factory. 2. When Manufacturer does not package material in gallon cans, deliver material

in new gallon containers, properly sealed and identified with typed labels indicating brand, type, and color.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Special coatings: One of the following or equal: 1. Carboline: Carboline, St. Louis, MO. 2. Ceilcote: International Protective Coatings, Berea, OH. 3. Dampney: The Dampney Company, Everett, MA. 4. Devoe: International Protective Coatings, Louisville, KY. 5. Dudick: Dudick, Inc., Streetsboro, OH. 6. GET: Global Eco Technologies, Pittsburg, CA. 7. Henkel: Henkel North America, Madison Heights MI. 8. IET: Integrated Environmental Technologies, Santa Barbara, CA. 9. PPC: Polymorphic Polymers Corp., N. Miami, FL. 10. PPG Amercoat: PPG Protective & Marine Coatings, Brea, CA. 11. Rustoluem : Rustoleum Corp., Sommerset, NJ. 12. Sanchem: Sanchem, Chicago, IL. 13. Superior: Superior Environmental Products, Inc., Addison, TX. 14. S-W: Sherwin-Williams Co., Cleveland, OH. 15. Tnemec: Tnemec Co., Kansas City, MO. 16. Wasser: Wasser High Tech Coatings, Kent, WA. 17. ZRC: ZRC Worldwide Innovative Zinc Technologies, Marshfield, MA.

2.02 PREPARATION AND PRETREATMENT MATERIALS

A. Metal pretreatment: As manufactured by one of the following or equal: 1. Henkel: Galvaprep 5. 2. International: AWLGrip Alumiprep 33.

B. Surface cleaner and degreaser: As manufactured by one of the following or equal: 1. Carboline Surface Cleaner No.3. 2. Devoe: Devprep 88. 3. S-W: Clean and Etch.

2.03 COATING MATERIALS

A. Wax coating: As manufactured by the following or equal: 1. Sanchem: No-Ox-Id A special.


B. High solids epoxy (self priming) not less than 72 percent solids by volume: As manufactured by one of the following or equal: 1. Carboline: Carboguard 891. 2. Devoe: Bar Rust 233H. 3. PPG Amercoat: Amerlock 2. 4. S-W: Macropoxy 646. 5. Tnemec: HS Epoxy Series 104.

C. Aliphatic or aliphatic-acrylic polyurethane: As manufactured by one of the following or equal: 1. Carboline: Carbothane 134 VOC. 2. Devoe: Devthane 379. 3. PPG Amercoat: Amershield VOC. 4. Non-submerged: S-W High Solids Polyurethane CA. 5. Tnemec: Endura-Shield II Series 1075 (U).

D. Polymorphic polyester resin coating system: 2 component, modified styrene based thermoset resin, EPA approved for potable water, with 100 percent solids and maximum 10 grams per liter volatile organic compounds. As manufactured by one of the following or equal: 1. IET: IET Prime Coat DS-101, Intermediate Coat DS-301, and Finish Coat

DS-401. 2. PPC: PPC Prime Coat, IC-Filler Coat, and FC-Final Coat.

E. High temperature coating 150 to 350 degrees Fahrenheit: As manufactured by one of the following or equal: 1. Carboline: Thermaline 4900. 2. Dampney: Thermalox 245 Silicone – Zinc Dust. 3. PPG Amercoat: Amerlock 2/400 GFK.

F. High temperature coating 400 to 1,000 degrees Fahrenheit (dry): As manufactured by one of the following or equal: 1. Carboline: Thermaline 4700. 2. Dampney: Thermolox 230C Series Silicone. 3. Devoe: HT-12, High Heat Silicone.

G. High temperature coating up to 1,400 degrees Fahrenheit: As manufactured by the following or equal: 1. Dampney: Thermalox 240 Silicone Ceramix.

H. Asphalt varnish: AWWA C 500.

I. Protective coal tar: As manufactured by one of the following or equal: 1. Carboline: Bitumastic No. 50. 2. PPG Amercoat: 78HB

J. Coal tar epoxy: As manufactured by one of the following or equal: 1. Carboline: 300-M, Bitumastic. 2. PPG Amercoat: 78HB. 3. S-W: Tar Guard 100. 4. Tnemec: Series 46H-413.


K. Vinyl ester: Glass mat reinforced, total system 125 mils DFT. As manufactured by one of the following or equal: 1. Carboline: Semstone 870. 2. Ceilcote: 6640 Ceilcrete. 3. Dudick: Protecto-Flex 800. 4. Tnemec: Chembloc Series 239SC.

L. Elastomeric polyurethane, 100 percent solids, VOC-free, self-priming, applied with heated plural component spray system. As manufactured by the following or equal: 1. GET: Endura-Flex EF-1988. 2. Sprayroq: SprayWall

M. Concrete floor coatings: As manufactured by one of the following or equal: 1. Carboline: Semstone 140SL. 2. Devoe: Devran 124. 3. Dudick: Polymer Alloy 1000. 4. Tnemec: Tneme-Glaze Series 282.

N. Waterborne acrylic emulsion: As manufactured by one of the following or equal: 1. S-W: DTM Acrylic B66W1. 2. Tnemec: Tneme-Cryl Series 6.

O. Galvanizing Zinc Compound: As manufactured by one of the following or equal: 1. ZRC: Cold Galvanizing Compound.

P. Epoxy Modified Cementitious Mortar: As manufactured by one of the following or equal: 1. Sauereisen Sewergard No. 210.

Q. Modified Aliphatic Amine Epoxy Mortar: As manufactured by one of the following or equal: 1. Tenemec: Perma-Shield H2S Series 434.

R. Glaze Coat: Modified Polyamine Epoxy: As manufactured by one of the following or equal: 1. Tenemec: Perma-Glaze Series 435.

S. Amine Cured Novalac Epoxy: As manufactured the following (no alternate): 1. Induron Protecto 401 Ceramic Epoxy (Ductile Iron). 2. Induron Ceramapure PL90 (Steel).

T. 100% Solids Epoxy: As manufactured by the following or equal: 1. Raven 405.

2.04 MIXES

A. Mix in accordance with Manufacturer's instructions.


PART 3 EXECUTION

3.01 GENERAL PROTECTION

A. Protect adjacent surfaces from coatings and damage. Repair damage resulting from inadequate or unsuitable protection:

B. Protect adjacent surfaces not to be coated from spatter and droppings with drop cloths and other coverings: 1. Mask off surfaces of items not to be coated or remove items from area.

C. Furnish sufficient drop cloths, shields, and protective equipment to prevent spray or droppings from fouling surfaces not being coated and in particular, surfaces within storage and preparation area.

D. Place cotton waste, cloths, and material which may constitute fire hazard in closed metal containers and remove daily from site.

E. Remove electrical plates, surface hardware, fittings, and fastenings, prior to application of coating operations. Carefully store, clean, and replace on completion of coating in each area. Do not use solvent or degreasers to clean hardware that may remove permanent lacquer finish.

3.02 GENERAL PREPARATION

A. Prepare surfaces in accordance with coating Manufacturer's instructions, unless more stringent requirements are specified in this Section.

B. Protect following surfaces from abrasive blasting by masking, or other means: 1. Threaded portions of valve and gate stems, grease fittings, and identification

plates. 2. Machined surfaces for sliding contact. 3. Surfaces to be assembled against gaskets. 4. Surfaces of shafting on which sprockets are to fit. 5. Surfaces of shafting on which bearings are to fit. 6. Machined surfaces of bronze trim, including those slide gates. 7. Cadmium-plated items except cadmium-plated, zinc-plated, or sherardized

fasteners used in assembly of equipment requiring abrasive blasting. 8. Galvanized items, unless scheduled to be coated.

C. Protect installed equipment, mechanical drives, and adjacent coated equipment from abrasive blasting to prevent damage caused by entering sand or dust.

D. Concrete: 1. Allow new concrete to cure for minimum of 28 days before coating. 2. Clean concrete surfaces of dust, mortar, fins, loose concrete particles, form

release materials, oil, and grease. Fill voids so that surface is smooth. Etch or brush off-blast clean in accordance with SSPC SP-7 to provide surface profile equal to 40 to 60-grit sandpaper, or as recommended by coating Manufacturer. All concrete surfaces shall be vacuumed clean prior to coating application.


E. Ferrous metal surfaces: 1. Remove grease and oil in accordance with SSPC SP-1. 2. Remove rust, scale, and welding slag and spatter, and prepare surfaces in

accordance with appropriate SSPC standard as specified. 3. Abrasive blast surfaces prior to coating.

a. When abrasive blasted surfaces rust or discolor before coating, abrasive blast surfaces again to remove rust and discoloration.

b. When metal surfaces are exposed because of coating damage, abrasive blast surfaces and feather in to a smooth transition before touching-up.

c. Ferrous metal surfaces not to be submerged: Abrasive blast in accordance with SSPC SP-10, unless blasting may damage adjacent surfaces, prohibited or specified otherwise. Where not possible to abrasive blast, power tool clean surfaces in accordance with SSPC SP-3.

d. Ferrous metal surfaces to be submerged: Unless specified otherwise, abrasive blast in accordance with SSPC SP-5 to clean and provide roughened surface profile of not less than 2 mils and not more than 4 mils in depth when measured with Elcometer 123, or as recommended by the coating Manufacturer.

4. All abrasive blast cleaned surfaces shall be blown down with clean dry air and or vacuumed.

F. Ductile iron pipe and fittings to be lined or coated: Abrasive blast clean in accordance with NAPF 500-03.

G. Sherardized, aluminum, copper, and bronze surfaces: Prepare in accordance with coating Manufacturer's instructions.

H. Galvanized surface: 1. Degrease or solvent clean (SSPC SP-1) to remove oily residue. 2. Power tool or hand tool clean or whip abrasive blast. 3. Test surface for contaminants using copper sulfate solution. 4. Apply metal pretreatment within 24 hours before coating galvanized surfaces

that cannot be thoroughly abraded physically, such as bolts, nuts, or preformed channels.

I. Shop primed metal: 1. Certify that primers applied to metal surfaces in the shop are compatible with

coatings to be applied over such primers in the field. 2. Remove shop primer from metal to be submerged by abrasive blasting in

accordance with SSPC SP-10, unless greater degree of surface preparation is required by coating Manufacturer’s representative.

3. Correct abraded, scratched, or otherwise damaged areas of prime coat by sanding or abrasive blasting to bare metal in accordance with SSPC SP-2, SP-3, or SP-6, as directed by the Engineer.

4. When entire shop priming fails or has weathered excessively (more than 25 percent of the item), or when recommended by coating MANUFACTURER’s representative, abrasive blast shop prime coat to remove entire coat and prepare surface in accordance with SSPC SP-10.

5. When incorrect prime coat is applied, remove incorrect prime coat by abrasive blasting in accordance with SSPC SP-10.

6. When prime coat not authorized by Engineer is applied, remove unauthorized prime coat by abrasive blasting in accordance with SSPC SP-10.


7. Shop applied bituminous paint or asphalt varnish: Abrasive blast clean shop applied bituminous paint or asphalt varnish from surfaces scheduled to receive non-bituminous coatings.

J. Cadmium-plated, zinc-plated, or sherardized fasteners: 1. Abrasive blast in same manner as unprotected metal when used in assembly

of equipment designated for abrasive blasting.

K. Abrasive blast components to be attached to surfaces which cannot be abrasive blasted before components are attached.

L. Grind sharp edges to approximately 1/16-inch radius before abrasive blast cleaning.

M. Remove and grind smooth all excessive weld material and weld spatter before blast cleaning in accordance with NACE SP0178.

N. PVC and FRP Surfaces: 1. Prepare surfaces to be coated by light sanding (de-gloss) and wipe-down with

clean cloths, or by solvent cleaning in strict accordance with coating MANUFACTURER's instructions.

O. Cleaning of previously coated surfaces: 1. Utilize cleaning agent to remove soluble salts such as chlorides and sulfates

from concrete and metal surfaces: a. Cleaning agent: Biodegradable non-flammable and containing no volatile

organic compounds. b. Manufacturer: The following or equal:

1) Chlor-Rid International, Inc. 2. Steam clean and degrease surfaces to be coated to remove oils and grease. 3. Cleaning of surfaces utilizing the decontamination cleaning agent may be

accomplished in conjunction with abrasive blast cleaning, steam cleaning, high-pressure washing, or hand washing as approved by the coating Manufacturer's representative and the Engineer.

4. Test cleaned surfaces in accordance with the cleaning agent Manufacturer's instructions to ensure all soluble salts have been removed. Additional cleaning shall be carried out as necessary.

5. Final surface preparation prior to application of new coating system shall be made in strict accordance with coating Manufacturer's printed instructions.

3.03 MECHANICAL AND ELECTRICAL EQUIPMENT PREPARATION

A. Identify equipment, ducting, piping, and conduit as specified in Section 15075 and Section 16150.

B. Remove grilles, covers, and access panels for mechanical and electrical system from location and coat separately.

C. Prepare and finish coat-primed equipment with color selected by the Engineer.

D. Prepare and prime and coat insulated and bare pipes, conduits, boxes, insulated and bare ducts, hangers, brackets, collars, and supports, except where items are covered with prefinished coating.


E. Replace identification markings on mechanical or electrical equipment when coated over or spattered.

F. Prepare and coat interior surfaces of air ducts, convector and baseboard heating cabinets that are visible through grilles and louvers with 1 coat of flat black paint, to limit of sight line.

G. Prepare and coat dampers exposed immediately behind louvers, grilles, convector and baseboard cabinets to match face panels.

H. Prepare and coat exposed conduit and electrical equipment occurring in finished areas with color and texture to match adjacent surfaces.

I. Prepare and coat both sides and edges of plywood backboards for electrical equipment before installing backboards and mounting equipment on them.

J. Color code equipment, piping, conduit, and exposed ductwork and apply color banding and identification, such as flow arrows, naming and numbering, in accordance with Contract Documents.

3.04 GENERAL APPLICATION REQUIREMENTS

A. Apply coatings in accordance with Manufacturer's instructions.

B. Coat metal unless specified otherwise: 1. Aboveground piping to be coated shall be empty of contents during application

of coatings.

C. Verify metal surface preparation immediately before applying coating in accordance with SSPC SP COM.

D. Allow surfaces to dry, except where coating Manufacturer requires surface wetting before coating.

E. Wash coat and prime sherardized, aluminum, copper, and bronze surfaces, or prime with MANUFACTURER's recommended special primer.

F. Prime shop primed metal surfaces. Spot prime exposed metal of shop primed surfaces before applying primer over entire surface.

G. Multiple coats: 1. Apply minimum number of specified coats. 2. Apply additional coats when necessary to achieve specified thicknesses. 3. Apply coats to thicknesses specified, especially at edges and corners. 4. When multiple coats of same material are specified, tint prime coat and

intermediate coats with suitable pigment to distinguish each coat. 5. Lightly sand and dust surfaces to receive high gloss finishes, unless instructed

otherwise by coating Manufacturer. 6. Dust coatings between coats.

H. Coat surfaces without drops, overspray, dry spray, runs, ridges, waves, holidays, laps, or brush marks.


I. Remove spatter and droppings after completion of coating.

J. Apply coating by brush, roller, trowel, or spray, unless particular method of application is required by coating Manufacturer's instructions or these Specifications.

K. Plural component application: Drums shall be premixed each day. All gauges shall be working order prior to the start of application. Ratio checks shall be completed prior to each application. A spray sample shall be sprayed on plastic sheeting to insure set time is complete prior to each application. Hardness testing shall be preformed after each application.

L. Spray application: 1. Stripe coat edges, welds, nuts, bolts, difficult to reach areas by brush before

beginning spray application, as necessary, to ensure specified coating thickness along edges.

2. When using spray application, apply coating to thickness not greater than that recommended in coating Manufacturer's instructions for spray application.

3. Use airless spray method, unless air spray method is required by coating MANUFACTURER's instruction or these Specifications.

4. Conduct spray coating under controlled conditions. Protect adjacent construction and property from coating mist, fumes, or overspray.

M. Drying and recoating: 1. Provide fans, heating devices, or other means recommended by coating

Manufacturer to prevent formation of condensate or dew on surface of substrate, coating between coats and within curing time following application of last coat.

2. For submerged service the Contractor shall provide a letter to the Engineer that the lining system is fully cured and ready to be placed into service.

3. Limit drying time to that required by these Specifications or coating Manufacturer's instructions.

4. Do not allow excessive drying time or exposure which may impair bond between coats.

5. Recoat epoxies within time limits recommended by coating Manufacturer. 6. When time limits are exceeded, abrasive blast clean and de-gloss clean prior

to applying another coat. 7. When limitation on time between abrasive blasting and coating cannot be met

before attachment of components to surfaces which cannot be abrasive blasted, coat components before attachment.

8. Ensure primer and intermediate coats of coating are unscarred and completely integral at time of application of each succeeding coat.

9. Touch up suction spots between coats and apply additional coats where required to produce finished surface of solid, even color, free of defects.

10. Leave no holidays. 11. Sand and feather in to a smooth transition and recoat and recoat scratched,

contaminated, or otherwise damaged coating surfaces so damages are invisible to naked eye.


N. Concrete: 1. Apply first coat (primer) only when surface temperature of concrete is

decreasing in order to eliminate effects of off-gassing on coating.

3.05 ALKALI RESISTANT BITUMASTIC

A. Preparation: 1. Prepare surfaces in accordance with general preparation requirements.

B. Application: 1. Apply in accordance with general application requirements and as follows:

a. Apply at least 2 coats, 8 to 14 mils dry film thickness each.

3.06 WAX COATING


B. Application: 1. Apply in accordance with general application requirements and as follows:

a. Apply at least 1/32-inch thick coat with 2-inch or shorter bristle brush. b. Thoroughly rub coating into metal surface with canvas covered wood

block or canvas glove.

3.07 HIGH SOLIDS EPOXY SYSTEM

A. Preparation: 1. Prepare surfaces in accordance with general preparation requirements and as

follows: a. Abrasive blast ferrous metal surfaces to be submerged at jobsite in

accordance with SSPC SP-5 prior to coating. When cleaned surfaces rust or discolor, abrasive blast surfaces in accordance with SSPC SP-10.

b. Abrasive blast non-submerged ferrous metal surfaces at jobsite in accordance with SSPC SP-10, prior to coating. When cleaned surfaces rust or discolor, abrasive blast surfaces in accordance with SSPC SP-6.

c. Abrasive blast clean ductile iron surfaces at jobsite in accordance with SSPC SP-7.

B. Application: 1. Apply coatings in accordance with general application requirements and as

follows: a. Apply minimum 2-coat system with minimum total dry film thickness (DFT)

of 12 mils. b. Recoat or apply succeeding epoxy coats within time limits recommended

by Manufacturer. Prepare surfaces for recoating in accordance with Manufacturer's instructions.

c. Coat metal to be submerged before installation when necessary, to obtain acceptable finish, and to prevent damage to other surfaces.

d. Coat entire surface of support brackets, stem guides, pipe clips, fasteners, and other metal devices bolted to concrete.

e. Coat surface of items to be exposed and adjacent 1 inch to be concealed when embedded in concrete or masonry.


3.08 HIGH SOLIDS EPOXY AND POLYURETHANE COATING SYSTEM


follows: a. Prepare concrete surfaces in accordance with general preparation

requirements. b. Touch up shop primed steel and miscellaneous iron. c. Abrasive blast ferrous metal surfaces at jobsite prior to coating. Abrasive

blast clean rust and discoloration from surfaces. d. Degrease or solvent clean, whip abrasive blast, power tool, or hand tool

clean galvanized metal surfaces. e. Lightly sand (de-gloss) fiberglass and poly vinyl chloride (PVC) pipe to be

coated and wipe clean with dry cloths, or solvent clean in accordance with coating Manufacturer's instructions.

f. Abrasive blast clean ductile iron surfaces.


follows: a. Apply 3 coat system consisting of:

1) Primer: 4 to 5 mils dry film thickness high solids epoxy. 2) Intermediate coat: 4 to 5 mils dry film thickness high solids epoxy. 3) Topcoat: 2.5 to 3.5 mils dry film thickness aliphatic or aliphatic-acrylic

polyurethane topcoat. 2. Recoat or apply succeeding epoxy coats within 30 days or within time limits

recommended by Manufacturer, whichever is shorter. Prepare surfaces for recoating in accordance with Manufacturer's instructions.

3.09 POLYMORPHIC POLYESTER RESIN SYSTEM


follows: 2. Prepare concrete to obtain clean, open pore with exposed aggregate in

accordance with Manufacturer's instructions. 3. Prepare ferrous metal surfaces in accordance with SSPC SP-5, with coating

Manufacturer's recommended anchor pattern. 4. Complete abrasive blast cleaning within 6 hours of applying prime coat. Dew

point shall remain 5 degrees above dew point 8 hours after application of coating. When cleaned surfaces rust or discolor, abrasive blast surfaces in accordance with SSPC SP-5.

5. When handling steel, wear gloves to prevent hand printing. 6. Adjust pH of concrete to within 5.5 to 8.0 before applying prime coat.


follows: 2. Apply minimum dry film thickness system consisting of primer, tie coat and top

coat in accordance with Manufacturer's instructions as follows: a. Steel: 35 mils. b. Concrete: 45 mils.


3.10 HIGH TEMPERATURE COATING


follows: a. Abrasive blast surface in accordance with SSPC SP-10.


follows: a. Apply number of coats in accordance with Manufacturer's instructions.

3.11 ASPHALT VARNISH



follows: a. Apply minimum 2 coats.

3.12 PROTECTIVE COAL TAR

A. Preparation: 1. Prepare surfaces in accordance with general preparation coal tar

requirements.


follows: a. Apply minimum 20 mils dry film thickness coating.

3.13 COAL TAR EPOXY


follows: a. Abrasive blast iron or steel surfaces to be coated as submerged metal in

accordance with SSPC SP-5. Prepare other metal surfaces to be coated with coal tar epoxy in accordance with epoxy Manufacturer's instructions.


follows: a. Waterproofing outside surfaces of concrete structures: Apply minimum

2 coats with total dry film thickness of 40 mils. b. Apply 2 coats of 8 mils each for a total 16 mils dry film thickness. c. Apply coal tar epoxy on blasted steel on same day that steel is blasted. d. Apply succeeding coats over previous coat as soon as application does

not cause sagging, within the following times, or as recommended by the coating Manufacturer, whichever is sooner.


Average Temperature Degrees (Fahrenheit)

Maximum Time Between Coats (Hours)

50 to 60 36

60 to 70 24

70 to 80 12

80 to 120 4

e. Apply additional coats required to obtain specified thickness. f. When previous coat has cured or set or Maximum Time Between Coats

has lapsed, abrasive blast previous coat until surface film is removed. Wash and clean surface with cleaning solvent. Apply succeeding coat within Maximum Time Between Coats or as recommended by coating Manufacturer, whichever is sooner.

g. When succeeding coat is applied over previous coat which has cured or set or Maximum Time Between Coats has lapsed, and surface has not been abrasive blasted, remove entire coating system to substrate, and apply new coating system.

h. Where coating system is applied to exterior concrete surfaces below grade, extend system at least 3 inches above finish grade in straight level. Step extended system down 3 inches when extended system reaches 6 inches above finish grade.

3.14 VINYL ESTER

A. Preparation: 1. Prepare surfaces in accordance with coating Manufacturer's recommendations

and as directed and approved by coating Manufacturer's representative.

B. Application: 1. Apply prime coat, as required by coating Manufacturer, base coat, glass mat,

and topcoat to total dry film thickness of 125 mils minimum: a. Final topcoat on floors shall include non-skid surface, applied in

accordance with Manufacturer's instructions. 2. Perform high voltage holiday detection test in accordance with SP0188-06,

over 100 percent of coated surface areas to ensure pinhole free finished coating system.

3. All work shall be accomplished in strict accordance with coating Manufacturer's instructions and under direction of coating Manufacturer's representative.

3.15 ELASTOMERIC POLYURETHANE (100 PERCENT SOLIDS)

A. Preparation: 1. Prepare surfaces in strict accordance with coating Manufacturer's instructions

and as directed and approved by coating Manufacturer's representative.

B. Application: 1. Apply epoxy primer at DFT of 1 to 2 mils, in strict accordance with

Manufacturer's instructions.


2. Apply polyurethane coating at minimum total DFT as follows: a. Steel: 60 mils DFT. b. Ductile iron and ductile iron pipe coating and lining: 30 mils DFT. c. Concrete: 120 mils DFT. d. Or as recommended by the coating Manufacturer and accepted by the

Engineer. 3. For concrete application, provide saw cutting for coating terminations in strict

accordance with Manufacturer's instructions. 4. Perform high voltage holiday detection test in accordance with SP0188-06,

over 100 percent of coated surface areas to ensure pinhole free finished coating system.

3.16 CONCRETE FLOOR COATINGS

A. Preparation: 1. Prepare surfaces in accordance with general application requirements and in

strict a accordance with coating Manufacturer’s instructions.

B. Application: 1. Apply primer if required by coating Manufacturer. 2. Apply 1 or more coats as recommended by coating Manufacturer to receive a

minimum total dry film thickness of 25 mils, color as selected by Owner.

C. Final topcoat shall include non-skid surface, applied in strict accordance with coating MANUFACTURER's instructions.

3.17 WATERBORNE ACRYLIC EMULSION

A. Preparation: 1. Remove all oil, grease, dirt, and other foreign material by Solvent Cleaning in

accordance with SSPC SP-1. 2. Lightly sand all surfaces and wipe thoroughly with clean cotton cloths before

applying coating.

B. Application: 1. Apply 2 or more coats to obtain a minimum dry film thickness (DFT) of

5.0 mils.

3.18 EPOXY MODIFIED CEMENTITIOUS MORTAR SYSTEM

A. Preparation: 1. Prepare surface by abrasive blast or mechanically abrade to remove laitance,

curing compounds, hardeners, sealers and other contaminants and to provide an ICRI-CSP 5 surface profile. Fill large cracks, voids and other surface imperfections.

B. Application: 1. Apply filler/surfacer epoxy modified cementitious mortar coating 1/8” thickness. 2. Apply liner modified aliphatic amine epoxy mortar coating 1/8” thickness. 3. Apply glaze coat modified polyamine epoxy coating 20 mils thickness.


3.19 AMINE-CURED NOVALEC EPOXY (CERAMIC EPOXY)

A. Remove any oil or grease by solvent.

B. Prepare suface by abrasive blasted using sand or grit abrasive media to remove all rust, loose oxides, etc.

C. Coat shall be applied by a certified firm with a successful history of applying this coating product.

D. Coating shall be applied within 12 hours of surface preparation.

E. Temperature of substrate at amrient air shall be above 40 degrees Fahreinheit during the coating application and curing.

F. Coating shall be applied at a 40 mil thickness minimum.

G. Applicatin procedure and number of coats shall be as recommended by the coating manufacturer.

H. Care shall be given to coat the ends of pipes, one diameter width on the exterior of plain-end wall thimbles, and inside of weld-o-lets, bosses, or other opening attachments to the pipe.

3.20 100% SOLIDS EPOXY

A. Remove any oil or grease by solvent.

B. Prepare suface by abrasive blasted using sand or grit abrasive media to remove all rust, loose oxides, etc.

C. Coating shall be applied in strict accordance with the manufacturer's written recommendations.

D. Coat shall be applied by a certified firm with a successful history of applying this coating product.

E. Coating shall be applied within 12 hours of surface preparation.

F. Coating shall be applied at a 80 mil thickness minimum.


A. Each coat will be inspected. Strip and remove defective coats, prepare surfaces and recoat. When approved, apply next coat.

B. Control and check dry film thicknesses and integrity of coatings.

C. Measure dry film thickness with calibrated thickness gauge.

D. Dry film thicknesses on ferrous-based substrates may be checked with Elcometer Type 1 Magnetic Pull-Off Gage or Positector 6000.


E. Verify coat integrity with low-voltage sponge or high-voltage spark holiday detector, for submerged service, in accordance with SP0188 06. Allow ENGINEER to use detector for additional checking.

F. Check wet film thickness before coal tar epoxy coating cures on concrete or non-ferrous metal substrates.

G. Arrange for services of coating Manufacturer's field representative to provide periodic field consultation and inspection services to ensure proper surface preparation of facilities and items to be coated, and to ensure proper application and curing: 1. Notify Engineer 24 hours in advance of each visit by coating Manufacturer's

representative. 2. Provide Engineer with a written report by coating Manufacturer's

representative within 48 hours following each visit.

3.22 SCHEDULE OF ITEMS NOT REQUIRING COATING

A. General: Unless specified otherwise, the following items do not require coating: 1. Items that have received final coat at factory and not listed to receive coating

in field. 2. Aluminum, brass, bronze, copper, plastic (except PVC pipe), rubber, stainless

steel, chrome, Everdur, or lead. 3. Buried or encased piping or conduit. 4. Exterior concrete. 5. Galvanized steel wall framing, galvanized roof decking, galvanized electrical

conduits, galvanized pipe trays, galvanized cable trays, and other galvanized items: a. Areas on galvanized items or parts where galvanizing has been damaged

during handling or construction shall be repaired as follows: 1) Clean damaged areas by SSPC SP-1, SP-2, SP-3, or SP-7 as

required. 2) Apply 2 coats of a Galvanizing Zinc Compound in strict accordance

with MANUFACTURER’s instructions. 6. Grease fittings. 7. Fiberglass ducting or tanks in concealed locations. 8. Steel to be encased in concrete or masonry. 9. Motors, gear reducers and other self-contained or enclosed components with

manudacturer's standard finish.

3.23 SCHEDULE OF SURFACES TO BE COATED IN THE FIELD

A. In general, apply coatings to steel, iron, galvanized surfaces, and wood surfaces unless specified or otherwise indicated on the Drawings. Coat concrete surfaces and anodized aluminum only when specified or indicated on the Drawings. Color coat all piping as specified in Section 15075.

B. Following schedule is incomplete. Coat unlisted surfaces with same coating system as similar listed surfaces. Verify questionable surfaces.

C. Concrete: 1. High solids epoxy:

a. Safety markings.


2. Vinyl ester: a. Secondary containment: All concrete surfaces inside chemical

containment areas including inside wall surfaces, top of wall surfaces, sump area, tank fill area, including equipment pads, and tank pads.

b. Suitable for 72 hours submerged in: 1) 12 percent to 15 percent sodium hypochlorite. 2) 39 percent to 47 percent ferric chloride solution. 3) 40 percent active polymer.

c. Concrete floor surfaces in chemical containment areas shall have a non-skid surface.

3. Concrete floor coating: a. Hypochlorite containment area. b. Hyochlorite pump room.

4. 100% Epoxy: a. Primary and secondary scum well interior walls.

D. Metals: 1. Alkali resistant bitumastic:

a. Aluminum surfaces to be placed in contact with wood, concrete, or masonry.

2. Wax coating: a. Sliding faces of sluice and slide gates and threaded portions of gate

stems. 3. High solids epoxy and polyurethane system: Interior and exterior

non-immersed ferrous metal surfaces including: a. Doors, doorframes, ventilators, louvers, grilles, exposed sheet metal, and

flashing. b. Pipe, valves, pipe hangers, supports and saddles, conduit, cable tray

hangers, and supports. c. Motors and motor accessory equipment without manufacturer's factory

finish. d. Drive gear, drive housing, coupling housings, and miscellaneous gear

drive equipment. e. Valve and gate operators and stands. f. Structural steel including galvanized structural steel. g. Crane and hoist rails. h. Exterior of tanks and other containment vessels. i. Mechanical equipment supports, drive units, and accessories. j. Pumps not submerged. k. Degritters, grit classifiers, frames, supports, and associated equipment. l. Other miscellaneous metals. m. Grit separation and washer, frames, supports, and associated equipment.

4. High solids epoxy system: a. Field priming of ferrous metal surfaces with defective shop prime coat

where no other prime coat is specified; for non-submerged service. b. Bell rings, underside of manhole covers and frames. c. Sump pumps and grit pumps, including underside of base plates and

submerged suction and discharge piping. d. Chlorine diffuser supports. e. Exterior of submerged piping and valves other than stainless steel or PVC

piping. f. Submerged pipe supports and hangers.


g. Stem guides. h. Vertical shaft mixers and aerators below supports. i. Other submerged iron and steel metal unless specified otherwise. j. Interior surface of suction inlet and volute of submersible influent pumps.

Apply coating prior to pump testing. k. Submerged piping. l. Exterior of influent pumps and influent pump submerged discharge piping.

5. Protective coal tar: a. Underground pipe flanges, excluding pipe, corrugated metal pipe

couplings, flexible pipe couplings and miscellaneous underground metals not otherwise specified to receive another protective coating.

K. Fiberglass and PVC pipe surfaces: 1. Waterborne acrylic emulsion.

a. Exterior of fiberglass ducting and fan housings. b. Fiberglass expose to sunlight. c. PVC piping exposed to view. d. ABS piping as determined by Engineer.

END OF SECTION


SECTION 10400

SIGNAGE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Plastic and metal signs for building and site use.

1.02 REFERENCES

A. National Fire Protection Association (NFPA): 1. 704 - Standard System for the Identification of the Hazards of Materials for

Emergency Response.

B. Occupational Safety and Health Administration OSHA.

1.03 SUBMITTALS

A. Product data:

B. Shop drawings: Include lists of sign types, sizes, text, and colors; mounting details; locations; and cast metal plaque rubbings and templates.

C. Samples: Include actual materials.

D. Manufacturer's installation instructions.


A. Manufacturer qualifications: Manufacturer of proposed products for minimum 5 years with satisfactory performance record of minimum 5 years.

B. Installer qualifications: Manufacturer approved installer of products similar to specified products on minimum 10 projects of similar scope as Project with satisfactory performance record.

C. Regulatory requirements: Provide signage in accordance with Americans with Disabilities Act as published in the Federal Register, Volume 56, No. 144, Friday, July 26, 1991.

PART 2 PRODUCTS

2.01 MESSAGE LANGUAGE

A. Message shall be in both English and Spanish when indicated.


2.02 PLASTIC SIGNAGE SYSTEM

A. Manufacturers: 1. One of the following or equal:

a. Best Manufacturing Sign Systems, Montrose, CO; System 900013. b. Andco Industries Corp., Greensboro, NC; equivalent product. c. Vomar Products, Inc., Sepulveda, CA; equivalent product.

B. Attachment: 1. Vinyl tape, self-adhering.

C. Lettering: 1. Helvetica medium, 3/4 inches high.

D. Material for interior use: 1. Plastic 1/8-inch thick raised letters.

E. Material for exterior use: 1. Fiberglass 1/4 inch thick with high gloss finish, raised letters, blasted from

single piece of fiberglass for integral letter and background. 2. No adhesive as mechanical fastening of letters shall be allowed.

F. Colors: 1. As selected by Engineer from manufacturer's standard colors.

G. See Schedule A for specific sign size, location, text, pictogram, and quantity.

2.03 METAL SAFETY SIGNS

A. Manufacturer: Meeting OSHA Requirements; 40-mil thick aluminum with baked enamel finish. One of the following or equal: 1. Seton Name Plate Co., Branford, Connecticut, Special Wording. 2. Emedco, Buffalo, New York.

B. Danger sign colors: 1. Background: White. 2. Heading: White lettering on red oval with white border in black rectangular

panel. 3. Message: Black lettering on white. 4. Size: As scheduled.

C. Caution sign colors: 1. Background: Yellow. 2. Heading: Yellow lettering on black rectangular panel. 3. Message: Black lettering on yellow. 4. Size: As scheduled.

D. Safety instruction signs: 1. Background: White. 2. Heading: White lettering on green rectangular panel. 3. Message: Black lettering. 4. Size: As scheduled.


E. Warning sign colors: 1. Background: Orange. 2. Heading: Black lettering on orange diamond in black rectangular panel. 3. Message: Flack lettering on orange. 4. Size: As scheduled.

F. Notice information signs: 1. Background: White. 2. Heading: White lettering on blue rectangular panel. 3. Message: Black lettering. 4. Size: As scheduled.

G. Fasteners: Round head stainless steel bolts or screws.

H. See Schedule B for specific sign size, location, text, and quantity.

2.04 EXTERIOR INFORMATION SIGNS

A. Able to withstand 100 miles per hour wind load without damage: 1. Manufacturers: One of the following or equal:

a. Best Manufacturing Sign Systems, Montrose, CO; equivalent product. b. Andco Industries Corp., Greensboro, NC; equivalent product. c. Vomar Products, Inc., Sepulveda, CA; equivalent product.

B. Sign panel: Nominal 3 inches thick, consisting of 1/8-inch thick fiberglass material with integral returns fully encapsulating wood and foam core, 1/8-inch radius edges and corners, size as indicated on the Drawings.

C. Text: Helvetica medium, size and wording as indicated on the Drawings.

D. Posts: Nominal 3 inch square extruded aluminum sections with aluminum fillers at top and bottom, mounting hardware, and aluminum baseplates drilled for anchor bolts.

E. Fasteners: Manufacturer's standard, suitable for application.

F. Colors: As selected from manufacturer's standard colors.

2.05 CAST METAL PLAQUE

A. Manufacturers: One of the following or equal: 1. Andco Industries Corp., Greensboro, NC. 2. Southwell Co., San Antonio, TX. 3. ARK-RAMOS Inc., Oklahoma City, OK.

B. Material: Cast bronze.

C. Size: Approximately 28 by 34 inches by minimum 3/16 inches thick; lettering, center panel, and trim raised 1/8 inch.

D. Lettering: Text as directed by Engineer. Verify before fabrication.


E. Finishes: 1. Lettering, center panel, and trim: Fine satin. 2. Background: Finely pebbled, oxidized to dull black color.

F. Mounting: Concealed with fasteners.

2.06 HAZARD MATERIAL SIGNALS

A. Manufacturer: One of the following or equal: 1. Seton Name Plate Co., Branford, Connecticut. 2. Emedco, Buffalo, New York.

B. Hazard material signals: In accordance with NFPA 704; 40-mil thick aluminum with baked enamel finish panels, letters, and symbols with pressure sensitive adhesive, sizes as required for viewing distances, letters and symbols in accordance with Schedule C.

2.07 CAST ALUMINUM LETTERS


a. Metal Arts, Mandan, ND. b. Southwell Company, San Antonio, TX. c. OMC Industries, Bryan, TX.

B. Material: 1. Cast aluminum.

C. Text size and font: 1. As indicated on the Drawings.

D. Finish: 1. Black duranodic coating.

E. Mounting: 1. Projected jamb nut mounting, concealed.

PART 3 EXECUTION

3.01 PREPARATION

A. Protect adjacent surfaces which may be damaged by installation of signs.

B. Prepare substrates in accordance with sign manufacturer's instructions.

C. Remove scale, dirt, grease, and other contaminates from substrates.

3.02 INSTALLATION

A. Install signs in accordance with sign manufacturer's instructions.

B. Fasten signs securely in level, plumb, and true to plane positions.


C. Install signs where indicated on the Drawings or as indicated in the following schedules.

3.03 SCHEDULES

A. Plastic Signage System Schedule.

B. Metal Safety Sign Schedule.

C. Hazard Material Signals.

END OF SECTION


SCHEDULE A

PLASTIC SIGNAGE SYSTEM SCHEDULE

A. Fire Extinguishers: 1. Location: Adjacent to fire extinguishers. 2. Height: 60 inches above floor to center of sign. 3. Size: 6 inches square, unless shown otherwise on the Drawings.. 4. Colors: White letters on OSHA Red background. 5. Text: FIRE EXTINGUISHER.

END OF SCHEDULE A

PLASTIC SIGNAGE SYSTEM SCHEDULE


SECTION 11225

PORTABLE ANOXIC SUBMERSIBLE MIXERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Portable anoxic submersible mixers and appurtenances.

B. Related section: 1. Section 01300 - Submittals. 2. Section 01732 - Operation and Maintenance Data. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 15170 – Electrical Motor, Induction, 600 volts and blow. 5. Section 15958 - Mechanical Equipment Testing.

1.02 REFERENCES

A. American Bearing Manufactures Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. American Iron and Steel Institute (AISI):

C. ASTM International (ASTM): 1. A 48 - Standard Specification for Gray Iron Castings.


A. General: Portable submersible mixers, guide rails, and a portable hoist, as specified.

B. System operation: Each mixer shall be on/off operation.

1.04 SUBMITTALS

A. Submit as specified in Section 01300.

B. Furnish motor submittals as specified in Section 15170.

C. Shop Drawings: 1. Complete shop and installation drawings. 2. Parts list, dimensions, materials, and details of construction and installation. 3. Electrical schematic and wiring diagrams and other data as required for the

complete system. 4. Dimensional data for components, including foundation and anchor bolts and

details. 5. Equipment data:

a. Manufacturer. b. Model.


c. Propeller type, and size. d. Gearbox type, size, and description e. Weight of complete mixer assembly motor.

6. Mixer performance data. 7. Motor data. 8. Descriptive brochures of each items of auxiliary equipment.

D. Provide vendor operation and maintenance manual as specified in Section 01730.

E. Provide Manufacturer’s Certificate of Source Testing as specified in Section 01650.

F. Provide Manufacturer’s Certificate of Installation and Functionality Compliance as specified in Section 01650.


A. Mixer testing: The mixer manufacturer shall perform the following inspections and tests on each mixer before shipment from the factory: 1. Propeller, motor rating, and electrical connections shall first be checked for

compliance to the customer's purchase order. 2. A motor and cable insulation test for moisture content or insulation defects

shall be made. 3. Prior to shipment, the mixer shall be run dry to establish correct rotation and

mechanical integrity. 4. The mixer shall be run for a minimum of 30 minutes submerged, at a minimum

of ten feet underwater. 5. After operational test item number 4 is complete, operational test item number

2 is to be performed again. 6. A written report stating the foregoing steps have been done must be supplied

with each mixer at the time of shipment.

1.06 ENVIRONMENTAL CONDITIONS

A. Site conditions are as follows: 1. Elevation: 440 feet. 2. Water temperature: 50 to 90 degrees Fahrenheit.

1.07 SPARE PARTS

A. Spare parts, at a minimum, to rebuild 2 mixers: 1. Upper and lower bearings. 2. Upper and lower mechanical seals. 3. O-ring kit. 4. Seals and gaskets. 5. Special tools (1 set).

B. All parts and tools shall be suitably marked and packed in a single hinge-covered box.


1.08 WARRANTY

A. The equipment manufacturer shall warrant the Owner against defects in workmanship and materials, including parts and labor for a period of 2 years. 1. The warranty period shall begin upon final acceptance of the project.

a. The manufacturer further agrees to provide warranty service at the project site or at the manufacturer's facility at the sole discretion of the Owner without additional costs to the Owner.

b. The provisions of this warranty shall not apply to any part or product which has been damaged through misuse, accident, negligence, or failure to connect the protective devices specified.

PART 2 PRODUCTS

2.01 DESIGN

A. Furnish 2 mixers for installation into the anoxic zones of the aeration basin. 1. Each mixer shall be equipped with a 9.0 horsepower, submersible electric

motor connected for operation on 480 volts, 3 Phase, 60 hertz, wire service, with 30 feet of 10 AWG Subcab cable.

2. Each mixer shall have a clean water pumping capacity of at least 10,000 gallons per minute.

3. All cables shall be oil resistant chloroprene rubber jacketed. a. Each unit shall be fitted with 40 feet of lifting cable of adequate strength to

permit raising and lowering the mixer.

B. Geometry of zones: 1. The anaerobic zone is 35 feet by 50 feet, 21 feet side water depth, with

approximately 5 feet of freeboard above water surface. 2. Mixers will be installed on opposing walls, which taper in approximately 2 feet,

3 inches approximately at mid-height of the wall.

C. Mixers to provide total suspension of 2,000 milligrams per liter mixed liquor suspended solids in the aeration basin.

D. Zones subject to flows up to 4.5 million gallons per day: 1. RAS flow through pipe at inlet of basin: 3.0 million gallons per day. 2. Influent flow through pipe at inlet of basin: 1.5 million gallons per day. 3. Manufacturer to review the drawings and verify the location of all flows into the

basin.

2.02 MANUFACTURERS REQUIREMENTS

A. The mixing equipment specified shall be the design and fabrication of a single manufacturer which shall have sole source responsibility for said equipment.

B. Manufacturer: No other manufacturer will be considered: 1. Landia, Inc. 2. Flygt.


2.03 COMPONENTS

A. Mixer design: 1. Each mixer shall be able to be raised and lowered and shall be easily removed

for inspection or service without the need for personnel to enter the mixing vessel.

2. A sliding guide bracket shall be an integral part of the mixer unit. 3. The entire weight of the mixer unit shall be guided by a single bracket which

must be able to handle all thrust created by the mixer. 4. The standard mixer, with its appurtenances and cable, shall be capable of

continuous submergence under water without loss of watertight integrity to a depth of 50 feet.

B. Mixer construction: 1. Each mixer shall be of the integral design, close coupled, submersible type.

a. All components of the mixer, including motor, shall be capable of continuous underwater operation.

b. All components of the mixer shall be capable of continuous operation completely unsubmerged for a minimum of 4 hours.

2. Major mixer components shall be constructed of stainless steel or ASTM A 48 Class 30B cast iron with smooth surfaces devoid of holes, pits, and other irregularities. a. The oil housing coverplate shall be of corrosion-resistant composite. b. All exposed nuts and bolts shall be of 300 series stainless steel.

3. All surfaces coming into contact with the process liquid, other than stainless steel, shall be painted with Tnemec series 66, or equal.

C. Motor: 1. The mixer motor shall be squirrel cage, induction, shell type design, housed in

an air-filled, watertight chamber. 2. The stator winding shall be insulated with moisture resistant Class F insulation

which will resist a temperature of 155 degrees Celsius (311 degrees Fahrenheit). a. The stator shall be dipped and baked 3 times in Class F varnish.

3. The motor shall be designed for continuous duty, capable of sustaining a maximum of at least 10 evenly spaced starts per hour.

4. The rotor bars and short circuit rings shall be made of aluminum. 5. The motor shaft, delivered with the rotor as an integral part, shall be AISI Type

431 stainless steel or AISI 4340 shaft steel. 6. The stator housing shall be of grey cast iron as specified in ASTM A 48.

D. Gearboxes: 1. The gearbox shall be a 1-stage planetary reduction gear, equipped with high

precision, low-loaded gears designed for infinite life. 2. Motor shaft shall be provided with spline to attach to the gear reducer. 3. The reduction stage shall consist of an integral toothed ring gear to which are

set 3 planet wheels mounted on the planet carriers, engaging also with the sun pinion.

4. The gear shaft shall be identical with the propeller shaft. 5. Gear casing as specified in ASTM A 48 gray cast iron.


E. Elastomers: 1. All mating surfaces where watertight sealing is required shall be machined and

fitted with a single or double set of Nitrile rubber or Viton O-rings. a. Fitting shall be such that sealing is accomplished by metal-to-metal

contact between machined surfaces. b. This will result in controlled compression of the O-rings without requiring a

specific torque limit. 2. No secondary sealing compounds, rectangular gaskets, elliptical O-rings,

grease or other devices shall be used.

F. Propeller: 1. The propeller shall be 3-blade polyurethane or AISI 304 Stainless Steel with a

Type 316 stainless steel hub dynamically balanced, non-clogging backward curved design.

2. Each blade shall be laser cut and welded to the hub to ensure that the propeller is properly balanced.

3. The propeller shall be capable of handling solids, fibrous materials, heavy sludge and other matter found in normal sewage applications.

4. Manufacturer shall provide owner with a minimum 20-year warranty on the propeller.

G. Cable entry: 1. The cable entry housing shall be an integral part of the back plate or stator

housing. 2. The cable entry shall have a double set of elastomer grommets in order to

ensure a redundant system in the event of a cable entry failure. a. Single sealing systems will not be deemed acceptable.

3. The cable entry shall be comprised of 2 cylindrical elastomer grommets, each flanked by washers and a ferrule designed with close tolerance fit against the cable outside diameter and the entry inside diameter. a. This will provide a leak proof seal at the cable entrance without the need

for specific torque requirements. 4. The assembly shall bear against a shoulder in the stator casing opening and

be compressed by a gland nut threaded into it. a. Interaction between the gland nut and the ferrule should move the

grommet along the cable axially instead of with a rotary motion. 5. The junction chamber and motor compartment shall be separated by a

terminal board which shall protect the motor interior from foreign material gaining access into the mixer top. a. Connection shall be made between the threaded compressed type binder

post, thus securely affixing the cable wires to the terminal board. 6. The use of the terminal compressed type post and a terminal board O-ring

shall render the motor compartment leakproof from any liquid which may enter the terminal compartment. a. Epoxies, silicones, or other secondary sealing systems shall not be

considered acceptable.

H. Bearings: 1. All bearings shall have a minimum L-10 rated life of 100,000 hours in

accordance with ABMA 9 or ABMA 11. 2. The outboard propeller bearing shall be an angular contact bearing.


3. The motor shaft end shall be supported by 2 bearings. a. A roller and an angular contact ball bearing shall take up the axial and

radial loads while an angular contact ball bearing shall take up the axial loads.

4. The bearings shall be pre-loaded by a bearing loading nut located on the motor end of the shaft in order to reduce shaft deflection and increase bearing life and seal life.

5. Mixers without pre-loaded bearings will not be considered acceptable or equal.

I. Thermal sensors: 1. Thermal sensors shall be used to monitor stator temperatures. 2. The stator shall be equipped with 3 thermal switches embedded in the end

coils of the stator winding. 3. These shall be used in conjunction with, and supplemental to, external motor

overload protection, and wired to the control panel.

J. Moisture protection: Moisture probes are required within the motor seal oil chamber and the propeller hub oil chamber.

K. Motor Monitor Relay: 1. Provide a motor monitor relay for interconnection with the thermal sensors and

moisture probes. 2. Relay shall have alarm contact rated for 5 Ampere at 120 VAC at minimum. 3. If motor over temperature condition is sensed or leakage is detected, the

sensor shall cause the alarm relay contacts to change state. 4. Relay shall be mounted in the control panel as shown on the drawings. 5. Refer to the control schematics shown on the drawings and coordinate with

the PICS as defined in Section 17100.

L. Oil housing: 1. The oil housing shall contain 2 compartments consisting of an inner and an

outer section with 4 ports to connect and facilitate oil flow. 2. In the event that the mixed media bypasses the other seal, this design will

allow the outer compartment to collect the heavier (denser) fluids by means of a simple gravity process.

M. Mechanical seals: 1. Each mixer shall be provided with 2 sets of lapped end-face type mechanical

seals running in oil reservoirs for cooling and lubrication. a. The mechanical seals shall be made of silicon carbine. b. In order to avoid seal failure due to sticking, clogging, and misalignment

from elements contained in the mixed media, only the seal faces of the outer seal assembly and its retaining clips shall be exposed to the mixed media.

c. All other components shall be contained in the oil housing. d. All seal faces must be capable of relapping.

2. The seals shall require neither maintenance nor adjustment, but shall be easy to check and replace. a. Shaft seals without positively-driven rotating members shall not be

considered acceptable.


N. Guide rail system: 1. The mixer manufacturer shall supply 2 stainless steel guide rail systems to

mount mixers in various basins and to guide the unit during installation and removal from service.

2. The assembly shall consist of an upper support, positioning device, bottom assembly, mixer support assemblies, and 4-inch by 4-inch guide pipe.

3. All guides and supports shall be made of Type 304 stainless steel. a. The upper bracket shall be fitted with a special receptacle that securely

holds and supports the hoisting assembly while the mixer is raised, lowered, installed, or removed from the tank.

b. The bottom assembly shall be bolted to the floor of the tank, and provide support for the guide pipe.

4. The assembly shall also be provided with cable holders to secure the mixer electric power and control cables (1 every 5 feet). A cable mesh system may also be used to secure the power cable. a. Their purpose shall be to prevent the electric cable from becoming

entangled in the mixer propeller during operation. b. In addition, the mast shall be constructed with a positioning locking plate

which will work in conjunction with a lock pin on the upper guide holder to positively lock the mast in place at various operating angles.

5. The mixer may have the capability of redirecting the centerline of its jet to 40 degrees in a vertical plane and 120 degrees in a horizontal plane, without draining the tank.

O. Manual crane: 1. One manual crane shall be supplied.

a. The crane shall be able to be moved to each mixer location. b. The boom and winch shall be easily assembled and removed from the

crane mast to better facilitate assembly and storage requirements, respectively.

c. The crane shall be capable of rotating a mixer 360 degrees. 2. The crane shall be capable of lifting the mixer assembly over standard handrail

located at the top of the basin. a. The crane shall be capable of hoisting the entire weight of the mixer

assembly. b. The winch shall be of marine grade construction, and shall be suitable for

use with a portable RIDGID electric drive operator. c. The main body of the crane (excluding the winch) shall be constructed of

Type 304 stainless steel. d. The entire manual crane assembly shall weigh no more than 70 pounds.

3. No less than 40 feet of Type 316 stainless steel cable (minimum 1/4-inch diameter) shall be supplied.


A. Test and inspections: The mixer manufacturer shall perform the following inspections and tests on each mixer before shipment from the factory: 1. Propeller, motor rating, and electrical connections shall first be checked for

compliance to the customers purchase order. 2. A motor and cable insulation test for moisture content or insulation defects

shall be made.


3. Prior to shipment, the mixer shall be run dry to establish correct rotation and mechanical integrity.

4. The mixer shall be run for a minimum of 30 minutes submerged, at a minimum of 6 feet underwater.

5. After operational test item number 4 is complete, operational test item number 2 is to be performed again.

6. A written report stating the foregoing steps have been done must be supplied with each mixer at the time of shipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install, wire and test mixers, motors, and accessories according to the manufacturer’s printed instructions.

B. Test mixer monitoring unit local and remote control and monitoring, per manufacturer's instructions, using thermal sensor simulation.

3.02 COMMISSIONING

A. As specified in Section 01650, 15958, and this Section.

B. Manufacturer services. 1. Provide Manufacturer’s Certificate of Source Testing. 2. Provide Manufacturer’s Certificate of Installation and Functionality

Compliance. 3. Training and other on-site services.

Manufacturer Rep Onsite

Source Testing (Witnessed or

Non-witnessed)

Training Requirements

Installation Testing

Functional Testing

Process Operational

Period Maintenance

(hrs per session)

Operation (hrs per session) Trips

Days (each trip) Trips


Days (each trip)

Non-witnessed 4 2 1 2 1 2 Not required

3.03 SCHEDULE

A. Tag Numbers: 1. SST-LMU-001 - Anaerobic Mixer 1. 2. SST-LMU-002 - Anaerobic Mixer 2.

END OF SECTION

March 1, 2019 - CONFORMED 11312E-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/11312E (CONFORMED)

SECTION 11312E

HORIZONTAL SCREW CENTRIFUGAL PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Pump systems including screw-centrifugal pumps and drives.

B. Related sections: 1. Section 01140 - Work Restrictions. 2. Section 01600 - Product Requirements. 3. Section 01610 - Project Design Criteria. 4. Section 01650 – Facility Startup/Commissioning. 5. Section 01730 - Operation and Maintenance Data. 6. Section 01783 - Warranties and Bonds. 7. Section 05190 - Mechanical Anchoring and Fastening to Concrete and

Masonry. 8. Section 09960 - High-Performance Coatings. 9. Section 15050 - Common Work Results for Mechanical Equipment. 10. Section 15170 – Electrical Motor, Induction, 600 volts and blow. 11. Section 15958 - Mechanical Equipment Testing.

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. American Society of Mechanical Engineers (ASME): 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Class 25, 125, and 250. 2. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

C. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A 108 - Standard Specification for Steel Bars, Carbon and Alloy, Cold-

Finished. 3. A276 - Standard Specification for Stainless Steel Bars and Shapes. 4. A283 - Standard Specification for Low and Intermediate Tensile Strength

Carbon Steel Plates. 5. A532 - Standard Specification for Abrasion-Resistant Cast Irons. 6. A536 - Standard Specification for Ductile Iron Castings. 7. A582 - Standard Specification for Free-Machining Stainless Steel Bars. 8. B584 - Standard Specification for Copper Alloy Sand Castings for General

Applications. 9. E10 - Standard Test Method for Brinell Hardness of Metallic Materials. 10. F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and

Studs. 11. F594 - Standard Specification for Stainless Steel Nuts.


D. Hydraulic Institute (HI): 1. 1.1-1.2 - Centrifugal Pumps for Nomenclature and Definitions. 2. 1.03 - Rotodynamic (Centrifugal) Pumps for Design and Application. 3. 1.6 - Centrifugal Pump Tests. 4. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application,

Sound, and Measurement and Decontamination.

1.03 DEFINITIONS

A. Pump head (total dynamic head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 1.1-1.2, 1.3, 1.6, and 9.1-9.5 and as modified in this Section.

B. Flow, head, efficiency, and motor horsepower specified in this Section are minimums unless stated otherwise.

C. ASD: Adjustable Speed Drive


A. Screw centrifugal pumps with components: Pump, drives, bearings, seals or packing, couplings, base plates, pedestals and suction elbows, guards, supports, anchor bolts, necessary valves, gauges, taps, lifting eyes, stands, and other items as necessary for a complete and operational system.

B. Design requirements: 1. Pump performance characteristics:

a. As specified in the Pump Schedule. b. Performance tolerances shall be the same as the test tolerances specified

in Section 15958. 2. Motor characteristics: As specified in the Pump Schedule.

1.05 SUBMITTALS


B. Torsional analysis: Submit as specified in Section 15050 when scheduled.

C. Furnish motor submittals as specified in Section 15170.

D. Manufacturer’s Representatives qualifications as specified in Section 01650.

E. Provide vendor operation and maintenance manual as specified in Section 01730.



B. Provide pumps in this Section from same manufacturer.

C. Manufacture’s Certificate of Installation and Functionality Compliance as specified in Section 01650.





A. Environmental requirements: As specified in Section 01610.


A. Coordinate work with restrictions as specified in Section 01140.

B. Coordinate work with Commissioning and Start-up as specified in Section 01650.

1.10 WARRANTY


1.11 MAINTENANCE

A. Special tools: For each type or size of pump specified, provide 1 set of all special tools required for complete assembly or disassembly of all pump system components.

B. Spare parts: Deliver the following as specified in Section 01600: 1. Seal packing material: 1 set of each type supplied. 2. Mechanical seal: 1 complete seal assembly for each type supplied. 3. Pump bearings: 1 set of radial and 1 set of thrust bearings for each pump size

supplied. 4. Impeller wear liner: 1 wear liner for each size of pump. 5. Pump impeller: 1 replacement impeller for each size supplied.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. The pumps are to be manufactured by following or equal: 1. Wemco Pumps, Hidrostal model. 2. Hayward Gordon XCS series.

2.02 MATERIALS

A. General: Materials in the Pump Schedule shall be the type and grade as specified in this Section.

B. Cast iron: In accordance with ASTM A48, Class 30 minimum.

C. Hi-chrome cast iron: In accordance with ASTM A532, Class III, Type A at 450 Brinell hardness.

D. Ductile iron: In accordance with ASTM A536, Grade 60-42-10.


E. Leaded tin bronze: In accordance with ASTM B584, Alloy C93800.

F. Type 316 stainless steel: In accordance with ASTM A276, Type 316 stainless steel.

G. Type 416 stainless steel: In accordance with ASTM A582, Type 416 stainless steel.

H. Steel: In accordance with ASTM A108, Grade as scheduled.

I. Structural steel: In accordance with ASTM A283, Grade D.

2.03 GENERAL PUMP CONSTRUCTION

A. Type: Industrial (heavy) duty, screw centrifugal pumps meeting performance and design requirements and features as specified in this Section.

B. Access to impeller: Back pull out design for bearing and impeller access without disconnecting piping.

C. Fasteners: Provide Type 316 stainless steel fasteners in accordance with ASTM F593 and ASTM F594.

2.04 PUMP CASINGS

A. Material: As scheduled.

B. Type: 1 piece case with liner; case with integrally cast suction and discharge nozzles; strength, weight, and thickness to maintain accurate alignment.

C. Suction and discharge piping connections: Flanged in accordance with ASME B16.1, Class 125, ASME B16.5, Class 150, or higher-pressure class as required to meet Design Working Pressure.

D. Discharge flange shall be centered on the casing, oriented as indicated on the Drawings.

E. Provide casings with both 3/4-inch NPT high point vent and low point drain taps.

F. Provide 1/2-inch NPT taps with pressure gauge and block valve on the discharge flange.

G. Design to withstand a design working pressure not less than 1.10 times the maximum shutoff total dynamic head with the maximum diameter impeller at the maximum operating speed plus the maximum suction static head.

H. Design to withstand a 5-minute hydrostatic test pressure not less than 1.5 times the design working pressure.

I. Suction and discharge piping connections: Flanged in accordance with ASME B16.1, Class 125, ASME B16.5, Class 150, or higher-pressure class as required to meet Design Working Pressure.

J. Design replaceable suction liner for the pump case; material as scheduled.


2.05 IMPELLERS

A. Material: As scheduled. 1. When nodular or ductile iron is scheduled, provide 0.015 inch thickness

aluminum/titanium oxide ceramic coating having a Rockwell C hardness of 60 minimum and a density of 3.5 grams per cubic centimeter.

B. Design with single-passage, single vane screw-centrifugal impeller with smooth water passages to reduce clogging by rags, stringy or fibrous materials on impellers, or shafting.

C. Design impeller or impeller flange to discharge solids from the space between the backplate and the impeller.

D. Design capable of passing solids with a sphere size as scheduled.

E. Design conical impeller and suction piece so that axial adjustments of the impeller result in uniform changes in clearance between the two.

F. Provide static, dynamic, and hydraulic balance of impeller and complete rotating element.

G. Method of securing impellers to shafts: Keyed and secured by a nut locked in place, but readily removable without use of special tools.

2.06 SHAFT

A. Material: 1. As scheduled. 2. Hard faced or with hardened sleeve where shafts pass through bearings and

stuffing boxes. Harden to 550 Brinell hardness number minimum in accordance with ASTM E10.

3. If mechanical seals are scheduled and mechanical seal cannot be installed on hardened shaft, shaft is not to be hardened in the mechanical seal area.

4. If sleeve provided, sleeve to be renewable and key locked in place.

B. Strength: Able to withstand minimum 1.5 times maximum operating torque and other imposed loads.

C. Resonant frequency: As specified in Sections 15050 and 15958.

D. Deflection: Maximum 0.002 inch under operating conditions.

E. Design a means to adjust shaft position or impeller case position to adjust impeller clearance.

F. When mechanical seals are specified, provide a means to allow removal of the seal without driver or suction and discharge piping removal.


2.07 STUFFING BOX

A. Type: 1. A 2-piece radially split stuffing box with provision for lantern ring and 6 packing

rings minimum. 2. As specified in Section 15050.

B. Material: As scheduled.

C. Provide separate stuffing box housing (not integral to the rear liner or wear plate) suitable for shaft seal type scheduled.

D. Shaft seal type: As scheduled and as specified in Section 15050.

2.08 BEARINGS

A. Bearing type: Anti-friction in accordance with ABMA standards; self-aligning spherical roller type radial bearings; angular contact ball type, or tapered roller for thrust bearings.

B. Bearing lubrication: 1. When grease lubrication is scheduled, provide:

a. External grease fittings with grease relief pipe. b. Lip type grease seals and labyrinth type grease deflectors at both ends of

bearing housings, able to prevent entrance of contaminants. 2. When oil lubrication is scheduled, provide:

a. Pressure lubricating system or separate oil reservoir type system. b. Oil filler pipe. c. External level indicator gauge.

3. Size sufficiently to safely absorb heat energy normally generated in bearing under maximum ambient temperature of 60 degrees Celsius.

C. Bearing life: Minimum L10 life of 100,000 hours at rated design point but not less than 24,000 hours in accordance with ABMA 9 or 11 at bearing design load imposed by pump shutoff with maximum sized impeller at rated speed.

2.09 COUPLINGS

A. Type: As scheduled and specified in Section 15050.

B. Flexible coupling life: Infinite at up to 0.3-degree misalignment angle total or per disk for disk type at maximum operating loads.

C. Design coupling to withstand a minimum of 1.5 times the maximum operating torque and other imposed loads.

2.10 VARIABLE DRIVE

A. Drive Type: MagnaDrive ASD 8.5

B. Performance Requirements:


1. Rated Continuous Operation Capacity: The MagnaDrive ASD 8.5 is rated to deliver 0.29 ft-lbf torque per rpm slip up to a maximum of 58 ft-lbf torque at 200 rpm slip in a fully coupled condition.

2. Peak Operation Capacity (safety factor): The MagnaDrive ASD 8.5 is rated to deliver not less than 1.5 times the peak rated continuous operation capacity for not more than 3 minutes per hour.

3. Heat dissipation capacity. The MagnaDrive ASD 8.5 is rated to dissipate heat in accordance with the following: a. 1200 RPM - 4 HP b. 1800 RPM - 6 HP c. 3600 RPM - 10 HP

C. Drive Manufacturers: 1. The following or equal:

a. ASD: MagnaDrive Corporation, 14660 NE North Woodinville Way, Woodinvile

D. Components: 1. Provide Adjustable Speed Drives (ASD) capable of transmitting design motor

speed and torque. 2. Electroless nickel & tin plated neodymium iron boron magnets 3. Zinc plated steel conductor assembly, hubs, and rotor plate 4. Uncoated copper and magnet rotor 5. Anodized aluminum magnet rotors, center pivot, air gap spacer, and outer tube 6. Electroless nickel plated steel center shaft

E. Actuator Assembly: 1. Provide actuator assembly capable of regulating drive speed. 2. Signal Interface 4-20 mA 3. Actuator motor stall torque not to exceed torque capability of the ASD 4. Suitable for full 90-degree stroke of ASD control arm. 5. Manual override hand wheel 6. Position indicator 7. 120 VAC 8. Stroke time equals 30 second or less for 90 degree stroke 9. NEMA 4 Enclosure

F. Operator Interface: 1. No operator interface to be provided locally on the actuator. 2. Automatic ASD speed control Engage/Disengage shall be controlled via

remote 4 to 20 mA analog signal.

G. Identification: 1. MagnaDrive shall be identified as stamped into the drive. 2. Actuator shall have a readily visible equipment identification tag.

2.11 SUPPORTS, PEDESTALS, AND BASEPLATES

A. Materials: Same as pump casing, ASTM A 36 or ASTM A283 steel, hot-dip galvanized after fabrication, and coated as specified in Section 09960.

B. Pump and driver support strength: Able to withstand minimum 1.5 times maximum imposed operating loads or imposed seismic loads, whichever is greater.


C. Configuration: Allow easy access to stuffing boxes, bearing frames, and couplings.

D. Design a structural steel base and support system for the drive arrangement specified in this Section and as schematically indicated on the Drawings. 1. Horizontally mounted: Design common pump and driver baseplate; minimum

3/8-inch thick fabricated steel; side mount motors on belt driven units and design adjustable motor mount.

2. Vertically mounted: Design pedestal base and provide suction elbow with hand-hole for inspection; pedestal of sufficient height to keep suction elbow at least 1 inch above the equipment foundation or floor.

E. Anchor bolts: As specified in Section 05190.

2.12 EQUIPMENT GUARDS

A. Provide equipment safety guards as specified in Section 15050.

2.13 DRIVERS

A. Horsepower: 1. As scheduled. 2. Listed driver horsepower is the minimum to be supplied.

a. Increase driver horsepower, if required, to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout.

b. When scheduled driver is a motor, increase motor horsepower if required to prevent operation in the service factor.

c. Make all structural, mechanical, and electrical changes required to accommodate increased horsepower.

B. Motors: Provide motors as specified in Section 15170 and as specified in this Section: 1. Revolutions per minute: As scheduled: 2. Enclosure: As scheduled. 3. Electrical characteristics: As scheduled. 4. Efficiency, service factor, insulation, and other motor characteristics: As

specified in Section 15170. 5. Motor accessories: As specified in Section 15170. 6. Coordinate motors with the magnetic drive manufacturer to ensure

compatibility between the motor and variable speed drive.

2.14 FINISHES

A. Finishes: Prepare surfaces and apply protective finishes as specified in Section 09960.


PART 3 EXECUTION

3.01 INSTALLATION

A. Installation shall be as indicated on the Drawings, in accordance with written instructions of the pump manufacturer and drive manufacturer, and as specified in Section 15050.

3.02 COMMISSIONING

A. As specified in Section 01650 and this Section.

B. Manufacturer services: Manufacturer Rep Onsite


Non-witnessed)



Functional Testing

Process Operational

Period Maintenance

(hrs per session)




Days (each trip)

Witnessed 4 2 1 1 1 1 24 hour on-call

C. Source Testing: 1. Pump:

a. Test witnessing: As scheduled and as specified in Section 01650. b. Performance test: Test level as scheduled; test as specified in Section

15958. c. Vibration test: Test level as scheduled; test as specified in Section 15958. d. Noise test: Test level as scheduled; test as specified in Section 15958.

2. Pump casing: Hydrostatic pressure tests if specified in this Section. 3. Motor: Test as specified in Section 15170. 4. Drive:

a. Conduct on each Magnetic Drive ASD. b. Perform under actual or approved simulated operating conditions. c. Test for continuous 12-hour period without malfunction. d. Demonstrate performance by operating during the continuous period while

varying the application load, as the input conditions allow, verifying system performance.

e. Record test data for report.

D. Functional Testing: 1. Pump assembly:

a. Performance test: Test level as scheduled; test as specified in Section 15958.

b. Vibration test: Test level as scheduled; test as specified in Section 15958. c. Noise test: Test level as scheduled; test as specified in Section 15958.

2. Motor: Test as specified in Section 15170. 3. Drive:

a. Inspect Magnetic Drive for proper installation and operation. b. 2.Record test data for report.


3.03 PUMP SCHEDULE

Tag Numbers

RAS Pumps: SST-SLP-003, SST-

SLP-004

WAS Pumps: SST-SLP-005, SST-

SLP-006 General Characteristics:

Service Return Activated Sludge

Waste Activated Sludge

Quantity 3 (2 installed) 2 First Named Manufacturer’s Model Number

Hayward Gordon XCS8C

Hayward Gordon XCS4MC

Maximum Noise, dBA at 3 feet 85 85 Torsional Analysis Not Required Not Required Minimum Pumped Fluid degrees Fahrenheit

50 50

Normal Pumped Fluid Degrees Fahrenheit 70 70 Maximum Pumped Fluid Degrees Fahrenheit

85 85

Pump Characteristics: Pass Minimum Sphere Size, inches 2 1/4 2 Bearing Lubrication Grease Grease Shaft Seal Type Dual Mechanical Dual Mechanical Coupling Type Spacer Spacer Speed Control Fixed Motor Speed

with Magnetic Drive Fixed

Maximum Pump revolutions per minute 1,200 1,200 Minimum Pump revolutions per minute N/A N/A Rated Design Point (at Maximum Revolutions per Minute): Flow, gallons per minute 1,045 360 Head, feet 15 30 Minimum Efficiency, percent 70 67 Required Condition 2 (at Maximum Revolutions per Minute): Flow, gallons per minute 1,250 450 Head Range, feet 13 25 Minimum Efficiency, percent 70 67 Required Condition 3 (at Maximum Revolutions per Minute): Flow, gallons per minute 750 200 Head Range, feet 20 37


Tag Numbers


SLP-004


SLP-006 Minimum Efficiency, percent 65 50 Other Conditions: Shut Off Head, Feet 33 42 Maximum NPSHr at every Specified Flow, feet

8 9

Minimum NPSHa at every Specified Flow, feet

4 9

Minimum Suction Static Head, feet 9.35 9.46 Maximum Suction Static Head, feet 9.46 9.57

Pump Materials: Pump Casing Cast Iron Cast Iron Suction Liner Hi-Chrome Cast Iron Hi-Chrome Cast Iron Impeller Hi-Chrome Cast Iron Hi-Chrome Cast Iron Impeller Shaft Key 416 Stainless 416 Stainless Shaft Steel, Gr 1141, 1045,

or 4140 Steel, Gr 1141, 1045,

or 4140 Shaft Sleeve 316 or 416 Stainless 316 or 416 Stainless Stuffing Box Cast Iron Cast Iron

Driver Characteristics: Driver Type Motor Motor Drive Arrangement Direct Coupled Direct Coupled Minimum Driver Horsepower 7.5 5 Maximum Driver Speed, revolutions per minute

1,200 1,200

Motor Characteristics (when motor is driver type): Inverter Duty Rated Yes Yes Motor Voltage/Phases/Hertz 460/3/60 460/3/60 Enclosure Type TEFC TEFC

Source Testing: Test Witnessing Not Witnessed Not Witnessed Performance Test Level 1 1 Vibration Test Level None None Noise Test Level None None

Function Testing:


Tag Numbers


SLP-004


SLP-006 Performance Test Level 1 1 Vibration Test Level None None Noise Test Level None None

END OF SECTION

March 1, 2019 - CONFORMED 11312J-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/11312J (CONFORMED)

SECTION 11312J

SUBMERSIBLE VORTEX SUMP PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Packaged submersible vortex sump pumps, with a control panel and instrumentation.

B. Related sections: 1. Section 01140 - Work Restrictions. 2. Section 01600 - Product Requirements. 3. Section 01610 - Project Design Criteria. 4. Section 01650 – Facility Startup/Commissioning. 5. Section 01730 - Operation and Maintenance Data. 6. Section 01783 - Warranties and Bonds. 7. Section 09960 - High-Performance Coatings. 8. Section 13390 - Packaged Control Systems 9. Section 15050 - Common Work Results for Mechanical Equipment. 10. Section 15958 - Mechanical Equipment Testing. 11. Section 16600 - Disconnect Switches and Enclosures. 12. Section 17200 - Instrumentation and Control Cabinets and Associated

Equipment. 13. Section 17380 - Field Instrumentation and Sensing Devices.

1.02 REFERENCES

A. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A276 - Standard Specification for Stainless Steel Bars and Shapes. 3. D2000 - Standard Classification System for Rubber Products in Automotive

Applications.

B. Hydraulic Institute (HI): 1. 1.1-1.2 - Centrifugal Pumps for Nomenclature and Definitions. 2. 1.3 - Rotodynamic (Centrifugal) Pumps for Design and Application. 3. 9.1-9.5 - Pumps - General Guidelines for Types, Application, Definitions, Sound

Measurement, and Documentation. 4. 11.6 - Submersible Pump Tests.

C. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum)

1.03 DEFINITIONS

A. NEMA: 1. Type 4X enclosures in accordance with NEMA 250.


B. Pump head (Total Dynamic Head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 1.1-1.2, 1.3, 9.1-9.5 and 11.6 and as modified in this Section.


A. Submersible sump pumps with components: Pumps, motors, electrical devices internal to pump housing, all submersible cabling for power and control conductors, and Vendor Control Panels (if scheduled), and other items as required for a complete and operational system.

B. Design requirements: 1. Pump performance characteristics: As specified in the Pump Schedule, Pump

Performance Characteristics: a. As specified in the Pump Schedule. b. Performance tolerances shall be the same as the test tolerances specified

in Section 15958. 2. Motor characteristics: As specified in the Pump Schedule. 3. Suitable for pumping raw sewage.

1.05 SUBMITTALS


B. Calculations per Section 15050 are not required for pumps specified in this Section.

C. Manufacturer’s Representatives qualifications as specified in Section 01650.




B. Provide pumps specified in this Section from same manufacturer.







A. Coordinate work with restrictions specified in Section 01140.



1.10 WARRANTY


1.11 MAINTENANCE

A. Special tools: For each type or size of pump specified, provide 1 set of all special tools required for complete assembly or disassembly of the pump system components.

B. Spare parts: Deliver the following as specified in Section 01600: 1. Pump impeller, trimmed to match installed impeller. 2. Mechanical seal set.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Pumps: One of the following or equal: 1. KSB. 2. Barnes. (Crane Pumps & Systems), SEV-DS series. 3. ITT Goulds Pumps.

2.02 MATERIALS

A. Cast Iron: ASTM A48, Class 30 minimum.

B. Stainless Steel: ASTM A276 or equal.

C. Buna N: ASTM D2000.

2.03 PUMP CASING

A. Material: Cast iron.

B. Design Working Pressure: 1.5 times the shut off pressure.

C. Provide support legs on sump bottom and clearance for suction entrance.

D. The discharge connection shall be a 2-inch NPT vertical connection.

2.04 IMPELLERS

A. Material: Cast iron.

B. Vortex; nonclogging; with pump-out vanes on backside; dynamically balanced; close coupled to motors.

C. Method of securing to shafts: Threaded lock nut or similar connection.


2.05 PUMP SHAFTS

A. Material: 400 series stainless steel.

2.06 BEARINGS

A. Upper bearing: Single row; oil or grease lubricated.

B. Lower bearing: Single row; oil or grease lubricated.

2.07 SHAFT SEAL

A. Double mechanical seal.

B. Materials: 1. Silicon carbide versus silicon carbide seal faces. 2. Carbon versus ceramic seal faces.

C. Elastomer and hardware: Buna-N and 300 series stainless steel.

2.08 DRIVERS

A. Motors: 1. NEMA B design. 2. Oil or air filled submersible motor. 3. Insulation:

a. 1.5 horsepower and above: Class F. b. Under 1.5 horsepower: Class F.

4. Power: 230/460 volt, 3 phase, 60 hertz. 5. 1.15 service factor. 6. Pumps shall be able to operate continuously without exceeding pumps service

capacity when immersed in water up to 104 degrees Fahrenheit. 7. Cable: Minimum length sump depth to the VCP, plus 15 feet, armored,

waterproof cable securely attached to motors with watertight fittings.

2.09 FINISHES

A. Pump manufacturer to factory prime and coat pump/motor and discharge elbow as specified in Section 09960.

B. Contractor to provide touch-up field coatings as specified in Section 09960.

2.10 CONTROLS

A. General: 1. Provide a vendor control panel at each installation for control of the pumps,

except as indicated on the pump schedule.

B. Vendor control panel: 1. Construction and components as specified in Section 13390. 2. Enclosure:

a. As indicated in the pump schedule.


3. Electrical components: a. Main circuit breaker:

1) Flange-mounted operator: a) Pad-lockable in the off position.

2) Disconnects all power to the panel. 3) Interlock with the panel door.

a) Defeat mechanism. b. Motor starter for each pump:

1) Motor circuit protector circuit breaker. 2) Full voltage non-reversing magnetic starter. 3) Thermal or electronic overloads.

c. Control power transformer: 1) Primary voltage: 230/460 VAC, 3 phase, 60 hertz. 2) Secondary voltages:

a) Status points to the facility SCADA system: 120 volt. b) Additional voltages as required by the application.

3) Sized for all panel components plus 10 percent spare capacity. 4) Primary and secondary fuses.

4. Control components: a. Terminal strips:

1) Provide terminal strips for landing all external wiring. b. Relays, timers, and other components as required providing the specified

functionality and remote monitoring connections. 5. Simplex operation:

a. Front panel controls: 1) HAND/OFF/AUTO switch. 2) START pushbutton. 3) STOP pushbutton. 4) Momentary LOW LEVEL OVERRIDE pushbutton. 5) Running pilot light. 6) Stopped pilot light. 7) Power pilot light. 8) Pump fault pilot light. 9) High-High level alarm.

b. Remote monitoring and control: 1) Provide dry relay contact outputs for the following:

a) Pump Fault alarm. b) Pump Run status. c) High-High Level Alarm.

c. Operation: 1) Hand:

a) The pump shall run when the START pushbutton is pressed. b) The pump shall stop when the STOP pushbutton is pressed. c) The LOW-level switch shall stop the pump. d) The LOW-level switch shall be over ridden by the momentary

LOW LEVEL OVERRIDE pushbutton. 2) Off: Pump shall stop operation.

a) Placing the hand switch in the OFF position shall re-set all alarm conditions.

3) Auto: the pump shall operate automatically in response to level switch signals.


a) The pump shall start when the rising water level in the sump causes level switch HIGH-level switch to activate.

b) The pump shall stop when the falling water level in the sump causes level switch LOW-level switch to activate.

c) A high-high level shall cause the HIGH–HIGH level switch to activate and activate the HIGH–HIGH level alarm.

d. Operation: 1) Hand:

a) The pump shall run when the START pushbutton is pressed. b) The pump shall stop when the STOP pushbutton is pressed.

2) Off: Pump shall stop operation. a) Placing the hand switch in the OFF position shall re-set all alarm

conditions. 3) Auto: The pump shall operate automatically in response to level

switch signals. a) The lead pump shall start when the rising water level in the

sump causes level switch HIGH-level switch to activate. b) The lead pump shall stop when the falling water level in the

sump causes level switch LOW-level switch to activate. c) If the lead pump fault alarm is activated the standby pump shall

replace the lead pump. d) A high- high level shall cause the HIGH–HIGH level switch to

activate and activate the HIGH–HIGH level alarm.

2.11 LEVEL SENSORS

A. Type: Ball float as specified in Section 17380.

B. Cable Length: The length of the cable shall be equal to sump depth to the VCP plus 5 feet.

PART 3 EXECUTION

3.01 INSTALLATION

A. Installation shall be as indicated on the Drawings, in accordance with written instructions of the manufacturer, and as specified in Section 15050.

3.02 COMMISSIONING





Non-witnessed)



Functional Testing

Process Operational

Period Maintenance

(hrs per session)




Days (each trip)

Non-witnessed 4 2 1 1 1 1 24 hour on-call


a. Test witnessing: Not Required b. Performance test: Not Required c. Vibration test: Not required. d. Noise test: Not required.

2. Pump casing: Hydrostatic pressure tests if specified in this Section.



b. Vibration test: Not required. c. Noise test: Not required.

3.03 PUMP SCHEDULE

A. Pump characteristics:

Tag Numbers SST-SP-001 Location RAS Pump Station Sump Service Sump Pump Type Simplex Capacity, gpm 50 gpm Total Dynamic Head (TDH), Feet 20 feet Motor Horsepower 0.5 minimum Min. Shutoff Head, feet 28 feet Motor Speed, revolutions per minute 1,750 rpm VCP Required Yes VCP Enclosure NEMA 4 Solids Passage, Minimum 2" Discharge size, min 2" Efficiency, min percentage 35

END OF SECTION

March 1, 2019 - CONFORMED 11312K-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/11312K (CONFORMED)

SECTION 11312K

SUBMERSIBLE MEDIUM CAPACITY CENTRIFUGAL PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Submersible pump with features scheduled in the Pump Schedule.


Masonry. 8. Section 09960 - High-Performance Coatings. 9. Section 15050 - Common Work Results for Mechanical Equipment. 10. Section 15958 - Mechanical Equipment Testing. 11. Section 16120 - 480 Volt Motor Control Centers 12. Section 16600 - Disconnect Switches and Enclosures 13. Section 17200 - Instrumentation and Control Cabinets and Associated


1.02 REFERENCES

A. American Bearing Manufacturers’’ Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A108 - Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished. 3. A276 - Standard Specification for Stainless Steel Bars and Shapes. 4. A582 - Standard Specification for Free-Machining Stainless Steel Bars. 5. B148 - Standard Specification for Aluminum-Bronze Sand Castings. 6. B505 - Standard Specification for Copper Alloy Continuous Castings. 7. B584 - Standard Specification for Copper Alloy Sand Castings for General

Applications. 8. F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and

Studs. 9. F594 – Standard Specification for Stainless Steel Nuts.

C. CSA International (CSA).

D. Food and Drug Administration (FDA).


E. FM Global (FM).

F. Hydraulic Institute (HI): 1. 1.1-1.2 - Centrifugal Pumps for Nomenclature and Definitions. 2. 1.3 - Rotodynamic (Centrifugal) Pumps for Design and Application. 3. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application, Sound

Measurement, and Decontamination. 4. 14.6 – Rotodynamic Pumps for Hydraulic Performance Acceptance Tests

G. Insulated Cable Engineer’s Association (ICEA).

H. National Electrical Code (NEC).

I. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

J. Underwriters Laboratories, Inc.

1.03 DEFINITIONS

A. NEMA: 1. Type 4 enclosure in accordance with NEMA 250. 2. Type 4X enclosure in accordance with NEMA 250.

B. Pump head (total dynamic head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 1.1-1.2, 1.3, 9.1-9.5 and 14.6 and as modified in this Section.

C. Tolerances: As stipulated in the listed HI standards, unless specified more restrictively.

1.04 SYSTEM DESCRIPTIONS

A. Submersible sump pumps with components: Pumps, motors, base elbows, guide rails and lifting devices, electrical devices internal to pump housing, all submersible cabling for power and control conductors, and Vendor Control Panels (if scheduled), and other items as required for a complete and operational system.

B. Design requirements: 1. Pump performance characteristics: Refer to Sump Pump Schedule appended

to this Section. 2. Motor characteristics: Refer to Sump Pump Schedule appended to this Section.

1.05 SUBMITTALS


B. Furnish control panel submittals as specified in Section 17200.






B. Single source responsibility: Pumps specified in this Section shall be by 1 manufacturer.









1.10 WARRANTY


1.11 MAINTENANCE

A. Special tools: Deliver 1 set of special tools required for complete assembly or disassembly of pump system components for each type or size of pump specified.

B. Spare parts: Deliver the following as specified in Section 01600: 1. Thrust bearing set. 2. Radial bearing set. 3. Mechanical seal: 1 each size and type. 4. O-Ring set. 5. Power cable entry seal set. 6. Wear ring set (rotating and stationary).

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Submersible Pumps; One of the following or equal: 1. KSB, model KRT K150-315/126XG-S. 2. Flygt, model NP 3153 LT 3


2.02 MATERIALS

A. General: When materials are referenced in this Section or on the pump schedule, the compositions shall be the UNS Alloys, Types, or Grades in this Article unless specified or scheduled otherwise.

B. Cast iron: ASTM A48, Class 35 B minimum.

C. Nickel cast iron: ASTM A48, Class 35 minimum with 3 percent nickel added.

D. Steel: ASTM A108, Grade or UNS Alloy as specified or scheduled.

E. Stainless steel: ASTM A276 or ASTM A582, Type or UNS Alloy as specified or scheduled.

F. Bronze: ASTM B505 or ASTM B584, UNS Alloy C83600.

G. Zincless bronze: ASTM B505 or ASTM B584, Leaded Tin Bronze, UNS Alloy C92700.

H. Aluminum bronze: ASTM B148, ASTM B505 or ASTM B584, UNS Alloy C95200.

I. Fasteners: Stainless steel, ASTM F593 or ASTM F594, type or grade as specified.


A. The pump shall be an overhung impeller, close coupled, single stage, volute style, end suction submersible unit, capable of handling raw unscreened sewage, storm water and other solids laden fluids without clogging.

2.04 PUMP AND MOTOR CASING

A. Type: Watertight, air filled.

B. Material: Cast Iron (minimum).

C. Design working pressure: Minimum 1.10 times maximum shutoff total dynamic head with maximum diameter impeller at maximum operating speed plus maximum suction static head or minimum 20 pounds per square inch gauge.

D. O-ring seals: Capable of sealing mated surfaces (major components) watertight; with the following features:

1. Machined surfaces and grooves. 2. O-ring contact on 4 surfaces and O-ring compression on 2 surfaces. 3. Does not require specific fastener torque or tension to obtain watertight joint. 4. Does not require secondary sealing compounds, gasket, grease, or other

devices.

E. Testing: Perform 5-minute hydrostatic test of pump casing at minimum 1.5 times Design Working Pressure.


2.05 IMPELLERS

A. General: 1. Water passages: Smooth enough to prevent clogging by stringy or fibrous

materials. 2. Passage sizes: Large enough to pass solids with sphere size of 3 inches or

smaller for motors larger than 2 horsepower. 3. Casting: 1 piece, free of cracks and porosity. 4. Balance vanes: On impeller back shrouds. 5. Method for securing impeller to shafts:

a. For pumps 5 horsepower and less, secured by bronze nut or allen head bolt locked in place, but readily removable without the use of special tools.

b. For pumps greater than 5 horsepower, keyed to the shaft and secured by bronze nut or allen head bolt locked in place, but readily removable without the use of special tools.

B. Rotation: As indicated on the Drawings; clockwise looking from top when not indicated.

C. Balance: As specified in Section 15050.

D. Vibration criteria: As specified in Section 15958.

E. Type: As specified in the Pump Schedule: 1. Standard Impeller:

a. Material: Cast Iron (minimum). b. Dynamically balanced, double shrouded, multi-vane, non-clog design.

2.06 WEAR RINGS

A. Provide one of the following systems: 1. Wear ring system:

a. General: Used to provide efficient sealing between the volute and suction inlet of the impeller.

b. Volute wear ring: 1) Material: 420 SST. 2) Fitted to the volute inlet.

c. Impeller wear ring: 1) Material: 420 SST. 2) Heat-shrunk fitted onto the suction inlet of the impeller. 3) Flyght N impeller: part of replaceable suction cover.

2. Wear plate system: a. Material: Cast iron, ASTM A48, Class 40, with a minimum Brinell

Hardness of 250. b. Attached to the pump volute to prevent rotation. c. Replaceable and adjustable to maintain proper clearances between the

wear plate and the impeller.

2.07 PUMP SHAFTS

A. Material: Type 420 stainless steel; turned, ground, and polished.


B. Features: 1. Strength: Able to withstand minimum of 1.5 times maximum operating torque

and other loads. 2. Resonant frequency: As specified in Sections 15050 and 15958. 3. Maximum deflection: Minimum 0.002 inches under operating conditions.

C. Tapered to fit at impeller with key and bolt for securing impeller.

D. Pump and motor shaft shall be a solid continuous shaft.

2.08 BEARINGS

A. Pump shaft shall rotate on a minimum of 2 permanently sealed, grease lubricated bearings:

1. Upper bearing for radial forces shall be self-aligning spherical roller type. 2. Lower bearing for combined axial and radial forces shall be angular contact ball

type.

B. Bearing type: Anti-friction in accordance with ABMA standards.

C. Bearing lubrication system shall be sized to safely absorb heat energy normally generated in bearing under maximum ambient temperature of 60 degrees Celsius.

D. Bearing life: 1 of the following whichever provides longer bearing life in intended service:

1. Minimum ABMA 9 or 11 L10 bearing life of 50,000 hours at rated design point. 2. Minimum 24,000 hours at bearing design load imposed by pump shutoff with

maximum sized impeller at rated speed.

2.09 SHAFT SEALS

A. Upper seal unit material: 1 stationary tungsten-carbide or silicon-carbide ring and 1 positively driven rotating carbon or silicon-carbide ring or tungsten-carbide ring.

B. Lower seal unit material: 1 stationary and 1 positively driven rotating tungsten-carbide ring.

C. Features: 1. Tandem arrangement running in an oil chamber. 2. Design oil chamber to assure that air is left in the oil chamber to absorb the

expansion of the oil due to temperature variations. 3. Oil in oil chamber shall be FDA approved, paraffin type, colorless, odorless, and

non-toxic. 4. Independent spring system between seal interfaces able to withstand maximum

suction submergences. 5. Does not require pressure differential to effect sealing. 6. Does not use pumped media for lubrication. 7. Lower mechanical seal effectively lubricated from oil chamber housings. 8. Not damaged when pump is run dry (unsubmerged) for extended periods. 9. Springs and other hardware: Stainless steel, 300 or 400 series.


2.10 DISCHARGE BASE AND ELBOW

A. Materials: Same as pump casing.

B. Features: 1. Structurally capable of firmly supporting guide rails, discharge piping, and

pumping unit under operating conditions. 2. Integral support legs or pads with bolting to sump floor provisions: 1 or more. 3. Incorporates 90 degree flanged elbow that receives horizontal flow from pump

and discharges flow vertically. 4. Discharge interface:

a. Sealing of the pumping unit to the discharge connection shall be accomplished by a machined metal-to-metal watertight contact.

b. Self-aligning without having to enter the wet well. c. Discharge elbow to mate to pump discharge and transition to discharge

piping.

2.11 GUIDE RAILS, BRACKETS, FASTENERS, AND LIFTING CHAIN FOR EACH PUMP

A. Material: Type 316 stainless steel, with the following features: 1. Dual pipes or dual rails that extend from discharge base to upper bracket

unless scheduled otherwise. 2. Rail wall thickness sufficient to suspend pump unit between brackets plus

minimum 50 percent safety factor. 3. Sized to fit discharge base and sliding bracket of pump. 4. Integral, self-aligning, guide rail sliding brackets that seal pump to discharge

base under operating conditions. 5. Upper guide rail bracket. 6. Intermediate guide rail brackets where indicated on the Drawings or at 10 foot

maximum intervals. 7. Lifting chain of sufficient strength and length to permit safe removal of pump

unit from sump.

2.12 DRIVERS


a. Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout.



B. Motors: 1. Revolutions per minute: As scheduled: 2. Enclosure: As scheduled. 3. Electrical characteristics: As scheduled.

C. Motor construction: 1. Squirrel cage induction motor, shell type design.


2. If explosion proof motor is scheduled, provide motor that is UL or FM listed for NEC Class I, Division 1, Groups C and D service, whether submerged or unsubmerged.

3. NEMA design type: B. 4. Motor insulation, either one:

a. Class F, moisture resistant, rated for 155 degrees Celsius. b. Class H, moisture resistant, rated for 185 degrees Celsius.

5. The motor shall be designed for continuous duty handling pumped media of 40 degrees Celsius and capable of a minimum of 15 evenly spaced starts per hour.

6. The motor shall be capable of continuous operation under load with the motor submerged, partially submerged, or exposed, without derating the motor.

7. Motor cooling, one of the following: a. Motor cooled by the surrounding media, either using a glycol cooling

system or pumped cooling jacket. 1) Glycol Cooling system:

a) Self-contained glycol cooling system with recirculating impeller. 2) Pumped Cooling jacket:

a) Non-clogging ports and channels that use pumped fluid as the cooling media.

b) Functional with motor submerged, partially submerged, or exposed.

c) Provide capability to relieve entrapped air from the system. b. Spray systems, air moving equipment or other secondary cooling systems

are not acceptable. 8. Motor sealing: Design motor case and seals to withstand 65 feet of

submergence.

D. Power and control cables: 1. Submersible to same water depth as motor casing. 2. Type SPC with Hypalon/Buna N or chloroprene rubber jacket. 3. Insulation rated for 90 degrees Celsius. 4. Non-wicking fillers. 5. Length: Sufficient to connect to surface junction box (without the need of

splices) as indicated on the Drawings or 30 feet, whichever is greater. 6. All power and control conductors shall terminate at terminal blocks in the local

control panel or junction box. 7. Sized in accordance with NEC, ICEA, and CSA specifications. 8. Provide stainless steel cable and stainless steel wire braid sleeve to support

power cable from underside of wet well roof slab or access frame.

E. Cable entry/junction chamber: 1. Cable entry seal design shall not require specific torque requirements to insure

a watertight and submersible seal. 2. Cable entry seal shall consist of a single cylindrical elastomer grommet, flanked

by stainless steel washers. 3. The entry body shall perform compression and strain relief that is separate from

the sealing function. 4. The cable entry junction chamber shall be separate from the motor chamber to

prevent foreign material from gaining access to the motor interior through the top of the pump.

5. Epoxy resin used for motor junction box to prevent water intrusion into motor.


F. Control/protection relay: 1. Each pump shall be supplied with its own self-contained control/protection relay

to provide for the direct connection to all internal pump monitoring devices, including: a. Thermal protection: Provide automatic reset motor stator temperature

detectors, 1 switch in each phase winding. If any detector is activated, the sensor shall activate an alarm and shut down the motor. The thermal detectors shall activate when the stator temperature exceeds 125 degrees Celsius.

b. Moisture detection: one of the following: 1) Provide capacitive type leakage sensor for the detection of water in

the oil chamber or a moisture sensor in the lower motor chamber to detect any fluid in the motor. The sensor shall have an explosion proof rating.

2) Provide a small float to detect the presence of water in the stator chamber.

2. Relay shall have alarm contact rated for 5 Ampere at 120 VAC at minimum. 3. If motor over temperature condition is sensed or leakage is detected, the

sensor shall cause the alarm relay contacts to change state. 4. Relay shall be mounted in the control panel as shown on the drawings. 5. Refer to the control schematics shown on the drawings and coordinate with

the PICS as defined in Section 17100.

2.13 CONTROLS

A. General: 1. Provide a local control panel for control of the pumps in the field.

B. Local control panel: 1. Construction and components as specified in Section 17200. 2. Enclosure:

a. As indicated in the Pump Schedule. 3. Front panel controls:

a. HAND/OFF/AUTO selector switch for each pump. b. RUNNING pilot light for each pump. c. STOPPED pilot light for each pump. d. RESET pushbutton. e. FAULT pilot light for each pump.

1) Pump fault is defined as motor overload, high temperature, or excessive moisture.

f. HIGH LEVEL ALARM pilot light. g. LOW-LOW LEVEL ALARM pilot light. h. LEAD/LAG selector switch.

1) Required only for duplex sump pump systems. 4. Power supply:

a. As indicated in the Pump Schedule. 5. Electrical components:

a. Main circuit breaker: 1) As specified in Section 16600. 2) Flange-mounted operator.

a) Pad-lockable in the off position. 3) Disconnects all power to the panel.


4) Defeatable interlock with the panel door. b. Motor starter for each pump:

1) As specified in Section 16120, located in the MCC. 2) Motor circuit protector circuit breaker. 3) Full voltage non-reversing magnetic starter. 4) Thermal or electronic overloads.

c. Control power transformer: 1) Primary voltage: Match the power supply voltage to the VCP. 2) Secondary voltage:

d. Sized for all panel components plus 10 percent spare capacity. 1) Primary and Secondary fuses.

6. Control components: a. Pump Protection Module as specified in this Section. b. Terminal strips:

1) Provide terminal strips for landing all external wiring. c. Relays, timers, and other components as required to provide the specified

functionality and remote monitoring connections. 7. Remote monitoring:

a. Provide dry relay contact outputs for the following: 1) RUNNING status for each pump. 2) FAULT ALARM for each pump. 3) HIGH LEVEL ALARM. 4) LOW-LOW LEVEL ALARM.

C. Description of operation: 1. General:

a. With the HAND/OFF/AUTO selector switch in the HAND position, the pump will run.

b. With the HAND/OFF/AUTO selector switch in the OFF position, the pump is prevented from running.

c. With the HAND/OFF/AUTO selector switch in the AUTO position, the pump will run based on sump level as specified below.

d. Interlocks: 1) A hardwired low-level interlock will prevent the pump(s) from

operating at or below this level. a) In the AUTO mode only. b) Activated by the low-level switch (LSL).

2) A motor high-temperature interlock will prevent the pump from running in all modes. a) Alarm is latched until the RESET pushbutton is pressed.

e. High level alarm is generated by the high level switch (LSH): 1) Alarm is latched until the RESET pushbutton is pressed.

f. Low-low alarm is generated by the low-low level switch (LSLL) 1) Indicates sump level lower than safe level for pump operation.

a) Hardwired interlock to stop the pump in both the HAND and AUTO modes.

2. Simplex AUTO operation: a. At low level, (LSL) the pump is off. b. At pump start level (LSA) the pump starts:

1) The pump continues to run until the low level (LSL) is reached. 3. Duplex AUTO operation:

a. At low level, (LSL) both pumps are off.


b. At lead pump start level, (LSA), the lead pump starts. c. At lag pump start level, (LSB), the lag pump starts. d. Both pumps continue to run until the low level (LSL) is reached.

D. Ancillary Instruments: 1. General: As part of the VCP provide level sensors as described below. 2. Type: As indicated in the Pump Schedule. 3. If explosion proof motor is scheduled, provide intrinsically safe level sensor

system. 4. Type: Ball float as specified in Section 17380.

a. Cable Length: The length of the cable shall be equal to sump depth to the VCP plus 5 feet.

5. Ultrasonic Level sensor as specified in Section 17380.

2.14 ACCESSORIES

A. Hoists: 1. Type 316 Stainless Steel. 2. Winch:

a. Type 316 Stainless Steel marine grade. 3. Anchor bolts: As specified in Section 05190. 4. Mounting: Type 316 stainless steel socket, off side of sump access opening. 5. Winch: Manual, adjustable boom with safety hook, and sufficient lift for pump

removal from deepest sump. 6. Hoist and winch safe load rating: Minimum 1.25 times heaviest sump pump

furnished or 1,000 pound minimum with maximum reach, whichever is greater. 7. Anchors:

Flush with internal thread anchor bolt sockets at each sump and socket with allowable working load of 5 times hoist pull out tension load on anchor bolts.

2.15 FINISHES

A. Pump manufacturer to factory prime and coat pump/motor and discharge elbow as specified in Section 09960.

B. Contractor to provide touch-up field coatings as specified in Section 09960.

PART 3 EXECUTION

3.01 INSTALLATION


3.02 COMMISSIONING





Non-witnessed)



Functional Testing

Process Operational

Period Maintenance

(hrs per session)




Days (each trip)

Non-Witnessed 4 2 1 1 1 1 24 hour on-call




2. Pump casing: Hydrostatic pressure tests if specified in this Section.



b. Vibration test: Not required for wet pit pump. Otherwise, Test level as scheduled; test as specified in Section 15958.

c. Noise test: Not required for wet pit pump. Otherwise, Test level as scheduled; test as specified in Section 15958.

2. Motor: Test as specified in Section 15170.

3.03 FIELD QUALITY CONTROL.

A. Witnessing: All field-testing shall be witnessed by the Engineer; provide advanced notice of field-testing as specified in Section 15958.

B. Inspection and checkout: As specified in Sections 15050 and 15958.

C. Equipment performance test: Test level as scheduled; test as specified in Section 15958.

D. Vibration test: None required.

E. Noise test: Test level as scheduled; test as specified in Section 15958.

F. Driver and motor tests: Test as specified in scheduled section.

G. Operational testing: As specified in Section 01650.

3.04 MANUFACTURER'S FIELD SERVICE

A. Start-up: Inspect system before initial start-up and certify that system has been correctly installed and prepared for start-up.


B. Training: As specified in Section 01650.

3.05 PUMP SCHEDULE

Tag Numbers SST-NP-001, SST-NP-002, SST-NP-

003 General Characteristics

Service Effluent Plant Water

Quantity 3

Maximum Noise, dBA at 3 Feet Not Required

Torsional Analysis Not Required

Minimum Pumped Fluid Degrees Fahrenheit 35

Normal Pumped Fluid Degrees Fahrenheit 70

Maximum Pumped Fluid Degrees Fahrenheit 85

Installation Configuration Wet Pit

Pump Characteristics

Impeller Type 2-Vane, enclosed type Pass Minimum Sphere Size, Inch 3"

Speed Control Constant

Maximum Pump Speed, rpm 1,200

Minimum Pump Speed, rpm N/A

Rated Design Point: (at Maximum rpm)

Flow, gpm 1390

Head, Feet 26

Minimum Hydraulic Efficiency, Percent 70

Required Condition 2 (at Maximum rpm)

Flow, gpm 1600

Head, Feet 20


Required Condition 3 (at Maximum rpm)

Flow, gpm 800

Head, Feet 35


Other Conditions

Shut Off Head, Feet 50

Minimum NPSHa at Every Specified Flow, Feet 35


Tag Numbers SST-NP-001, SST-NP-002, SST-NP-

003 Minimum Suction Static Head, Feet 18

Minimum Discharge Size, Inches 6

Motor Characteristics

Minimum Submergence Exposed

Maximum Driver Speed, rpm 1,200

Motor Horsepower, Minimum 15

Voltage/Phases/Hertz 460/3/60

Service Factor 1.15

Starting Current, Amperes 150

Full Load Current, Amperes 22

Motor Efficiency (At 100-Percent Load) Minimum 83

Enclosure Type Submersible

NEMA Design Type B

Local Control Panel Required Yes

Enclosure Type NEMA 4X Stainless Steel Level Control Type Ball Floats

Ultrasonic Level sensor Operation Triplex

Accessories Basin Cover Not Required

Hoist Required

Source Testing

Test Witnessing Not Required

Performance Test Level 1

Vibration Test Level Not Required

Noise Test Level Not Required

Functional Testing


Vibration Test Level Not Required

Noise Test Level Not Required

END OF SECTION

March 1, 2019 - CONFORMED 11312Q-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/11312Q (CONFORMED)

SECTION 11312Q

HORIZONTAL CHOPPER CENTRIFUGAL PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Horizontal or vertical dry pit, flexibly coupled, centrifugal chopper pump with drivers and features as specified.


Masonry. 8. Section 09960 - High-Performance Coatings. 9. Section 15050 - Common Work Results for Mechanical Equipment. 10. Section 15170 – Electrical Motor, Induction, 600 volts and blow. 11. Section 15958 - Mechanical Equipment Testing.

1.02 REFERENCES


B. American Society of Mechanical Engineers (ASME): 1. B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, and 250.

C. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A108 - Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished. 3. A148 - Standard Specification for Steel Castings, High Strength, for Structural

Purposes. 4. A276 - Standard Specification for Stainless Steel Bars and Shapes. 5. A536 - Standard Specification for Ductile Iron Castings. 6. A582 - Standard Specification for Free-Machining Stainless Steel Bars. 7. E10 - Standard Test Method for Brinell Hardness of Metallic Materials.

D. Hydraulic Institute (HI): 1. 1.1-1.2 - Centrifugal Pumps for Nomenclature and Definitions. 2. 1.3 - Rotodynamic (Centrifugal) Pumps for Design and Application. 3. 1.4 - Centrifugal Pumps for Installation, Operation and Maintenance. 4. 1.6 - Centrifugal Pump Tests. 5. 9.1-9.5 - Pumps - General Guidelines for Types, Definitions, Application,

Sound, Measurement and Decontamination.


1.03 DEFINITIONS

A. Pump head (total dynamic head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 1.1-1.2, 1.3, 1.6, and 9.1-9.5 and as modified in the Section.

B. Suction head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.

C. Tolerances: In accordance with HI 1.1-1.2, 1.3, 1.4, 1.6, and 9.1-9.5, unless specified more restrictively.


A. Chopper centrifugal pumps with components: Pump, driver, motors, and drive arrangements as specified or as scheduled with shafts, seals or packing, couplings, or belts, base plates or pedestals, guards, supports, anchor bolts, necessary valves, gauges, taps, lifting eyes, stands, and other items as required for a complete and operational system.

B. Chopping/maceration of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter box at the intake opening.

C. The pumps shall be capable of continuous operation while pumping sludge containing up to 6 percent solids with heavy rags, plastics, grease, hair, grit, and other stringy fibrous material.

1.05 SUBMITTAL


B. Torsional analysis: Submit as specified in Section 15050 when scheduled.


D. Certifications: Submit Certification of Rockwell C Hardness for cutter bars and impeller.

E. Furnish motor submittals as specified in Section 15170.



B. Provide pumps in this Section from same manufacturer.










1.10 WARRANTY


1.11 MAINTENANCE

A. Special tools: Provide 1 set of all special tools required for complete assembly or disassembly of all the pump system components.

B. Spare parts: Deliver the following as specified in Section 01600: 1. Mechanical seal: 1 complete seal assembly for each type supplied. 2. Pump bearings: 1 set of radial and 1 set of thrust bearings. 3. Impeller cutter bar: 1 set.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Vaughan Company, Inc. 2. Wemco Pumps, Model CF. 3. Hayward Gordon Ltd.

2.02 MATERIALS

A. General: Materials in the Pump Schedule shall be the type and grade as specified in this Section.

B. Cast iron: ASTM A48, Class 30 minimum.

C. Ductile iron: ASTM A536.

D. Cast steel: ASTM A148, Grade 90 - 60; minimum Rockwell C hardness number as scheduled.

E. Steel: ASTM A108, Grade as scheduled.


F. 316 Stainless: ASTM A276, Type 316 stainless steel; nickel - chrome- boron coating as scheduled.

G. 420F Stainless: ASTM A582, Type 420 Stainless Steel.


A. Type: Industrial (heavy) duty chopper centrifugal pumps.

B. Other requirements: 1. Vibration: As specified in Section 15958.

2.04 PUMP CASINGS


B. Provide a single piece casing with integrally cast discharge flange.

C. Design to withstand a design working pressure not less than 1.10 times the maximum shutoff total dynamic head with the maximum diameter impeller at the maximum operating speed plus the maximum suction static head.

D. Design to withstand a 5-minute hydrostatic test pressure not less than 1.5 times the design working pressure.

E. Provide suction and discharge flanges with ASME B16.1 Class 125 bolt patterns.

F. Provide a cast cleanout to permit inspection and cleaning of the pump suction area. 1. The cleanout shall have a bolted cover with inner contour that matches

contour of suction piece.

G. Provide casings with both 1/4-inch NPT high point vent and 1 inch low point drain taps on suction side; install pipe nipples with threaded gate valves.

H. Provide 1/4-inch NPT taps for pressure gauges on the suction and discharge flanges.

2.05 BACK PLATES

A. Material: as scheduled.

B. The back pullout plate shall be a separate component part and shall allow removal of the pump components from above the casing.

C. The back pullout plate shall allow external adjustment of the impeller to cutter bar clearance.

D. The pump shall include a rear cutting mechanism designed to cut against the pump out vanes and the impeller hub, reducing and removing stringy materials from the mechanical seal.


2.06 CUTTER BAR


B. Design cutter bar plate to prevent blockage of intake and binding of debris at the shaft and impeller vanes.

C. Cutter bar shall be replaceable without replacement of the suction flange or suction plate. 1. Cutter bars, which are integral to the suction flange, or suction plate are not

acceptable.

2.07 IMPELLERS


B. Type: Single-passage, semi-open chopper-centrifugal impeller with smooth water passages to reduce clogging by rags, stringy or fibrous materials on impellers or shafting.

C. Provide static, dynamic, and hydraulic balance of impeller and complete rotating element.

D. Impeller cutter nut: As scheduled.

E. Provide for external adjustment of impeller to cutter bar clearances without pump disassembly or disturbances of suction or discharge piping.

2.08 PUMP SHAFTS

A. Material: 1. As scheduled. 2. Hard faced or with hardened sleeve where shafts pass through bearings.

Harden to 550 Brinell hardness number minimum per ASTM E10. 3. If mechanical seals are scheduled and mechanical seals cannot be installed

on hardened shaft, shaft is not to be hardened in the mechanical seal area. 4. If sleeve provided, sleeve to be renewable and key locked in place.

B. Strength: Able to withstand minimum 1.5 times maximum operating torque and other loads.

C. Resonant frequency: As specified in Sections 15050 and 15958.

D. Deflection: Maximum 0.002 inches under operating conditions.

E. Impeller attachment: Readily removable without use of special tools.

F. Shaft seal type: 1. Mechanical seals: Provide scheduled seal type meeting the following

requirements: a. Balanced hydraulically. b. Spring: Stationary, out of pumping fluid, Hastelloy C or Elgiloy 17-7 PH

stainless steel for split seals.


c. O-Ring: Viton 747. d. Set screws: Type 316 Stainless Steel. e. Faces: Reaction bonded Silicon Carbide, Tungsten Carbide.

2.09 BEARINGS AND BEARING FRAME

A. Bearing type: Back-to-back mounted single-row angular contact ball bearing and radial bearings, self-aligning spherical roller type radial bearings, angular contact ball type, or tapered roller for thrust bearings.

B. Bearing lubrication: As scheduled.

C. Bearing life: Minimum L10 life of 100,000 hours at rated design point or 24,000 hours in accordance with ABMA 9 or 11 at bearing design load imposed by pump shutoff with maximum sized impeller at rated speed, whichever provides longest bearing life in intended service.

D. Pump bearing frames: 1. Material: As scheduled. 2. Provide a 1-piece rigid construction with bearing housing.

COUPLINGS

E. Type: As scheduled and specified in Section 15050.

F. Design coupling to withstand a minimum of 1.5 times the maximum operating torque and other imposed loads.

2.10 SUPPORTS, PEDESTALS, AND BASEPLATES

A. Pump base: Design a minimum 3/8-inch fabricated structural steel base and support system for the drive arrangement scheduled and as schematically indicated on the Drawings.

B. Pump, driver, and bearing support strength: Able to withstand minimum 1.5 times maximum imposed operating loads or imposed seismic loads, whichever is greater.

C. Configuration: Allow easy access to stuffing boxes, bearing frames, and couplings.

D. Anchor bolts: As specified in Section 05190.

2.11 EQUIPMENT GUARDS

A. Provide safety guards as specified in Section 15050.

2.12 DRIVERS


a. Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied pump operating head-flow curve including runout.




B. Motors: Provide motors as specified in Section 15170 and as specified in this Section: 1. Revolutions per minute: As scheduled: 2. Enclosure: As scheduled. 3. Electrical characteristics: As scheduled. 4. Efficiency, service factor, insulation, and other motor characteristics: As

specified in Section 15170. 5. Motor accessories: As specified in Section 15170 and in this Section. 6. Coordinate motors with the variable frequency drive manufacturer to ensure

compatibility between the motor and variable frequency drive.

C. Other drivers: As scheduled and as specified in sections listed in the Schedule.

2.13 FINISHES

A. Finishes: Prepare surfaces and apply protective finishes as specified in Section 09960.

PART 3 EXECUTION

3.01 INSTALLATION


3.02 COMMISSIONING




Non-witnessed)



Functional Testing

Process Operational

Period Maintenance

(hrs per session)




Days (each trip)

Witnessed 4 2 1 1 1 1 24 hour on-call





2. Pump casing: Hydrostatic pressure tests if specified in this Section. 3. Motor: Test as specified in Section 15170.



b. Vibration test: Test level as scheduled; test as specified in Section 15958. c. Noise test: Test level as scheduled; test as specified in Section 15958.

2. Motor: Test as specified in Section 15170.

3.03 PUMP SCHEDULE

Tag Numbers

SST-SLP-001, SST-SLP-002, SST-SCP-001, SST-SCP-002,

SST-SCP-003 General Characteristics

Service Digested Sludge and Scum

Quantity 5

First Named Manufacturer’s Model Number Vaughn HE3L6CS

Maximum Noise, dBA at 3 feet 85

Torsional Analysis Not Required

Minimum Pumped Fluid degrees Fahrenheit 65

Normal Pumped Fluid degrees Fahrenheit 80

Maximum Pumped Fluid degrees Fahrenheit 95

Pump Characteristics

Impeller Semi-open with chopper

Impeller Bearing Lubrication Oil

Shaft Seal Type Mechanical

Coupling Type Flexible Direct Speed Control Fixed

Maximum Pump revolutions per minute 1,750

Minimum Pump revolutions per minute 1,750

Rated Design Point:

Flow, gallons per minute 300

Head, feet 19 to 22

Min. Efficiency, percent 45%


Tag Numbers


SST-SCP-003 Required Condition 2:


Head Range, feet 10 to 13


Required Condition 3:


Head Range, feet 26 to 31


Other Conditions:

Shut Off Head, feet 36

Min. NPSHa at Every Specified Flow, feet 34

Max. Suction Static Head, feet 24

Pump Materials

Pump Casing Ductile Iron or Cast Iron

Impeller Cast Steel, 60 Rockwell C

Impeller Cutter Nut Cast Steel, 60 Rockwell C

Cutter Bar T-1 Alloy Steel or Cast Steel, 60 Rockwell C

Shaft Steel, Grade 4140

Shaft Sleeve 316 Stainless

Stuffing Box None

Pump Bearing Frame Cast Iron

Nuts and Bolts 316 Stainless

Driver Characteristics

Driver Type Motor

Drive Arrangement Horizontally Coupled

Non-reverse Ratchets None

Minimum Driver Horsepower 5

Maximum Driver Speed, revolutions per minute 1,750

Motor Characteristics (when motor is driver type) Inverter Duty Rated No

Motor Voltage/Phases/Hertz 460/3/60

Enclosure Type TEFC


Tag Numbers


SST-SCP-003 Source Testing

Test Witnessing Not Witnessed


Vibration Test Level 1

Functional Testing Performance Test Level 1

Vibration Test Level 1

END OF SECTION


SECTION 11352

CIRCULAR PRIMARY CLARIFIER EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Sludge collector equipment for installation in circular primary clarifiers of center

feed, peripheral overflow design.

B. Related sections: 1. Section 01140 - Work Restrictions. 2. Section 01410 - Regulatory Requirements. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 05500 - Metal Fabrications. 5. Section 06611 - Fiberglass Reinforced Plastic Fabrications. 6. Section 09960 - High-Performance Coatings. 7. Section 13390 - Packaged Control Systems. 8. Section 15170 – Electrical Motor, Induction, 600 volts and blow. 9. Section 17200 - Instrumentation and Control Cabinets and Associated

Equipment.

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings.

B. American Gear Manufacturers Association (AGMA): 1. 908 - Information Sheet - Geometry Factors for Determining the Pitting

Resistance and Bending Strength of Spur, Helical, and Herringbone Gear Teeth.

2. 915-1 - Inspection Practices - Part 1: Cylindrical Gears - Tangential Measurements.

3. 915-2 - Inspection Practices - Part 2: Cylindrical Gears - Radial Measurements.

4. 2001 - Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth.

5. 2004 - Gear Materials, Heat Treatment and Processing Manual. 6. 2009 - Bevel Gear Classification, Tolerances and Measuring Methods. 7. 2011 - Cylindrical Wormgearing Tolerance and Inspection Methods. 8. 2015-1 - Accuracy Classification System - Tangential Measurements for

Cylindrical Gears. 9. 2015-2 - Accuracy Classification System - Radial Measurements for Cylindrical

Gears. 10. 6013 - Standard for Industrial Enclosed Gear Drives. 11. 6022 - Design Manual for Cylindrical Wormgearing. 12. 6034 - Practice for Enclosed Cylindrical Wormgear Speed Reducers and

Gearmotors. 13. 9005 - Industrial Gear Lubrication.


C. American Institute of Steel Construction (AISC): 1. 360 - Specification for Structural Steel Buildings.

D. American Society of Mechanical Engineers (ASME): 1. B29.1M - Precision Power Transmission Roller Chains, Attachments, and

Sprockets.

E. American Welding Society (AWS): 1. D1.1 - Structural Welding Code for Steel. 2. D1.6 - Structural Welding Code - Stainless Steel.

F. ASTM International (ASTM): 1. A 36 - Standard Specifications for Carbon Structural Steel. 2. A 48 - Standard Specification for Gray Iron Castings. 3. A 148 - Standard Specification for Steel Castings, High Strength, for Structural

Purposes. 4. A 276 - Standard Specification for Stainless Steel Bars and Shapes. 5. A 325 - Standard Specification for Structural Bolts, Steel, Heat Treated,

120/105 ksi Minimum Tensile Strength. 6. A 536 - Standard Specification for Ductile Iron Castings.

G. International Organization for Standardization (ISO): 1. 53 - Cylindrical Gears for General and Heavy Engineering - Standard Basic

Rack Tooth Profile.

H. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1,000 V Maximum).

1.03 DEFINITIONS


B. Continuous operation: 24 hour-per-day operation for design life of not less than 20 years which equals 175,200 hours.

C. Intermittent operation: Periodic operation, including starts and stops, and prolonged periods of resting.

D. Subassemblies: Includes, but may not be limited to, complete center column, drive cage, drive assembly, truss arms, and scum skimming system.

E. Set: Equipment necessary to completely furnish 1 clarifier.

F. Continuous running torque: 1. The 100 percent AGMA torque, assumed to be continuously applied, 24 hours

a day, to the drive system. 2. Bearing life, gear strength, gear durability, gear rating, mechanism structural

design, and alarm and shutdown setpoints are specified as a percentage of the continuous running torque.


G. Momentary peak torque: 1. The maximum torque for rating yield strength or ultimate strength of center

drive mechanism components. 2. The numerical value for momentary peak torque shall be 2.0 times continuous

running torque.

H. Manufacturer: 1. Firm responsible for the design, operation, delivery, installation certification,

and warranty of sludge collection equipment. 2. Manufacturer shall also provide sludge collector drive mechanism.

I. Fabricator: 1. Firm responsible for the fabrication of sludge collection equipment conforming

to the manufacturer’s design. 2. Manufacturer may also be the fabricator if fabrication of all components is self-

performed.


A. Nominal clarifier dimensions: 1. Diameter: 45 feet. 2. Side water depth: 13.2 feet. 3. Bottom slope: Field Verify (bottom grout is to be remove and reapplied by

contractor).

B. Sludge collector mechanism: 1. Supply as a complete and operational system by a single manufacturer. 2. Equipment to include, but not be limited to, the following components:

a. Center column. b. Influent well. c. Center drive cage. d. Sludge collector truss arms with segmented plow-type scrapers. e. Scum skimming system. f. Center drive mechanism. g. Drive motor. h. Electrical controls. i. Overload devices and alarms. j. Alarms. k. Other components necessary to provide a complete system.

3. Process conditions:

Parameter (per clarifier) Minimum Average Peak

Influent Flow, million gallons per day

0.50 1.1 1.50

Primary Sludge Underflow, million gallons per day

0.30 0.43 0.50

a. Maximum allowable headloss through the center column and influent well at peak flow = 12 inches.


4. Process description: a. The sludge collector mechanism includes a central driving mechanism

mounted on a center support pier which supports and rotates a center cage with 2 truss arms and 1 surface skimmer.

b. Sludge accumulated in the clarifier is scraped to a center well for continuous removal.

c. Scum from the surface of the clarifier is collected and deposited into a scum collection hopper using skimming arms with articulated blades.

C. Mechanical design: 1. Use no chains, sprockets, bearings, or gears below the water surface. 2. Design for a continuous running torque of 5,100 foot pounds. 3. Design collector mechanism to operate at a tip speed, measured at the ends

of the truss arms, of approximately 10 feet per minute.

D. Structural design: 1. Design the sludge collector mechanism in accordance with AISC 360 except:

a. Provide a 3/16 inch minimum thickness for all members, except where specifically modified for specified equipment components.

b. Include stresses in members caused by bending and twisting due to eccentricities in members.

2. Slenderness ratio (KL/R) using K value of 1.0 shall not exceed the values specified below: a. Tension members not greater than 240. b. Compression members not greater than 200.

3. Base member weights used for design on final full member thickness. 4. Full member thickness may be used for performing deflection calculations. 5. Design the center cage and the truss arms as an integral structure. Design the

center cage and the connections to the truss arms for the reactions from the truss arms.

6. Do not include live load where its inclusion results in lower stresses in a member under investigation.

7. Load combinations: Design each structural member of the sludge collector mechanism shall for the most critical load combination resulting from the following load combinations: a. Dead load plus live load plus continuous running torque. b. Dead load plus live load plus torque due to screening grout topping on

slab using sludge collector mechanism. c. Dead load plus live load plus torque due to cutout torque test. d. Other load combinations selected by the manufacturer. e. Truss arm load cases: Use the following load cases on the truss arms for

load combinations: 1) Equal uniform horizontal load along the full length of both truss arms

which results in a combined torque equal to the continuous running torque.

2) Uniform horizontal loads along the full length of both truss arms which results in 70 percent of the torque from 1 truss arm and 30 percent of the torque from the other truss arm for a combined torque equal to the continuous running torque.

3) Load on truss arms due to spreading grout topping on slab using sludge collector mechanism.

4) Load on truss arm due to cutout torque load test.


8. Deflections: a. The horizontal deflection of the truss arm, due to truss deflection plus

rotational deflection of the center cage for load cases which contain continuous running torque, shall not exceed a deflection equal to the radius of the clarifier divided by 400 (L/400). 1) Not more than 60 percent of the total horizontal deflection shall be

due to center cage rotation. 2) Horizontal deflection of the truss arm shall be measured at the end of

the sludge collection header furthest from the center column. b. The vertical deflection of the truss arm due to equipment dead load shall

not exceed the length of the truss arm divided by 800 (L/800).

1.05 SUBMITTALS

A. Submit product data and shop drawings, operation and maintenance manuals, and test reports.

B. Product data and shop drawings: 1. Shop drawings shall consist of a cover sheet indicating the drawing number

and specification page and number to which referenced, intended use and data summary, outline drawings, cut-away drawings, parts lists, material specification lists, and all information required to substantiate that the proposed equipment meets the specifications. a. Shop drawings submittals will not be considered complete if cut-away or

assembly drawings with part and material specification lists are not included.

2. General arrangement drawings showing the complete assembly, part numbers, and materials list.

3. Detailed drawings: a. Sludge collector mechanism indicating dimensions, member sizes and

thicknesses, welding, and connection details. b. Drive mechanism showing sizes, dimensions, and arrangement of each

drive component. c. For gears, except those contained in the gearmotor speed reducer,

detailed drawings with the following minimum data for each gear: 1) Number of teeth. 2) Net face width. 3) Outside diameter of external gears. 4) Inside diameter of internal gears. 5) Normal diameter pitch or axial pitch for worms. 6) Normal generating pressure angle. 7) Lead angle (for worms). 8) Operating center distance. 9) Addendum modification coefficient. 10) Tooth thickness or pin or span measurements. 11) Quality numbers in accordance with AGMA 915-1, 915-2, 2009,

2011, 2015-1, and 2015-2. 12) Material alloy. 13) Type of heat treatment. 14) Tooth surface hardness. 15) Tooth core hardness. 16) For case hardened gears, effective case depth to Rc 50.


17) Lubricant type (mineral/synthetic/EP). 18) Lubricant viscosity.

d. Certified motor data sheets. e. Shop primer and coating data. f. Control system data, schematics, and wiring diagrams. g. Spare parts lists. h. Qualifications and resume of installation engineer. i. Training course outlines. j. Manufacturer's experience and reference list as specified in Article Quality

Assurance.

C. Manufacturer's Installation Instructions.

D. Calculations: Include, without necessarily being limited to: 1. Structural calculations:

a. Calculations shall be prepared and signed by a professional civil engineer licensed in the state where the Project is located demonstrating compliance with structural criteria specified in this Section.

b. Submit design calculations with complete shop drawings. 2. Mechanical and hydraulic calculations: Performed by a professional civil or

mechanical engineer licensed in the state where the Project is located. Calculations are intended to: a. Substantiate continuous running torque rating and overload torque loading

of each component of drive mechanism. 1) Calculations shall be in accordance with AGMA 908. 2) Calculations shall clearly specify all design parameters used in

developing the ratings, including materials in accordance with AGMA 2004.

3) All ratings shall be in strict conformance with the latest revisions of AGMA 6034 and AGMA 2011.

b. Demonstrate that each bearing in drive mechanism complies with life requirements of this Section.

E. Reference list: Include the following information as a minimum: 1. Name and location of installation. 2. Name and telephone number of the person in direct responsible charge of the

equipment. 3. Name and contact information for equipment fabricator. 4. Name and contact information for manufacturer’s engineer responsible for

structural design. 5. Month and year the equipment was placed in operation. 6. Size of equipment. 7. Number of units installed. 8. Service.

F. Quality control submittals: 1. Welder’s certificates. 2. Submit manufacturer's or designated contract fabrication facility’s structural

steel fabrication qualifications and information. 3. Engineer’s qualifications to complete structural analysis and design.


G. Fabrication certification report: 1. Provide fabrication certification report prior to equipment delivery to project

site.

H. Test reports: 1. Method of conducting cutout test and verification that method of testing will not

impose stresses in any member which exceeds maximum allowable stresses specified in this Section.

2. Results of field torque tests on sludge collector mechanism.

I. Operation and Maintenance Manuals.

J. Certificates: Manufacturer's certification that equipment was installed in accordance with the manufacturer's instructions, inspected by the manufacturer, serviced with the proper initial lubricants, and equipped with applicable safety equipment and controls.

K. Technician's qualifications resume: Submit resume of technician to perform manufacturer’s field service.


A. Manufacturer qualifications: 1. Experience: Demonstrate minimum 5 years experience in the manufacture and

fabrication of plow-type segmented scraper sludge collectors which have been successfully utilized in domestic wastewater applications. a. Experience of fabricator, if manufacturer does not self-perform fabrication,

shall meet or exceed that required of manufacturer. b. Submit substantial information as necessary to establish qualifications of

fabricator, if manufacturer does not self-perform fabrication, including location (address), experience, qualifications, and certifications of all fabricator’s staff to be utilized.

c. Manufacturer’s engineer responsible for structural design shall also demonstrate minimum 5 years experience designing sludge collectors to withstand operational loads, including sloshing of tank contents on sludge collection mechanism.

2. References: Provide a reference list of at least 5 different installations in domestic wastewater treatment plants of not less than 5 million gallons per day in the continental United States, where the manufacturer has supplied equipment substantially similar in design and characteristics to that proposed in this Section. a. The installations listed must:

1) Have been designed and fabricated by the manufacturer. If manufacturer does not self-perform fabrication, the installation list shall also include the experience of the Project equipment fabricator.

2) Are at least 45 feet in diameter. 3) Have been in operation for last 5 years.

b. Provide the following information related to the installation: 1) Owner name, address, and telephone number. 2) Design flow of plant. 3) Sludge collector dimensions. 4) Time in operation.


5) References for manufacturer’s engineer responsible for the structural design.

B. Welding and welder qualifications: 1. Perform welding and qualify and certify welders in accordance with AWS D1.1

and D1.6. 2. Welds:

a. Use shielded arc welding. b. Conform to requirements of design loads. c. Conform to information indicated on the Drawings. d. Use a minimum weld size of 3/16-inch. e. Field welding permitted only for bridge splice (if required). f. Engineer may check materials, equipment, and qualifications of welders. g. Remove welders performing unsatisfactory Work, or require to requalify. h. Engineer may use gamma ray, magnetic particle, dye penetrant,

trepanning, or other aids to visual inspection to examine any part of welds or all welds.

i. Manufacturer shall bear costs of retests on defective welds. j. Manufacturer shall also bear costs in connection with qualifying welders

C. Steel fabrication: 1. Manufacturer’s authorized representative shall be present during fabrication of

equipment 2. Manufacturer’s authorized representative shall provide a fabrication

certification report complete with certified fabrication drawings, a journal of the fabrication work process, photo documentation of the shop assembly of all components required to be field erected, and a certification that the fabricated equipment is complete and ready for installation by the Contractor.

D. Equipment subassemblies: 1. Each component subassembly requiring field erection shall be test assembled

and documented at the Manufacturer’s fabrication facility. 2. Digital photographic evidence of assembly shall be submitted as part of the

fabrication certification report. 3. Mark parts with erection matchmarks for ease of field erection. 4. Lubricate moving parts before shipment. 5. When necessary to disassemble parts for shipping, coat uncoated exposed

machine surfaces with suitable, easily removable, rust-preventive compound before shipping.


A. Environmental project conditions: 1. Installation in a wastewater treatment plant. 2. Moderate quantities of commercial and industrial waste. 3. Exposure to industrial solvents and petroleum products. 4. Operation 440 feet above mean sea level. 5. Ambient air temperature:

a. Maximum 120 degrees Fahrenheit. b. Minimum 20 degrees Fahrenheit.

6. Wastewater temperature: a. Maximum 90 degrees Fahrenheit.


b. Minimum 55 degrees Fahrenheit.


A. Preparation for shipment: 1. All materials shall be suitably packaged and braced to protect against damage

during transit, handling, and unloading. 2. Manufacturer shall package equipment, be responsible for, and make good,

any and all damage until the equipment is delivered to the job site. 3. Accessories shall be packaged separately in containers clearly marked

"ACCESSORIES ONLY". 4. A packing list, listing the contents of each container, shall be placed in a

moistureproof envelope and securely fastened to the outside of the container. 5. Provide written storage procedures for all equipment.

B. Delivery to job site: 1. Manufacturer shall fabricate and deliver materials to the job site in

conformance with the Contractor's construction schedule to minimize handling and on-site storage of equipment.

C. Storage and protection: 1. Protect the system components at the site and during installation prior to

project completion. 2. As a minimum, provide cover, ventilation, and proper stacking to prevent

warping of any equipment stored on-site.


A. Coordinate work with work sequence specified in Section 01140.

1.10 MAINTENANCE

A. Spare parts: Furnish the following spare parts suitably packaged and marked. Include a price list and name, address, and telephone number of local supplier: 1. 2 sets of scum skimmer blade wear strips. 2. 1 set of brass squeegees for each clarifier furnished. 3. 4 sets of shear pins. 4. 1 set neoprene scum skimmer wipers. 5. 1 set each of oil seals for the worm shaft and pinion shaft.

B. Special tools: Provide the following special tools: 1. Tools required to assemble, disassemble, repair, and maintain equipment, and

that have been specifically made for use on the equipment. 2. Necessary eyebolts, hooks, and rods for handling equipment parts. 3. List of tools with the maintenance and operation data describing the uses of

the tools.


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Sludge collector mechanism: 1. All equipment components of the sludge collector mechanism including the

center column, influent well, center drive cage, sludge collector truss arms, scum skimming system, segmented scraper blades, center drive mechanism, drive motor, electrical controls, and overload devices and alarms, shall be furnished by the same manufacturer.

2. Some equipment may require modification from the manufacturer's standard. 3. Exercise care to assure that the electrical, mechanical, structural, and

miscellaneous systems comply with the requirements specified or in other referenced sections.

B. One of the following or equal: 1. Ovivo USA. 2. Siemens Water Technologies/Envirex, Inc. 3. Westech, Inc. 4. Walker Process Equipment.

2.02 MATERIALS

A. For all components, unless otherwise specified, use the materials of construction specified below.

B. Structural steel: 1. In accordance with ASTM A 276, Type 304L stainless steel. In accordance

with astm A36 for clarifier bridge construction, and for all other components ASTM A 276, type 304L stainless steel.AD2

2. Grind all edges of steel members to approximately 1/16-inch minimum radius using standard workmanship and a grinder.

C. Stainless steel, ASTM A 276, Type 304. 1. Components or structural shapes which are welded:

a. Materials: Type 304L stainless steel. b. Manufacturer's shop welds, welding procedures, and welders:

1) Qualified and certified in accordance with the requirements of AWS D1.6.

D. Anchor bolts: Type 316 stainless steel.

E. Weir plate: Preserved from existing mechanism.

F. Scum baffles: Preserved from existing mechanism.

G. Fasteners and washers: Type 304 stainless steel, except for bolts which will be removed during installation and any high strength bolts.

H. High strength bolts: Use ASTM A 325 hot-dip galvanized high strength bolts in attaching truss arms to cage, and cage to center drive gear casting.

I. Do not use cadmium plated parts and fasteners.


J. Dissimilar metals: All aluminum components shall be isolated from steel components as specified in Section 05500 to prevent electrolysis.

J.K. Handrails shall be aluminum as specificed in Section 00500. AD2

2.03 SLUDGE COLLECTOR MECHANISM

A. Center column: 1. Materials:

a. Vertically mounted cylindrical 304L stainless steel center column. 1) Inside diameter: 14 inches. 2) Wall thickness: 1/4 inch minimum.

2. Design: a. Support the entire sludge collector mechanism including inboard end of

bridge. b. Size and anchor the entire assembly to be capable of resisting overturning

moments when tank is empty or full. 3. Center column anchorage: Mount center column over influent port at center of

clarifier. Connect the base flange of the center column to the concrete foundation using anchor bolts. a. Use a rigid steel template of minimum 1/4-inch thickness to accurately

locate anchor bolts for the center column. b. Supplier shall coordinate with the Contractor to ensure proper anchor bolt

location. c. Center column base anchor bolts:

1) Not less than 8 in number. 2) Not less than 15 bolt diameters of embedment length. 3) Not less than 3/4 inches in diameter. 4) Minimum edge distance for anchor bolts shall be the larger of

6 inches or 6 anchor bolt diameters, and as required to clear reinforcing bars located around opening.

d. Center column base mounting flange: 1) Size and reinforce using gussets or other stiffeners as necessary to

adequately transfer loads from the sludge collector mechanism to clarifier structure.

2) Bolt holes in flange to accommodate anchor bolts shall not exceed 1/8 inch plus bolt diameter.

4. Center column outlet ports: Provide outlet ports to disperse influent flow into the feedwell, including the following: a. Total of 4 ports. b. An open area of each port not less than 40 square inches. c. Appropriately reinforced port openings. d. Other dimensions as indicated on the Drawings.

5. Flange and stiffen the top of the center column for supporting the sludge collector mechanism, the drive mechanism, and the access bridge. a. Attach the center column to the drive assembly using bolts. b. Attach center column to drive assembly using bolts.

6. Drain holes: Provide two 2-inch holes at bottom to allow column to drain within the tank.

B. Influent well: 1. Materials:


a. 3/16 inch minimum thickness stainless steel plate. b. Reinforced with steel stiffening angles where necessary.

2. Design: a. Supported around the outside of the center drive cage using rigid

connection. Other methods of connection such as swinging or breakaway supports are not permitted.

b. Reduce influent flow energy in a contained area and prevent short-circuiting of flow.

c. Dimensions: As indicated on the Drawings. d. Equip with a minimum of 4 baffled slots as indicated on the Drawings to

allow for removal of floating material in the well.

C. Center drive cage: 1. Materials: Structural steel members. 2. Design:

a. Box truss design. b. Design to carry load from the truss arms plus its own dead load. c. Fasten center drive cage to spur gear assembly using bolted connection. d. Center drive cage shall support and rotate the truss arm assemblies with

the attached plow-type segmented scrapers and surface skimming arm.

D. Sludge collector truss arms: 1. Materials: Structural steel. 2. Design:

a. Truss design. Tie rods not permitted. b. Design with sufficient structural strength to sweep in a layer of grout on

the clarifier bottom under its own power. c. Maintain width of truss arm same as the width of center drive cage to

ensure alignment and proper connection. d. Rigidly connect truss arms to center drive cage. e. Conform truss arms to slope of tank floor. f. Use the truss arm to support the segmented scraper blades and scum

skimmer arm.

E. Segmented scrapers and squeegees: 1. Scraper blades: Setting similar for each truss.

a. Materials: Structural steel. b. Sized and spaced so entire circular portion of tank is scraped twice for

each revolution of the mechanism. c. Having a minimum depth of 9-1/2 inches. d. Having adjustable squeegees.

2. Squeegees: a. Materials: Brass or stainless steel, spring type, not less than 26 gauge

thickness. b. Projecting approximately 2 inches below the bottom of the segmented

scraper blades. c. Attach squeegees to blades utilizing stainless steel hardware. Squeegees

shall be designed to allow 2 inches of vertical adjustment.

F. Scum skimming system: Consisting of a scum skimmer assembly that pushes floating scum to a scum trough for removal. Basic components of skimmer assembly include scum deflector blades and skimmer device.


1. Scum deflector blades: a. Material: Structural steel plate. b. Designed to collect and push floating scum radially outward toward the

circumferential scum baffle. c. Extends from the flocculating well to the scum skimmer device. d. Attached to the rotating collector mechanism at the flocculating well,

supported with skimmer assembly supports from the sludge collector truss arms.

e. Attach inner end of deflector blade tangentially to the flocculating well where practicable. Otherwise, provide maximum angle of approach of scum deflector blade to the scum in order to drift the scum to circumferential baffle.

2. Scum skimmer device: a. Materials: Structural steel plate and members. b. Attach to outer end of the scum deflector blade to trap scum for discharge

into scum trough. c. Size: Full length of the scum trough. d. Design:

1) Maintain continuous contact and proper alignment with scum baffle and inclined scum ramp to positively rake scum to the scum trough.

2) Use a hinged blade to move entrapped scum up the scum beach to the scum trough.

3) Provide a replaceable wear block on the outer edge of each scum skimmer device.

e. Hinged blade: 1) Adjustable vertically to control the dewatering of scum as it travels up

the inclined ramp to the scum trough. 2) Adjustable vertically over the length to ensure contact with the scum

trough even though the trough may not be level. 3) Capable of being raised and locked out above the water level or held

horizontally against the circumferential scum baffle when skimming is not required.

4) Equipped with replaceable scum skimmer wipers on the bottom inner and outer edges to seal the entrapped scum and water when moving up the inclined approach ramp to the scum trough.

f. Scum skimmer wipers: Oil resistant neoprene. g. Wear block:

1) Material: Polyvinyl chloride. 2) Wear block constantly forced against circumferential scum baffle to

keep baffle clean using a coiled spring arrangement. 3) Force between baffle and wear block adjustable between 1 to

5 pounds. h. Wear block coiled springs:

1) Material: Type 18-8 stainless steel. 2) Enclosed to protect them from the weather. 3) Spring enclosures:

a) Material: Welded steel or cast iron housing. b) Bronze bushed and grease lubricated for easy movement of

hinged blades. 3. Scum trough and scum beach:

a. Fabricated from 3/16-inch minimum thickness stainless steel plate. b. Supported from clarifier wall by structural steel members.


c. Scum trough: 1) Width: 5'-0". 2) No internal stiffeners or structural members which obstruct scum

flow. 3) Standard pipe flanged connection for scum discharge pipe. Size as

indicated on the Drawings. d. Scum beach (inclined approach ramp):

1) Length: 3'-0". 2) Shaped to contain scum as it is moved up the incline to the trough by

the scum skimmer. e. Connect the new scum trough to existing 6" scum piping.

4. Skimmer assembly supports: a. Material: Structural steel members. b. Attached to the sludge collector truss arms. Do not support scum skimmer

assembly from the scum baffle. c. Space supports, brought up from the truss arm, at not greater than 10 feet

apart. 5. Equipment manufacturer shall size and locate counterweights to be installed

by the Contractor. 6. Threaded fasteners: Type 18-8 stainless steel.

G. Center drive mechanism: Provide a center drive mechanism consisting of a primary speed reducer driven by electric motor, through a roller chain using an intermediate gearset consisting of a cylindrical-worm and helical-wormgear, and a low speed gearset consisting of a spur pinion and internal spur gear supported within a cast iron housing by a circular main bearing featuring replaceable bearing race inserts. Center drive mechanisms utilizing housings and internal spur gears featuring integral gothic arch style bearing races are not acceptable. 1. Gear motor speed reducer:

a. Type: Cylindrical-worm or helical-wormgear motor. Planetary gear units will not be acceptable.

b. Speed reducer in accordance with AGMA 6013 and 6034. c. Service factors: Minimum speed reducer service factor of 2.0 minimum

based on continuous running torque. d. Connect speed reducer output shaft to drive sprocket of chain drive. e. Speed reducer overhung load rating:

1) Exceed the chain pull (based on continuous running torque) by 1.50 minimum.

f. Oil bath lubrication: 1) Lubricant in accordance with AGMA 9005. 2) Provide oil fill, drain, and oil level indicator devices. 3) Oil bath protection seal: Felt.

g. All gears supported by anti-friction bearings. 2. Intermediate gearset:

a. Type: Cylindrical-worm and wormgear. b. Materials:

1) Worm: Alloy steel, hardened, ground, and polished. 2) Wormgear: Centrifugally cast bronze. 3) Washers: Hardened steel to prevent embedding of bolt head or nut. 4) Bushings: Bronze. 5) Housing: Cast iron in accordance with ASTM A 48, Class 30

minimum.


c. Load capacity: Rated in accordance with AGMA 6034. d. Service factor: Minimum of 1.25 based on continuous running torque. e. Wormgear shaft:

1) Drives pinion of low-speed gearset. 2) Support shaft by anti-friction bearings or combination of anti-friction

bearings and bushing. f. Wormgear: In accordance with AGMA 6022. g. Worm shaft: Support by anti-friction bearings. If the wormgear is bolted to

a drive hub, it shall be piloted for concentricity. h. Worm and wormgear shaft: Anti-friction bearings shall have ABMA 9,

L-10 life of 180,000 hours minimum based upon continuous running torque.

i. Provide oil bath lubrication. 1) Lubricant in accordance with AGMA 9005. 2) Provide oil fill, drain, and oil level indicator devices.

3. Low-speed gearset: a. Provide low-speed gearset using spur pinion and internal spur gear. b. Spur pinion shall be:

1) Integral with its shaft or keyed to a shaft. a) If keys are used, the pinion shall be secured to the shaft with a

shrink fit. b) Set screws will not be acceptable.

2) Welded spur pinion and shafts will not be acceptable. 3) Keyed spur pinions shall have a wall thickness above the keyway

equal to 1 tooth whole depth minimum. a) Keyway and keyseat shall have 0.02 inch minimum inside radii. b) Keys shall have 0.04 inch minimum chamfer on all edges.

4) Manufactured to have a minimum AGMA Quality Class 8 in accordance with AGMA 915-1, 915-2, 2015-1, and 2015-2.

c. Provide full depth teeth in accordance with ISO 53: 1) Stub pitch gear teeth will not be accepted. 2) Undercut gear teeth will not be accepted.

d. Load capacity rated according to AGMA 2001. e. Power rating based on continuous service and the lower of the:

1) Pitting resistance for the pinion and gear. 2) Bending strength for the pinion and gear.

f. Minimum service factor of 1.25 based on continuous running torque. g. Overload torque capacity (based on yielding of the pinion or gear teeth)

exceeding the momentary peak torque by 1.8 minimum. h. Internal spur gear:

1) Material: Ductile (nodular) iron in accordance with ASTM A 536 or cast steel in accordance with ASTM A 148, or heat-treated alloy steel.

2) Minimum AGMA Quality Class 6 in accordance with AGMA 915-1, 915-2, 2015-1, and 2015-2.

3) Internal spur gear bolted to the center drive cage. i. Turntable base:

1) Material: a) Ductile (nodular) iron in accordance with ASTM A 536 or cast

iron in accordance with ASTM A 48, Class 40 30AD2 minimum. b) Fabricated steel bases will not be accepted.


2) Bolted to the center column to provide support for the internal spur gear, entire rotating collector mechanism, and one end of the access bridge.

j. Raceways, ball bearings, and oil bath: 1) Raceways and ball bearings:

a) Raceways: Heat-treated alloy steel. b) Ball bearings: Heat-treated alloy steel.

2) Provide replaceable annular raceways to support vertical and horizontal forces transmitted by ball bearings on turntable base and internal spur gear. a) Raceway 40 35AD2 inches minimum in diameter. b) Size the raceways using the following equation:

31

2*466,59

DN

Pq

Where:

q = Contact stress, pounds per square inch (maximum = 300,000 pounds per square inch)

P = Total rotating (hung) load, pounds, including truss arms, center cage, internal spur gear, influent well, skimmers, tapered spiral scraper blades, counterweights, and any other rotating weight.

N = No. of balls.

D = Ball diameter, inch.

3) Design raceway and ball bearings for ABMA 9, L-10 life of 200,000 hours minimum.

4) Provide oil bath for turntable base and internal spur gear. a) Include felt seal and dust shield protection. b) Provide oil fill, oil drain, and oil level indicator devices in readily

accessible locations. c) Lubricant in accordance with AGMA 9005.

4. Chain drive: a. Material:

1) Sprockets: Steel. b. Type: Standard roller chain in accordance with ASME B 29.1M connecting

drive sprocket of the gear motor speed reducer to the driven sprocket. c. Drive sprocket: Minimum of 12 teeth. d. Chain and sprockets enclosure: Enclose roller chain and sprockets in

weatherproof fabricated steel guard with service openings. e. Chain:

1) Minimum tensile strength greater than 4 times chain pull based on momentary peak torque.

2) Power rating exceeding the transmitted power (based on continuous running torque) by 1.50 minimum.

5. Drive motor: a. Motor design:

1) Drive motor shall be a squirrel-cage indication type. 2) Motor characteristics:

a) Minimum continuous horsepower not less than 3/4.


b) Voltage: 480-volts. c) Phase: 3. d) Frequency: 60-hertz. e) Insulation: Class B, moisture resistant. f) Service factor: 1.15. g) Maximum ambient temperature: 40 degrees centigrade. h) Enclosure: TEFC, suitable for installation in a Class I, Division 2

environment. i) Synchronous speed: 1,800 revolutions per minute.

3) Nameplate: Include all information listed above under subparagraph "Motor Characteristics."

4) As specified in Section 15170.

H. Electrical controls: 1. Local control panel in compliance with Section 13390:

a. Enclosure: NEMA Type 4X. b. Mount local control panel near drive mechanism on guardrail as indicated

on the Drawings. 2. Electrical wiring as specified in Section 17200 3. Overload device and alarms:

a. Torque overload device: Incorporate into drive assembly. 1) Mechanical overload device shall be actuated by torque from the

rotation of the wormgear. 2) Torque indicator:

a) Provide a visual torque indicator oriented so that it may be read from the walkway at all times during operation.

b) Calibrate torque indicator from 0 to 160 percent of the continuous running torque.

3) Include with the overload device, 2 independently adjustable switches as follows: a) Alarm switch: An alarm switch that shall be adjusted to activate

an alarm when load reaches 90 percent of the continuous running torque.

b) Cutout switch: A cutout switch that shall be adjusted to shut-off the motor when load reaches 100 percent of the continuous running torque.

c) Alarm circuit to sound an alarm horn and illuminate a red lamp, both mounted at the local control panel.

d) Alarm contacts of the maintained type rated at 10 amps continuous pilot duty.

e) Overload device indicating meter enclosure: Weather proof steel,

f) NEMA Type 7. 4) Provide electrical supply to overload device as indicated on the

Drawings. Include: a) Electrical components of overload device compatible with alarm

devices. b) Other electrical requirements as indicated on the Drawings.

b. Additional protection: 1) Provide shear pins in the drive assembly for additional protection

above the shut-off torque rating.


a) This additional protection device shall function at approximately 125 percent of continuous running torque.

b) Shear pins: Corrosion resistant material. 2) Provide limit switch that indicates breakage of the shear pin due to

any circumstance. Shear pin limit switch shall be interlocked with motor controls to prevent mechanism from operating with a broken shear pin. a) Materials: Corrosion resistant. b) Electrical enclosure: NEMA Type 4X.

c. Alarm horn: 1) Suitable for outdoor installation. 2) Manufacturers: One of the following or equal:

a) Federal Horn, Catalog Number 350W. d. Alarm lamp:

1) Provide vapor-tight red alarm lamp suitable for outdoor installation. e. Equipment identification plates: Provide 16-gauge stainless steel

identification plate, securely mounted on equipment in readily visible location, bearing equipment identification tag number.

PART 3 EXECUTION

3.01 INSTALLATION

A. Sludge collector mechanism: Install mechanism and appurtenances as indicated on the Drawings and in accordance with the manufacturer's installation instructions and recommendations.

B. Field welding: 1. Field welding is permitted only for the bridge splice. 2. Use shielded arc welding and conform to requirements of design loads.

C. Guardrail with kickplate: Install around center turntable as specified in Section 05500.

D. Scum skimming system: Install counterweights designed and located by manufacturer.

E. Center column: Mount center column vertically over influent port at center of basin floor.


A. Testing, training, and start-up: As specified in Section 01650 and the following requirements below.

B. Tests: 1. General: Conduct tests in presence of the Engineer. 2. Working under direction of manufacturer's engineer, perform field tests on

each mechanism as follows: a. Cutout torque test:

1) Perform cutout torque test prior to placement of grout topping on concrete slab.


2) The manufacturer shall propose a method of conducting this test and shall verify that the method of testing will not impose stresses in members that exceed allowable stresses.

b. Adjustments and settings to overload device: 1) Adjustments and settings: Perform necessary adjustments and

settings to overload device to ensure that sludge collector mechanism will sound an alarm and switch off drive motor when specified overload conditions occur in tank.

2) Test run: Perform test run following completion of adjustments and settings of overload device to confirm effectiveness of overload device.

c. Dry test run of equipment: 1) Special attention: Give attention during dry test run of equipment to

operation of scum skimming device. 2) Settings of skimmer boom to scum box lip and rubber wiping and

sealing strips: Set as required to ensure that adequate volume of scum is discharged under normal operating conditions.

C. Required results: 1. Sludge collector mechanism:

a. In the event the mechanism fails to meet field quality control test requirements of this Section, make necessary changes and retest mechanism.

b. If mechanism remains unable to meet test requirements to satisfaction of the Engineer, remove and replace such mechanism with satisfactory mechanism at no additional cost.

D. Manufacturer's field service: 1. Contractor to coordinate field service work with the manufacturer's service

representative, Owner, and Engineer prior to initiating such work. 2. Manufacturer's service representative:

a. Manufacturer is to furnish services of representative experienced in erection and operation of the sludge collector mechanism.

b. Period of services: The manufacturer shall include in his bid a minimum of two 8-hour days and 1 trip. The specified durations are the minimum required time on the job site and do not include travel time.

c. Services are to include the following: 1) Installation consultation and advice. 2) Checking and supervision of the collector installation. 3) Inspection and certification that unit is ready to sweep in grout prior

to grouting operation. 4) Final inspection and adjustments prior to testing. 5) Supervision of testing. 6) Instruction of personnel on operation and maintenance of equipment

as specified in Section 01650.

END OF SECTION AD2 Addendum No. 2

March 1, 2019 - CONFORMED 11353B-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/11353B (CONFORMED)

SECTION 11353B

CIRCULAR SECONDARY CLARIFIER EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Specification of equipment for installation in circular secondary clarifiers of

center feed, peripheral overflow design. 2. Clarifier accessories:

a. Density current baffle.

B. Related sections: 1. Section 01140 - Work Restrictions. 2. Section 01410 - Regulatory Requirements. 3. Section 01612 - Seismic Design Criteria. 4. Section 01650 – Facility Startup/Commissioning. 5. Section 05500 - Metal Fabrications. 6. Section 06611 - Fiberglass Reinforced Plastic Fabrications. 7. Section 09960 - High-Performance Coatings. 8. Section 15061 - Pipe Supports. 9. Section 15170 - Electrical Motor, Induction 600 Watts and Below. 10. Section 16222 - Low Voltage Motors up to 500 Horsepower. 11. Section 17200 - Instrumentation and Control Cabinets and Associated

Equipment. 12. Section 17710 - Control Systems: Panels, Enclosures, and Panel

Components.

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9 - Load Ratings and Fatigue Life for Ball Bearings.

B. American Gear Manufacturers Association (AGMA): 1. 908 - Information Sheet - Geometry Factors for Determining the Pitting

Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth.

2. 915-1 - Inspection Practices - Part 1: Cylindrical Gears - Tangential Measurements.

3. 915-2 - Inspection Practices - Part 2: Cylindrical Gears - Radial Measurements.

4. 2001 - Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth.

5. 2004 - Gear Materials, Heat Treatment and Processing Manual. 6. 2009 - Bevel Gear Classification, Tolerances and Measuring Methods. 7. 2011 - Cylindrical Wormgearing Tolerance and Inspection Methods. 8. 2015-1 - Accuracy Classification System - Tangential Measurements for

Cylindrical Gears.


9. 2015-2 - Accuracy Classification System - Radial Measurements for Cylindrical Gears.

10. 6013 - Standard for Industrial Enclosed Gear Drives. 11. 6022 - Design Manual for Cylindrical Wormgearing. 12. 6034 - Practice for Enclosed Cylindrical Wormgear Speed Reducers and

Gearmotors. 13. 9005 - Industrial Gear Lubrication.

C. American Institute of Steel Construction (AISC): 1. 360 - Specification for Structural Steel Buildings - Allowable Stress Design and

Plastic Design.

D. American Welding Society (AWS): 1. D 1.1 - Structural Welding Code for Steel. 2. D1.6 - Structural Welding Code - Stainless Steel.

E. ASTM International (ASTM): 1. A 36 - Standard Specifications for Structural Steel. 2. A 48 - Standard Specification for Gray Iron Castings. 3. A 148 - Standard Specification for Steel Castings, High Strength, for Structural

Purposes. 4. A 276 - Standard Specification for Stainless Steel Bars and Shapes. 5. A 325 - Standard Specification for Structural Bolts, Steel, Heat Treated,

120/105 ksi Minimum Tensile Strength. 6. A 536 - Standard Specification for Ductile Iron Castings. 7. D 638 - Standard Test Method for Tensile Properties of Plastics. 8. D 790 - Standard Test Methods for Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials. 9. D 2583 - Standard Test Method for Indentation Hardness of Rigid Plastics by

Means of a Barcol Impressor.

F. International Organization for Standardization (ISO): 1. 53 - Cylindrical Gears for General and Heavy Engineering - Standard Basic

Rack Tooth Profile.

G. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1,000 volts maximum).

1.03 DEFINITIONS

A. NEMA: 1. Type 4X enclosure in accordance with NEMA 250. 2. Type 7 enclosure in accordance with NEMA 250

B. Continuous operation: 24 hour-per-day operation for design life of not less than 20 years, which equals 175,200 hours.

C. Intermittent operation: Periodic operation, including starts and stops, and prolonged periods of resting.

D. Subassemblies: Includes, but may not be limited to, complete center column, drive cage, drive assembly, truss arms, and scum skimming system.


E. Set: Equipment necessary to completely furnish 1 clarifier.

F. Continuous running torque: 1. The 100 percent AGMA torque, assumed to be continuously applied, 24 hours

a day, to the drive system. 2. Bearing life, gear strength, gear durability, gear rating, mechanism structural

design, and alarm and shutdown setpoints are specified as a percentage of the continuous running torque.

G. Momentary peak torque: 1. The maximum torque for rating yield strength or ultimate strength of center

drive mechanism components. 2. The numerical value for momentary peak torque shall be 2.0 times continuous

running torque.

H. Spiral scraper angle of attack: The angle between the clarifier radial line and the line tangent to the spiral scraper.

I. Manufacturer: 1. Firm responsible for the design, operation, delivery, installation certification,

and warranty of sludge collection equipment. 2. Manufacturer shall also provide sludge collector drive mechanism.

J. Fabricator: 1. Firm responsible for the fabrication of sludge collection equipment conforming

to the manufacturer’s design. 2. Manufacturer may also be the fabricator if fabrication of all components is self-

performed.


A. Nominal clarifier dimensions: 1. Diameter: As indicated on the Drawings. 2. Side water depth: As indicated on the Drawings. 3. Bottom slope: As indicated on the Drawings.

B. Sludge collector mechanism: 1. Supply as a complete and operational system by a single manufacturer. 2. Equipment to include, but not be limited to, the following components:

a. Walkways and access bridges with guardrail and grating. b. Center column. c. Influent well. d. Flocculating well. e. Center drive cage. f. Sludge collector truss arms. g. Scum skimming system. h. Tapered spiral scraper blades. i. Center drive mechanism. j. Drive motor. k. Electrical controls. l. Overload devices and alarms. m. Other components necessary to provide a complete system.


3. Process description: a. Mixed liquor enters the clarifier through a center column and is discharged

into the influent well through openings in the center column. b. The influent well dissipates the kinetic energy of the influent mixed liquor

flow. Peripheral outlet ports in the influent well create a controlled discharge of the mixed liquor into the flocculating well to enhance flow distribution and flocculation.

c. The flocculating well promotes flocculation of the mixed liquor suspended solids and allows for a gradual redirection of the flow velocity into the clarifier.

d. A central drive mechanism mounted on a center column supports and rotates a center cage with 2 truss arm assemblies, each supporting a tapered spiral scraper blade and 1 surface skimming arms.

e. Clarifier connected directly to RAS pump suction: 1) Sludge is transported in a single revolution toward a manifold or

center sludge hopper. 2) Sludge removal is accomplished by the combined action of the

continuously rotating sludge collection mechanism and the return activated sludge pumping system.

f. The sludge accumulated in the clarifier is scraped to a center sludge hopper by tapered spiral scraper blades mounted on the truss arms for continuous removal.

g. The scum skimming system consists of a full radius skimming arm that collects secondary scum from the surface of the clarifier and deposits it into the scum collection hopper.

h. The density current baffle extends along the periphery of the clarifier and keeps the rising density current from carrying solids over the weirs.

C. Design requirements: 1. Operating parameters:

a. Process flows:

Parameter (Per Clarifier) Minimum Average Maximum Peak Effluent Flow, million gallons per day (mgd)

1.0 1.1 1.5

Return Activated Sludge (RAS) Flow, mgd

0.75 2.2 3.0

Total Mixed Liquor (ML) Flow, mgd

1.75 3.3 4.5

b. Maximum allowable headloss through the center column, the influent well, and the flocculating well at peak flow = 6 inches.

c. Mixed liquor suspended solids concentration range = milligrams per liter to 2,000 to 3,500 milligrams per liter.

2. Mechanical design: a. Design for a continuous running torque of 10,000 foot pounds. b. Design collector mechanism to operate at a tip speed, measured at the

ends of the rake arms, of approximately 8 feet per minute. c. Use no chains, sprockets, bearings, or gears below the water surface for

the sludge collector mechanism.


3. Structural design: a. Design the sludge collector mechanism in accordance with AISC 360,

except: 1) Provide a 3/16 inch minimum thickness for all members, except

where specifically modified by this Section. 2) Include stresses in members caused by bending and twisting due to

eccentricities of members at joints. b. Slenderness ratio (Kl/r) using K Value of 1.0 shall not exceed the values

specified below: 1) Tension members: Not greater than 240. 2) Compression members: Not greater than 200.

c. Base member weights used for design on final full member thickness. d. Full member thicknesses may be used for performing deflection

calculations. e. Design the center cage and the truss arms as an integral structure.

Design the center cage and the connections to the truss arms for the reactions from the truss arms.

f. Do not include live load where its inclusion results in lower stresses in a member under investigation.

g. Seismic loads: Seismic loads shall be as required by the Building Code specified in Section 01410, where load and resistance factor design (strength design) is used. 1) Hydrodynamic loads for load and resistance factor design (strength

design): a) Flocculating well: Total load of 4.1 kilopounds applied

appropriately to the inside and outside surfaces. b) Influent well: Total load of 1.4 kilopounds applied appropriately

to the inside and outside surfaces. c) Center column: Total load of 0.1 kilopounds applied

appropriately to the outside surfaces. d) All other elements: Hydrodynamic loads as determined using the

seismic criteria specified in Section 01612. 2) Hydrodynamic loads for allowable stress design (alternate design

method) shall be equal to the load and resistance factor design loads divided by 1.4.

3) Seismic loads due to weight of mechanism; as determined using the seismic criteria specified in Section 01612. Include the water inside the center column as part of the weight of the center column.

h. Load combinations: Design each structural member of the sludge collector mechanism for the most critical load combination resulting from the following load combinations: 1) Dead load plus live load plus continuous running torque. 2) Dead load plus live load plus continuous running torque plus seismic

load. a) Seismic load shall include seismic load from the water inside the

clarifier acting on members of the clarifier mechanism. b) For elements of the clarifier such as the center column, the

influent well, and the flocculating well, impulsive and convective seismic loads from the water shall be applied appropriately on both the inside and outside surfaces.

c) These seismic loads shall be in addition to the seismic loads due to the dead loads of the elements.


3) Dead load plus live load plus torque due to screeding grout topping on slab using sludge collector mechanism.

4) Dead load plus live load plus torque due to cutout torque test. 5) Other load combinations selected by the manufacturer. 6) Truss arm load cases: Use the following load cases on the truss

arms for load combinations: a) Equal uniform horizontal load along the full length of both truss

arms which results in a combined torque equal to the continuous running torque.

b) Uniform horizontal loads along the full length of both truss arms which results in 70 percent of the torque from 1 truss arm and 30 percent of the torque from the other truss arm for a combined torque equal to the continuous running torque.

c) Load on truss arms due to spreading grout topping on slab using sludge collector mechanism.

d) Load on truss arms due to cutout torque load test. i. Deflections:

1) The horizontal deflection of the truss arm, due to truss arm deflection plus rotational deflection of the center cage for load cases which contain continuous running torque, shall not exceed a deflection equal to the radius of the clarifier divided by 400 (L/400). a) Not more than 60 percent of the total horizontal deflection shall

be due to center cage rotation. b) Horizontal deflection of the truss arm shall be measured at the

end of the truss arm furthest from the center column. 2) The vertical deflection of the truss arm due to equipment dead load

shall not exceed the length of the truss arm divided by 800 (L/800). j. Seismic design criteria: As specified in Section 01612. k. With sufficient strength to sweep in a 2-inch grout layer on the basin

bottom under its own power.

1.05 SUBMITTALS

A. Submit product data and shop drawings, operation and maintenance manuals, and test reports.

B. Product data and shop drawings: 1. Shop drawings shall consist of a cover sheet indicating the drawing number

and specification page and number to which referenced, intended use and data summary, outline drawings, cut-away drawings, parts lists, material specification lists, and all information required to substantiate that the proposed equipment meets the specifications. a. Shop drawing submittals will not be considered complete if cut-away or

assembly drawings with part and material specification lists are not included.

2. General arrangement drawings showing the complete assembly, part numbers, and materials list.

3. Detailed drawings: a. Sludge collector mechanism indicating dimensions, member sizes and

thicknesses, welding, and connection details. b. Drive mechanism showing sizes, dimensions, and arrangement of each

drive component.


c. For gears, except those contained in the gearmotor speed reducer, detailed drawings with the following minimum data for each gear: 1) Number of teeth. 2) Net face width. 3) Outside diameter of external gears. 4) Inside diameter of internal gears. 5) Normal diametral pitch or axial pitch for worm gears. 6) Normal generating pressure angle. 7) Lead angle (for worm gears). 8) Operating center distance. 9) Addendum modification coefficient. 10) Tooth thickness or pin or span measurements. 11) Quality numbers in accordance with AGMA 915-1, 915-2, 2009,

2011, 2015-1, and 2015-2. 12) Material alloy. 13) Type of heat treatment. 14) Tooth surface hardness. 15) Tooth core hardness. 16) For case hardened gears, effective case depth to Rc 50. 17) Lubricant type (mineral/synthetic/EP). 18) Lubricant viscosity.

d. Setting drawings, templates, and directions for the installation of anchor bolts and other anchorages. In addition to the manufacturer supplying installation instructions as specified, the manufacturer shall supply storage procedures for all equipment as required. Submit design calculations as shop drawings prior to the completion of all shop drawings.

4. Certified motor data sheets. 5. Shop primer and coating data. 6. Control system data, schematics, and wiring diagrams. 7. Spare parts list. 8. Qualifications and resume of installation engineer. 9. Training course outlines. 10. Manufacturer’s experience and reference list as specified in Article Quality

Assurance.

C. Manufacturer's installation instructions.

D. Calculations: Include, without necessarily being limited to: 1. Structural calculations:

a. Calculations shall be prepared and signed by a professional civil engineer licensed in the state where the Project is located demonstrating compliance with structural criteria specified in this Section and seismic design criteria as specified in Section 01612.

b. Submit design calculations with complete shop drawings. 2. Mechanical and hydraulic calculations: Performed by a professional civil or

mechanical engineer licensed in the state where the Project is located. Calculations are intended to: a. Substantiate continuous running torque loading and overload torque rating

of each component of drive mechanism. 1) Calculations shall be in accordance with AGMA 908.


2) Calculations shall clearly specify all design parameters used in developing the ratings, including materials in accordance with AGMA 2004.

3) All ratings in accordance with AGMA 2001 and AGMA 6034. b. Demonstrate that each bearing in drive mechanism complies with bearing

life requirements of this Section. c. Verify that the tapered spiral scraper blade design, as proposed by the

manufacturer, is capable of transporting settled sludge from the entire floor area of the clarifier to the withdrawal point under all specified flow and sludge loading conditions without resulting in excessive sludge accumulation. An excessive accumulation is defined as a depth of settled sludge which exceeds the spiral scraper blade depth. 1) The manufacturer shall submit modeling results which incorporate

both hydraulic and mechanical transport mechanisms for review.

E. Reference list: Include the following information as a minimum: 1. Name and location of installation. 2. Name and telephone number of the person in direct responsible charge of the

equipment. 3. Name and contact information for equipment fabricator. 4. Name and contact information for manufacturer’s engineer responsible for

structural design. 5. Month and year the equipment was placed in operation. 6. Size of equipment. 7. Number of units installed. 8. Service.

F. Quality control submittals: 1. Welder’s certificates. 2. Submit Manufacturer's or designated contract fabrication facility’s structural

steel fabrication qualifications and information. 3. Engineer’s qualifications to complete structural analysis and design.

G. Fabrication certification report: 1. Provide fabrication certification report prior to equipment delivery to project

site.

H. Test reports: 1. Method of conducting cutout torque test and verification that method of testing

will not impose stresses in any member which exceeds maximum allowable stresses specified in this Section.

2. Results of field torque tests on sludge collector mechanism.

I. Operation and Maintenance Manuals.

J. Certificates: Manufacturer’s certification that equipment was installed in accordance with the manufacturer's instructions, inspected by the manufacturer, serviced with the proper initial lubricants, and equipped with applicable safety equipment and controls.

K. Technician's Qualifications Resume: Submit resume of technician to perform Manufacturers Field Service.



A. Manufacturer qualifications: 1. Experience: Demonstrate minimum 5 years’ experience in the manufacture

and fabrication of tapered spiral scraper sludge collectors which have been successfully utilized in domestic wastewater applications. a. Experience of fabricator, if manufacturer does not self-perform fabrication,

shall meet or exceed that required of manufacturer. b. Submit substantial information as necessary to establish qualifications of

fabricator, if manufacturer does not self-perform fabrication, including location (address), experience, qualifications, and certifications of all fabricator’s staff to be utilized.

c. Manufacturer’s engineer responsible for structural design shall also demonstrate minimum 5 years’ experience designing sludge collectors to withstand operational and seismic loads, including sloshing of tank contents on sludge collection mechanism.

2. References: Provide a reference list of at least 5 different installations in domestic wastewater treatment plants of not less than 5 million gallons per day in the continental United States, where the manufacturer has supplied equipment substantially similar in design and characteristics to that proposed in this Section. a. The installations listed must:

1) Have been designed and fabricated by the manufacturer. If manufacturer does not self-perform fabrication, the installation list shall also include the experience of the Project equipment fabricator.

2) Be at least 50 feet in diameter. 3) Have been currently operating for last 5 years.

b. Provide the following information related to the installation: 1) Owner name, address, and telephone number. 2) Design flow of plant. 3) Sludge collector dimensions. 4) Time in operation. 5) References for manufacturer’s engineer responsible for the structural

design.

B. Welding and welder qualifications: 1. Perform welding and qualify and certify welders in accordance with AWS D1.1

and D1.6. 2. Welds:

a. Use shielded arc welding. b. Conform to requirements of design loads. c. Conform to information indicated on the Drawings. d. Use a minimum weld size of 3/16 inch. e. Field welding is permitted only for bridge splice (if required). f. Engineer may check materials, equipment, and qualifications of welders. g. Remove welders performing unsatisfactory Work, or require to requalify. h. Engineer may use gamma ray, magnetic particle, dye penetrant,

trepanning, or other aids to visual inspection to examine any part of welds or all welds.

i. Manufacturer shall bear costs of retests on defective welds. j. Manufacturer shall also bear costs in connection with qualifying welders.


C. Steel fabrication: 1. Manufacturer’s authorized representative shall be present during fabrication of

equipment. 2. Manufacturer’s authorized representative shall provide a fabrication

certification report complete with certified fabrication drawings, a journal of the fabrication work process, photo documentation of the shop assembly of all components required to be field erected, and a certification that the fabricated equipment is complete and ready for installation by the Contractor.

D. Equipment subassemblies: 1. Each component subassembly requiring field erection shall be test assembled

and documented at the manufacturer’s fabrication facility. 2. Digital photographic evidence of assembly shall be submitted as part of the

fabrication certification report. 3. Mark parts with erection matchmarks for ease of field erection. 4. Lubricate moving parts before shipment. 5. When necessary to disassemble parts for shipping, coat uncoated exposed

machine surfaces with suitable, easily removable, rust-preventive compound before shipping.


A. Environmental project conditions: 1. Installation in a wastewater treatment plant. 2. Moderate quantities of commercial and industrial waste. 3. Exposure to industrial solvents and petroleum products. 4. Operation at 440 feet above mean sea level. 5. Ambient air temperature:

a. Maximum 120 degrees Fahrenheit. b. Minimum 20 degrees Fahrenheit.

6. Wastewater temperature: a. Maximum 90 degrees Fahrenheit. b. Minimum 55 degrees Fahrenheit.




any and all damage until the equipment is delivered to the job site. 3. Accessories shall be packaged separately in containers clearly marked

“ACCESSORIES ONLY”. 4. A packing list, listing the contents of each container, shall be placed in a



conformance with the Contractor’s construction schedule to minimize handling and on-site storage of equipment.


C. Storage and protection: 1. Protect the system components at the site and during installation prior to

project completion. 2. As a minimum, provide cover, ventilation, and proper stacking to prevent

warping of any equipment stored on-site.


A. Coordinate work with work sequence specified in Section 01140.

1.10 MAINTENANCE

A. Spare parts: Furnish the following spare parts suitably packaged and marked. Include a price list and name, address, and telephone number of local supplier: 1. 2 sets of scum skimmer blade wear strips. 2. 1 set of squeegees for each spiral scraper mechanism furnished. 3. 4 sets of shear pins. 4. 1 set of scum skimmer wipers. 5. 1 set each of oil seals for the worm shaft and pinion shaft.

B. Special tools: Provide the following special tools: 1. Tools required to assemble, disassemble, repair, and maintain equipment, and

that have been specifically made for use on the equipment. 2. Necessary eyebolts, hooks, and rods for handling equipment parts. 3. List of tools with the maintenance and operation data describing the uses of

the tools.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Sludge collector mechanism: 1. All equipment components of the sludge collector mechanism including the

walkways and access bridges, center column, influent well, flocculating well, center drive cage, sludge collector truss arms, scum skimming system, tapered spiral scraper blades, center drive mechanism, drive motor, electrical controls, and overload devices and alarms, shall be furnished by the same manufacturer.

2. Some equipment may require modification from the manufacturer’s standard. 3. Exercise care to assure that the electrical, mechanical, structural, and

miscellaneous systems comply with the requirements specified or in other referenced sections.

4. Manufacturers: One of the following or equal: a. Ovivo/Eimco Water Technologies. b. Siemens Water Technologies/Envirex, Inc. c. Westech, Inc. d. Walker Process Equipment.

B. Density current baffle: 1. Manufacturer: The following or equal:AD2

a. Nefco, Inc.


2.02 MATERIALS

A. For all components unless specified otherwise the materials of construction are specified below.

B. Structural steel: 1. In accordance with ASTM A 36. for clarifier bridge construction, and for all

other components, ASTM A 276, Type 304L Stainless Steel. 2. Grind all edges of steel members to approximately 1/16-inch minimum radius

using a grinder.AD2

C. Stainless steel, ASTM A 276, Type 304. 1. Components or structural shapes which are welded:

a. Materials: Type 304L stainless steel. b. Manufacturer's shop welds, welding procedures, and welders:

1) Qualified and certified in accordance with the requirements of AWS D1.6.

D. Anchor bolts: Type 316 stainless steel.

E. Weir plate: Fiberglass reinforced plastic as specified in Section 06611.

F. Scum baffles: Fiberglass reinforced plastic as specified in Section 06611.

G. Fasteners and washers: Type 304 stainless steel, except for bolts which will be removed during installation and any high strength bolts.

H. High strength bolts: In accordance with ASTM A 325 hot-dip galvanized high strength bolts in attaching truss arms to cage, and cage to center drive gear casting.

I. Do not use cadmium plated parts and fasteners.

J. Dissimilar metals: All aluminum components shall be isolated from steel components as specified in Section 05500, to prevent electrolysis.

K. Handrails shall be aluminum as specified in Section 05500.AD2

2.03 SLUDGE COLLECTOR MECHANISM

A. Walkways and access bridges: 1. Materials:

a. Welded steel beam construction. 2. Design:

a. Composed of 2 main members laterally braced together. b. Minimum live load of 100 pounds per square foot. c. Maximum deflection not to exceed span length divided by 360 (L/360) for

dead plus live loads. d. Support light standards and fixtures as indicated on the Drawings. e. Supported using:

1) Center column at one end and the outer concrete clarifier wall at the other as indicated on the Drawings.

2) Make allowance at outer concrete wall for expansion and contraction of walkway due to temperature changes.


a) Use self-lubricating bearings. b) Do not use non-lubricated metal-to-metal slide plates or direct

metal-to-concrete bearing. c) Prevent lateral movement of bridge at outer wall.

f. Provide additional structural supports as required for piping and conduit on the bridge as indicated on the Drawings.

3. Platform at the center turntable: Provide a minimum clearance of 2 feet 6 inches around all sides of drive mechanism and allow uninhibited access to all parts of the drive unit.

4. Guardrail with kickplate: a. On both sides of walkway and all around center turntable platform. b. Guardrail and kickplate as specified in Section 05500 and matching other

railing supplied for Project. 5. Walking surface:

a. Materials: Aluminum grating as specified in Section 05500. b. Location: Over entire bridge and center turntable platform.

B. Center column: 1. Materials:

a. Vertically mounted, cylindrical steel column. 1) Inside diameter: 20 inches. 2) Wall thickness: 1/4-inch minimum.

2. Design: a. Support the entire sludge collector mechanism including inboard end of

bridge. b. Size and anchor the center column to be capable of resisting design loads

when the tank is empty or full. 3. Center column anchorage: Mount the center column over the influent port at

the center of the clarifier floor. Connect the base flange of the center column to the concrete foundation using anchor bolts. a. Use a rigid steel template of minimum 1/4 inch thickness to accurately

locate anchor bolts for the center column during concrete placement. b. Supplier shall coordinate with the Contractor to ensure proper anchor bolt

location. c. Center column base anchor bolts:

1) Not less than 8 in number. 2) Not less than 15 bolt diameters of embedment length. 3) Not less than 3/4 inch in diameter. 4) Use a minimum edge distance for anchor bolts of the larger of

6 inches or 6 anchor bolt diameters, and as required to clear reinforcing bars located around opening.

d. Center column base mounting flange: 1) Size and reinforce using gussets or other stiffeners as necessary to

adequately transfer loads from the sludge collector mechanism to clarifier structure.

2) Bolt holes in flange to accommodate anchor bolts shall not exceed 1/8 inch plus bolt diameter.

4. Center column outlet ports: Provide outlet ports in the upper end of the center column to disperse influent flow into the influent well. Provide the following: a. A total of 4 ports. b. Appropriately reinforced port openings. c. Port dimensions: As indicated on the Drawings.


5. Flange and stiffen the top of the center column for supporting the sludge collector mechanism, the drive mechanism, and the access bridge. a. Attach the center column to the drive assembly using bolts.

6. Drain holes: Provide two 2-inch holes at bottom to allow column to drain into the tank.

C. Influent well: 1. Materials:

a. Structural steel plate and members. b. Reinforced with steel stiffening angles where necessary.

2. Design: a. Closed-bottom tub concentric with the center column. b. Supported around the outside of the center drive cage. c. Diffuse influent flow into the clarifier tangentially, evenly, and efficiently

without excessive disturbances. d. Influent well outlet ports:

1) Shall direct and control flow into the clarifier. 2) Dimensions: As indicated on the Drawings.

e. Dimensions: As indicated on the Drawings. f. Provide two 2-inch orifices in the bottom to allow the well to drain as the

clarifier is emptying.

D. Flocculating well: 1. Materials:

a. Structural steel plate and members. b. Reinforced with steel stiffening angles where necessary.

2. Design: a. Dimensions: As indicated on the Drawings. b. Equip with a minimum of 4 baffled slots as indicated on the Drawings to

allow for removal of floating material in the well. c. Support from center cage using rigid connection.

1) Other methods of connection such as swinging supports or breakaway supports are not permitted.

E. Center drive cage: 1. Materials:

a. Structural steel members. 2. Design:

a. Box truss design. b. Design to carry load from the truss arms plus its own dead load. c. Fasten center drive cage to spur gear assembly using bolted connection. d. Design to support and rotate the truss arm assemblies with the tapered

spiral scraper blades, and the surface skimming arm.

F. Sludge collector truss arms: 1. Materials:

a. Structural steel. 2. Design:

a. Truss design. Tie rods not permitted. b. Design with sufficient structural strength to screed in a layer of grout on

the clarifier bottom under its own power.


c. Maintain width of the truss arm the same as the width of center drive cage to ensure alignment and proper connection.

d. Rigidly connect truss arm to the center drive cage. e. Use the truss arm to support the sludge collection tapered spiral scraper

blades, and scum skimmer arms.

G. Tapered spiral scraper blades: 1. General:

a. Manufacturer shall be solely responsible for the design of the spiral scraper blades.

b. Number and dimensions of blades shall be based upon sludge transport model results prepared by manufacturer and submitted for review.

c. Spiral sludge blades indicated on the Drawings are for illustration purposes only, and shall not be construed as design intent.

d. Additional blades to transport sludge away from center column to withdrawal point shall be provided, if required by manufacturer’s design configuration.

2. Blades: a. Materials: Structural steel. b. Thickness and stiffeners as required to limit blade deflection.

1) Taper blades as required to match floor slope. 2) Top of blade shall be horizontal.

3. Squeegees: a. Materials: Brass or stainless steel, spring type, not less than 26 gauge

thickness. b. Attach squeegees to blades utilizing stainless steel hardware. Squeegees

shall be designed to allow 2 inches of vertical adjustment.

H. Scum skimming system: Consisting of a scum skimmer assembly that pushes floating scum to a scum trough for removal. Basic components of skimmer assembly include scum deflector blades and skimmer device. 1. Scum deflector blades:

a. Material: Structural steel plate. b. Designed to collect and push floating scum radially outward toward the

circumferential scum baffle. c. Extends from the flocculating well to the scum skimmer device. d. A central drive mechanism mounted on a center column support and

rotates a center cage with 2 truss arm assemblies, including tapered spiral scraper blades and 1 surface skimming arms.

e. Attach inner end of deflector blade tangentially to the flocculating well where practicable. Otherwise, provide maximum angle of approach of scum deflector blade to the scum in order to drift the scum to circumferential baffle.

2. Scum skimmer device: a. Materials: Structural steel plate and members. b. Attach to outer end of the scum deflector blade to trap scum for discharge

into scum trough. c. Size: Full length of the scum trough. d. Design:

1) Maintain continuous contact and proper alignment with scum baffle and inclined scum ramp to positively rake scum to the scum trough.


2) Use a hinged blade to move entrapped scum up the scum beach to the scum trough.

3) Provide a replaceable wear block on the outer edge of each scum skimmer device.

e. Hinged blade: 1) Adjustable vertically to control the dewatering of scum as it travels up

the inclined ramp to the scum trough. 2) Adjustable vertically over the length to ensure contact with the scum

trough even though the trough may not be level. 3) Capable of being raised and locked out above the water level or held

horizontally against the circumferential scum baffle when skimming is not required.

4) Equipped with replaceable scum skimmer wipers on the bottom inner and outer edges to seal the entrapped scum and water when moving up the inclined approach ramp to the scum trough.

f. Scum skimmer wipers: Oil resistant neoprene. g. Wear block:

1) Material: Polyvinyl chloride. 2) Wear block constantly forced against circumferential scum baffle to

keep baffle clean using a coiled spring arrangement. 3) Force between baffle and wear block adjustable between 1 to

5 pounds. h. Wear block coiled springs:

1) Material: Type 18-8 stainless steel. 2) Enclosed to protect them from the weather. 3) Spring enclosures:

a) Material: Welded steel or cast iron housing. b) Bronze bushed and grease lubricated for easy movement of

hinged blades. 3. Scum trough and scum beach:

a. Fabricated from 3/16 inch minimum thickness stainless steel plate. b. Supported from clarifier wall by structural steel members. c. Scum trough:

1) Width: As indicated on the Drawings. 2) No internal stiffeners or structural members which obstruct scum

flow. 3) Standard pipe flanged connection for scum discharge pipe. Size as

indicated on the Drawings. d. Scum beach (inclined approach ramp):

1) Length: As indicated on the Drawings. 2) Shaped to contain scum as it is moved up the incline to the trough by

the scum skimmer. 4. Skimmer assembly supports:

a. Material: Structural steel members. b. Attached to the sludge collector truss arms. Do not support scum skimmer

assembly from the scum baffle. c. Space supports, brought up from the truss arm, at not greater than 10 feet

on center. 5. Equipment manufacturer shall size and locate counterweights to be installed

by the Contractor. 6. Threaded fasteners: Type 18-8 stainless steel.


I. Center drive mechanism: Provide a center drive mechanism consisting of a primary speed reducer driven by electric motor, through a roller chain using an intermediate gearset consisting of a cylindrical-worm and helical-wormgear, and a low speed gearset consisting of a spur pinion and internal spur gear supported within a cast iron housing by a circular main bearing featuring replaceable bearing race inserts. Center drive mechanisms utilizing housings and internal spur gears featuring integral gothic arch style bearing races are not acceptable. 1. Gear motor speed reducer:

a. Type: 1) Cylindrical-worm or helical-wormgear motor. 2) Planetary gear units will not be acceptable.

b. Speed reducer in accordance with AGMA 6013 and 6034. c. Service factors: Minimum speed reducer service factor of 2.0 minimum

based on continuous running torque. d. Connect speed reducer output shaft to drive sprocket of chain drive. e. Speed reducer overhung load rating:

1) Exceed the chain pull (based on continuous running torque) by 1.50 minimum.

f. Oil bath lubrication: 1) Lubricant in accordance with AGMA 9005. 2) Provide oil fill, drain, and oil level indicator devices. 3) Oil bath protection seal: Felt.

g. All gears supported by anti-friction bearings. h. Lubricant: In accordance with AGMA 9005.

2. Intermediate gearset: a. Type: Cylindrical-worm and wormgear. b. Materials:

1) Worm: Alloy steel, hardened, ground, and polished. 2) Wormgear: Centrifugally cast bronze. 3) Washers: Hardened steel to prevent embedding of bolt head or nut. 4) Bushings: Bronze. 5) Housing: Cast iron in accordance with ASTM A 48, Class 30

minimum. c. Load capacity: Rated in accordance with AGMA 6034. d. Service factor: Minimum of 1.25 based on continuous running torque. e. Wormgear shaft:

1) Drives pinion of low-speed gearset. 2) Support shaft by anti-friction bearings or combination of anti-friction

bearings and bushing. f. Wormgear: In accordance with AGMA 6022. g. Worm shaft: Support by anti-friction bearings. If the wormgear is bolted to

a drive hub, it shall be piloted for concentricity. h. Worm and wormgear shaft: Anti-friction bearings shall have ABMA 9,

L-10 life of 180,000 hours minimum based upon continuous running torque.

i. Provide oil bath lubrication. 1) Lubricant in accordance with AGMA 9005. 2) Provide oil fill, drain, and oil level indicator devices.

3. Low-speed gearset: a. Provide low-speed gearset using spur pinion and internal spur gear. b. Spur pinion shall be:

1) Integral with its shaft or keyed to a shaft.


a) If keys are used, the pinion shall be secured to the shaft with a shrink fit.

b) Set screws will not be acceptable. 2) Welded spur pinion and shafts will not be acceptable. 3) Keyed spur pinions shall have a wall thickness above the keyway

equal to 1 tooth whole depth minimum. a) Keyway and keyseat shall have 0.02-inch minimum inside radii. b) Keys shall have 0.04 inch minimum chamfer on all edges.

4) Manufactured to have a minimum AGMA Quality Class 8 in accordance with AGMA915-1, 915-2, 2015-1, and 2015-2.

c. Provide full depth teeth in accordance with ISO 53. 1) Stub pitch gear teeth will not be accepted. 2) Undercut gear teeth will not be accepted.

d. Load capacity rated in accordance with AGMA 2001. e. Power rating based on continuous service and the lower of the:

1) Pitting resistance for the pinion and gear. 2) Bending strength for the pinion and gear.

f. Minimum service factor of 1.25 based on continuous running torque. g. Overload torque capacity (based on yielding of the pinion or gear teeth)

exceeding the momentary peak torque by 1.8 minimum. h. Internal spur gear:

1) Material: Ductile (nodular) iron in accordance with ASTM A 536 or cast steel in accordance with ASTM A 148, or heat-treated alloy steel.

2) Minimum AGMA Quality Class 6 in accordance with AGMA 915-1, 915-2, 2015-1, and 2015-.

3) Internal spur gear bolted to the center drive cage. i. Turntable base:

1) Material: a) Ductile (nodular) iron in accordance with ASTM A 536 or cast

iron in accordance with ASTM A 48, Class 30AD2 minimum. b) Fabricated steel bases will not be accepted.

2) Bolted to the center column to provide support for the internal spur gear, entire rotating collector mechanism, and one end of the access bridge.

j. Raceways, ball bearings, and oil bath: 1) Raceways and ball bearings:

a) Raceways: Heat-treated alloy steel. b) Ball bearings: Heat-treated alloy steel.

2) Provide replaceable annular raceways to support vertical and horizontal forces transmitted by ball bearings on turntable base and internal spur gear. a) Raceway 35AD2 inches minimum in diameter.


b) Size the raceways using the following equation:

q = 59,466 3/1

2D*NP

Where: q = Contact stress, pounds per square inch (maximum = 300,000 pounds per square inch) P = Total rotating (hung) load, pounds, including truss arms, center cage, internal spur gear, influent well, flocculating well, skimmers, tapered spiral scraper blades, counterweights, and any other rotating weight. N = Number of balls. D = Ball diameter, inches.

3) Design raceway and ball bearings for ABMA 9, L-10 life of 200,000 hours minimum.

4) Provide oil bath for turntable base and internal spur gear. a) Include felt seal and dust shield protection. b) Provide oil fill, oil drain, and oil level indicator devices in readily

accessible locations. c) Lubricant in accordance with AGMA 9005.

4. Chain drive: a. Material:

1) Sprockets: Steel. b. Type: Standard roller chain in accordance with ASME B 29.1M connecting

drive sprocket of the gear motor speed reducer to the driven sprocket. c. Drive sprocket: Minimum of 12 teeth. d. Chain and sprockets enclosure: Enclose roller chain and sprockets in

weatherproof fabricated steel guard with service openings. e. Chain:

1) Minimum tensile strength greater than 4 times chain pull based on momentary peak torque.

2) Power rating exceeding the transmitted power (based on continuous running torque) by 1.50 minimum.

5. Drive motor: a. Type: Drive motor shall be a squirrel-cage induction type. b. As specified in Section 15170. c. Motor characteristics:

1) Minimum continuous horsepower not less than 0.75. 2) Voltage: 480-volts. 3) Phase: 3. 4) Frequency: 60-hertz. 5) Insulation: Class B, moisture resistant. 6) Service factor: 1.15. 7) Maximum ambient temperature: 40-degrees Celsius. 8) Enclosure: TEFC Class I, Division 2 compliant. 9) Synchronous speed: 1,800 revolutions per minute.

d. Nameplate information: Include all information listed under subparagraph "Motor Characteristics" above.

J. Electrical controls: 1. Local control panel:

a. Enclosure: NEMA Type 4X.


b. Mount local control panel near drive mechanism on guardrail as indicated on the Drawings.

2. Electrical wiring as specified in Section 17200. 3. Overload device and alarms:

a. Torque overload device: Incorporate into drive assembly. 1) Mechanical overload device shall be actuated by torque from the

rotation of the wormgear. 2) Torque indicator:

a) Provide a visual torque indicator oriented so that it may be read from the walkway at all times during operation.

b) Calibrate torque indicator from 0 to 160 percent of the continuous running torque.

3) Include with the overload device, 2 independently adjustable switches as follows: a) Alarm switch: An alarm switch that shall be adjusted to activate

an alarm when load reaches 90 percent of the continuous running torque.

b) Cutout switch: A cutout switch that shall be adjusted to shut off the motor when load reaches 100 percent of the continuous running torque.

c) Alarm circuit to sound an alarm horn and illuminate a red lamp, both mounted at the local control panel.

d) Alarm contacts of the maintained type rated at 10 amps continuous pilot duty.

e) Overload device indicating meter enclosure: Weather proof steel, NEMA Type 4X.

4) Provide electrical supply to overload device as indicated on the Drawings. Include: a) Electrical components of overload device compatible with alarm

devices. b) Other electrical requirements as indicated on the Drawings.

b. Additional protection: 1) Provide shear pins in the drive assembly for additional protection

above the shut-off torque rating. a) This additional protection device shall function at approximately

125 percent of continuous running torque. b) Shear pins: Corrosion resistant material.

2) Provide limit switch that indicates breakage of the shear pin due to any circumstance. Shear pin limit switch shall be interlocked with motor controls to prevent mechanism from operating with a broken shear pin. a) Materials: Corrosion resistant. b) Electrical enclosure: NEMA Type 4X.

c. Alarm horn: 1) Suitable for outdoor installation. 2) Manufacturers: The following or equal:

a) Federal Horn, Catalog Number 350W. d. Alarm lamp: Provide vapor-tight red alarm lamp suitable for outdoor

installation. e. Equipment identification plates: Provide 16-gauge stainless steel

identification plate, securely mounted on equipment in readily visible location, bearing equipment identification tag number.


2.04 CLARIFIER ACCESSORIES

A. Density current baffle: 1. The baffle system shall consist of a series of baffle panels which are attached

to the wall of the clarifier and form an inclined, shelf-like surface around the entire inner periphery of the tank as indicated on the Drawings.

2. Construct panels of corrosion-resistant, UV-treated fiberglass-reinforced plastic. a. For the resin, use an isophthalic polyester with corrosion-resistant

properties, 33-402 resin or equivalent, which is typically used in submerged wastewater treatment applications.

b. Do not use any fillers in the resin except as required for viscosity control, for which, up to 5 percent by weight of a thixotropic agent may be added.

c. Treat the resin to provide ultraviolet suppression. 3. Glass reinforcement to consist of chemically bonded surfacing mat and

copped strand roving, with the glass contents of the finished laminate to be not less than 30 percent by weight.

4. The nominal thickness of each baffle panel shall be 3/16 inches minimum. 5. Attach the panels to the clarifier wall at a reinforced mounting flange and

support them at the proper angle with a triangular shaped bracket. a. The brackets may be molded as an integral part of each panel, or

separate brackets may be supplied. b. If separate brackets are supplied, the brackets shall be fabricated of Type

316 stainless steel. 6. Design the baffle to withstand a buoyant force load equal to the weight of the

water displaced from the volume beneath the baffle. a. In addition, design the baffle to withstand common wind and snow loads

where applicable. b. Provide sufficient pitch and width of the angle’s working surface of the

baffle to divert the flow and create a self-cleaning action of the baffle. 7. Include provisions to vent gases which may form beneath the baffle through

the installation of vents located in the panel. 8. Manufacturer shall furnish certified test reports of the physical and mechanical

properties of the product. Each panel shall have the following minimum physical properties:

Tensile Strength 5,000 psi per ASTM D 638

Flexural Strength 16,000 psi per ASTM D 790

Hardness Barcol 60 per ASTM D 2583

9. Manufacturer shall also furnish certified design calculations and drawings showing details of installation.

10. Install the baffle as indicated on the Drawings and in accordance with the manufacturer’s recommendations. a. For attachment of the baffle panels, use concrete expansion anchors with

neoprene-backed fender washers, lock washers and hex nuts. b. Use Type 316 stainless steel for all the installation fasteners.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install sludge collector mechanism and clarifier accessories as indicated on the Drawings and in accordance with the manufacturer's installation instructions and recommendations.

B. Field welding: 1. Field welding is permitted only for the bridge splice. 2. Use shielded arc welding and conform to requirements of design loads.

C. Guardrail with kickplate: Install on both sides of walkway and around center turntable as specified in Section 05500.

D. Scum skimming system: Install counterweights designed and located by the manufacturer.

E. Center column: Mount center column vertically over influent port at center of basin floor.


A. Testing, training, and start-up: As specified in Section 01650 and the following requirements below.

B. Tests: 1. General: Conduct tests in presence of the Engineer. 2. Working under direction of manufacturer's engineer, perform field tests on

each mechanism as follows: a. Cutout torque test:

1) Perform cutout torque test prior to placement of grout topping on concrete slab.

2) The manufacturer shall propose a method of conducting this test and shall verify that the method of testing will not impose stresses in members that exceed allowable stresses.

b. Adjustments and settings to overload device: 1) Adjustments and settings: Perform necessary adjustments and

settings to overload device to ensure that sludge collector mechanism will sound an alarm and shutdown the drive motor when specified overload conditions occur in clarifier.

2) Test run: Perform test run following completion of adjustments and settings of overload device to confirm effectiveness of overload device.

c. Dry test run of equipment: 1) Special attention: Give attention during dry test run of equipment to

operation of scum skimming device. 2) Settings of skimmer boom to scum box lip and rubber wiping and

sealing strips: Set as required to ensure that adequate volume of scum is discharged under normal operating conditions.


C. Required results: 1. Sludge collector mechanism:

a. In event mechanism fails to meet field quality control test requirements of this Section, make necessary changes and retest mechanism.

b. If mechanism remains unable to meet test requirements to satisfaction of the Engineer, remove and replace such mechanism with satisfactory mechanism at no additional cost to the Owner.

D. Manufacturer's field service: 1. Contractor to coordinate field service work with the manufacturer's service

representative, Owner, and Engineer prior to initiating such work. 2. Manufacturer's service representative:

a. Manufacturer is to furnish services of representative experienced in erection and operation of the sludge collector mechanism.

b. Period of services: The manufacturer shall include in his bid a minimum of 3 8-hour days and 2 trips. The specified durations are the minimum required time on the job site and do not include travel time.

c. Services are to include the following: 1) Installation consultation and advice. 2) Checking and supervision of the collector installation. 3) Inspection and certification that unit is ready to sweep in grout prior

to grouting operation. 4) Final inspection and adjustments prior to testing. 5) Supervision of testing. 6) Instruction of personnel on operation and maintenance of equipment


END OF SECTION AD2 Addendum No. 2


SECTION 11376E

MULTI-STAGE CENTRIFUGAL BLOWER SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. The Contractor shall install, test, and place in satisfactory operation a complete and automated aeration blower system for aeration basins, and miscellaneous small demands, as specified herein. The aeration blower system shall be made up of, but not be limited to the following primary components: 1. Three (3) Multi-stage centrifugal blowers. 2. Drive motors (one per blower). 3. Blower drive couplings and guards (one per blower). 4. Inlet transition and silencer (one per blower). 5. Air filtration system (one per blower). 6. Vendor control panel (VCP) including individual blower local control panels,

blower system master control panel, and the following: a. Surge protection system. b. Blower bearings vibration detection and monitoring system. c. Motor windings temperature detection and monitoring system. d. Blower bearings temperature detection and monitoring system.

7. Master Control Panel (MCP) which will control the three new Blowers, with the capability of adding a fourth Blower in the future.

8. Blower instrumentation. 9. All other appurtenances and custom designed software necessary for a

complete and automated blower system.

B. Blower units, instrumentation, controls, and appurtenances shall be provided as shown on the Drawings and as specified herein for a complete and automated aeration system.

C. Any additional components or accessories not included in the Blower Manufacturer’s scope of supply and required for a complete system shall be provided by the Contractor. Blower Manufacturer shall provide the Contractor a complete list of all equipment, lubricants, hardware, gaskets, and any other accessories not included in their scope of supply, which are required to provide a workable, operational, and complete system. Contractor shall include cost of these items in the Bid Price.

D. All equipment specified shall be installed by the Contractor.

E. Related sections: 1. Section 01600 - Product Requirements. 2. Section 01610 - Project Design Criteria. 3. Section 01612 - Seismic Design Criteria. 4. Section 01650 – Facility Startup/Commissioning. 5. Section 01730 - Operations and Maintenance Data. 6. Section 01770 - Closeout Procedures. 7. Section 09960 - High-Performance Coatings.


8. Section 13390 - Packaged Control Systems. 9. Section 13446 - Manual Actuators. 10. Section 13447 - Electric Actuators. 11. Section 15050 - Common Work Results for Mechanical Equipment. 12. Section 15052 - Common Work Results for General Piping. 13. Section 15112 - Butterfly Valves. 14. Section 15114 - Check Valves. 15. Section 15117 - Specialty Valves. 16. Section 15120 - Piping Specialties. 17. Section 15170 – Electrical Motor, Induction, 600 volts and blow. 18. Section 15958 - Mechanical Equipment Testing. 19. Section 16800 - Calibration, Testing and Settings. 20. Section 17100 - Process Instrumentation and Control Systems (PICS). 21. Section 17200 - Instrumentation and Control Cabinets and Associated

Equipment. 22. Section 17380 - Field Instrumentation and Sensing Devices. 23. Section 17600 - Distributed Control System

F. Tag numbers: 1. Aeration Blower Number 1.

1.02 REFERENCES


B. American Iron and Steel Institute (AISI).

C. American National Standards Institute (ANSI).

D. American Petroleum Institute (API): 1. 617 - Rotary Assembly Dynamic Balancing.

E. American Society of Mechanical Engineers (ASME): 1. PTC 10 - Performance Test Code on Compressors and Exhausters.

F. Institute of Electrical and Electronics Engineers (IEEE): 1. 85 - Test Procedure for Airborne Noise Measurements on Rotating Electric

Machinery.

G. National Electrical Manufacturers Association (NEMA).

1.03 DEFINITIONS

A. Continuous operation: 24-hour-per-day operation for design life of not less than 20 years, or 175,200 hours.

B. Intermittent operation: Periodic operation, including starts and stops; including extended periods of time when not in use.

C. Centrifugal blower system: The blower unit, including but not limited to: Centrifugal blower, motor, VCP, and appurtenances required to furnish a complete installation.



A. The blower units will be used for providing variable airflow to the Aeration Basins, and associated channel air. The Vendor Control Panels (VCPs), Master Control Panel (MCP), system software, instrumentation, and accessories shall optimize blower operation. All items specified in this Section shall be supplied by the Blower Manufacturer to provide a single source of responsibility for a properly functioning blower system with the objective to minimize power consumption while providing the optimum discharge pressure. All components shall be new. Components specified establish minimum requirements only, and do not relieve the Contractor of responsibility for providing a properly functioning system.

B. Some equipment may require modifications from the standard equipment to meet specification. Electrical, instrumentation, and other systems shall comply with other sections of these Specifications except as specifically modified within this section.

C. Blower Manufacturer shall furnish all equipment included in their Proposal and the Contractor shall install all equipment, which is required to provide a workable, operational, and complete blower system. The Specifications define the minimum system requirements. Changes, if required, shall be per the Blower Manufacturer’s recommendations, subject to the ENGINEER’s acceptance.

D. The control and instrumentation systems for the aeration system shall be furnished by the Blower Manufacturer. The Contractor shall be responsible for the coordination, communication, operation, debugging, and calibration for equipment, and instrumentation and controls for the complete blower system.

E. Design requirements:

Characteristics Units Blower

Numbers Quantity of Blowers Number 3

Flow Rate (per blower) Standard cubic feet per minute 3,200

Inlet Pressure Pounds per square inch absolute 14.10

Barometric Pressure Pounds per square inch absolute 14.50 Maximum Relative Humidity Percent 90

Discharge Pressure Pounds per square inch gauge 8.0 Maximum Inlet Temperature Degrees Fahrenheit 115

Minimum Inlet Temperature Degrees Fahrenheit 32 Maximum Blower Speed Revolutions per minute 3,550

Motor Horsepower (nameplate) Horsepower 200


Characteristics Units Blower

Numbers Minimum Turndown Reduction from Rated Condition

Percent 55

Site Elevation Feet 440

Minimum Surge Pressure Pounds per square inch gauge 8.5

1. General: a. Design blowers for heavy, continuous, industrial service. b. Design blowers which operate within specified noise levels. c. Design blowers which operate within specified vibration levels without

overloading the drive motor. d. Design blowers which operate without sign of distress when operating at

specified ambient air temperatures, and discharge pressures from design system pressure to surge pressure.

e. Blower shall possess a pressure-volume curve which extends from the design system pressure to the upper system surge pressure with a continuously rising pressure characteristic.

f. Design blowers which will not be in surge at or above flow rate corresponding to specified surge pressure.

g. Design blowers such that the maximum required motor horsepower will not exceed specified nameplate horsepower when operating at design flows (1,600 standard cubic feet per minute and 3,200 standard cubic feet per minute) at 40 degrees Fahrenheit.

h. Design blowers to be driven from the inlet end. i. Design blowers to deliver oil-free air.

F. Motor design requirements: 1. Characteristics: Horizontal squirrel cage induction type as specified in

Section 15170, as supplemented below: a. Volts/phase/hertz: 480 volts, 3 phase, 60 hertz. b. Speed maximum: 3,600 revolutions per minute. c. Service factor: 1.15. d. Enclosure: TEFC. e. Minimum efficiency 3/4 load and above: 94 percent. f. NEMA design: B. g. Insulation Class: F. h. Lubrication: Grease.

G. Performance requirements: 1. Hydraulic:

a. Meet pressure, capacity, efficiency, and vibration design requirements of this Section.

2. Vibration: a. Maximum unfiltered peak-to-peak radial or axial vibration displacement

shall not exceed 1.25 mils when measured at every point on the blower, motor, or its furnished base; and measured at every operating blower speed.


3. Noise: a. Free field (R equals infinity) sound pressure level shall not exceed 92 dbA

at every point within 5 feet of each blower and motor assembly when operating at design speed and specified airflow rates.

1.05 SUBMITTALS

A. Product data: Submit data completely describing products and listings of components and materials of construction, including but not limited to: 1. Blower characteristics and specifications. 2. Motor characteristics and specifications. 3. Calculations and other information to substantiate that base plates, supports,

and anchor bolts meet minimum design strength requirements and seismic design criteria as specified in Sections 01610 and 01612. a. Calculations shall be stamped and signed by a registered professional

engineer. 4. Blower bearing lubrication system details and applicable design notes. 5. Standard cubic feet per minute versus horsepower and standard cubic feet per

minute versus pressure curves for blowers at specified minimum and maximum temperatures, including efficiency and polytropic head from surge point to 120 percent of rated capacity. Include throttling curves for various inlet valve positions.

6. Pressure curves for blowers: a. ICFM versus horsepower and ICFM versus pressure curves for blowers at

specified minimum and maximum temperatures, including efficiency and polytropic head from surge point to 120 percent of rated capacity.

b. Include throttling curves for various inlet valve positions. 7. Expansion joint drawings, specifications, and characteristics. 8. Flexible coupling specifications and characteristics. 9. Installation instructions including leveling, alignment, grouting, lubrication, and

initial startup procedures. 10. Coupling guard details. 11. Proposed surface preparation and factory prime coat to be applied to the

equipment compatible with finish coating as specified in Section 09960. 12. Weight of blower and motor. 13. Other information as required or specified elsewhere in this Section. 14. Blower VCP wiring diagrams.

B. Shop drawings: 1. Certified dimensional drawings of the blower unit, including cutaway views. 2. Certified dimensional drawings of drive motor. 3. Certified dimensional drawings for blower and motor foundation. 4. Certified anchor bolt layout drawings. 5. Instrumentation and control system schematics, and wiring diagrams for

electrical and control components furnished. Contractor to provide tubing and conduit details.

6. Any necessary dimensioned drawings to coordinate piping layout with structural, architectural, and/or other mechanical work.

7. Certified drawings of the blower VCP.


C. Quality control submittals: 1. General:

a. Test reports: Submit after fabrication, but prior to delivery of equipment to jobsite location.

b. Results of each required test: Summarized in a separate, certified, written report.

c. Reports: Organized and clearly present testing methods and procedures, testing equipment, test data, calculations and analyses, conclusions and recommendations.

d. Test reports shall be signed and sealed by the blower manufacturer's engineer in charge of the testing.

e. Four copies of each certified written test report shall be submitted to the Engineer for review and acceptance. 1) Test reports shall have been reviewed and accepted by the Engineer

prior to jobsite delivery. f. If the certified factory test reports indicate noncompliance with the

requirements of the Contract Documents, the blowers shall be reworked and retested at the manufacturer's full expense until compliance with the specifications is attained.

2. Certified factory test results: a. Certified acoustical test results for each blower and motor assembly. b. Certified hydrostatic test results for each blower. c. Certified report of dynamic balancing and maximum vibration amplitude.

3. Motor efficiency certification: a. Provide certificates of factory test results as specified in Section 15170. b. Submit typical motor efficiency test results for like-motors.

4. Certified Blower Performance Test, ASME PTC 10.

D. Closeout submittals: 1. Operation and maintenance manuals:

a. Prepare operation and maintenance manuals for the entire centrifugal blower system, including appurtenances included in this Section.

b. Provide Project Record Documents showing as-built dimensions, as-built wiring and control diagrams, as-built logic diagrams and design information for supplied parts and equipment.

c. Manuals shall be in accordance with Sections 01730, 01770 and 15050. d. Provide a detailed description of the control system. e. Provide panel drawings, wiring diagrams, specifications, and a detailed

description of the blower VCP.


A. Manufacturer qualifications: 1. Blower manufacturer shall have a minimum of 5 years experience in the

design and manufacture of the specified centrifugal blowers. 2. Blower manufacturer shall coordinate design of blower and drive system

components.

B. References: Provide with shop drawing submittals a list of references (name, location, and phone number) of at least 2 installations currently using the same model and drive configuration blower as proposed, operating under similar conditions (pressure, flow rate, and speed).


C. Blower manufacturer shall provide components described in this Section, including motors and VCP.

D. Blower manufacturer shall assume responsibility for compatibility of components furnished, and control systems as specified.


A. Packing and shipping: 1. Protect equipment in accordance with manufacturers recommendations and as

specified Section 01610. 2. If storage prior to installation exceeds 1 month, apply temporary corrosion

protective coatings to unpainted components and pack components to protect from the elements.

B. Storage and protection: 1. Protect blower system components at the project site and during installation

prior to project completion. 2. Apply protective coatings and manually rotate shafts regularly as

recommended by the manufacturer.

1.08 WARRANTY

A. As specified in Section 15050

1.09 MAINTENANCE

A. Special tools: 1. For each type of size of blower specified, provide 1 set of special tools

required for complete assembly or disassembly of the blower system components.

2. Special tools shall be defined as every tool not typically necessary for general plant maintenance.

B. Spare parts: 1. For each blower unit furnished, provide the following spare parts labeled and

packed for warehouse storage as specified in Sections 01600 and 01610. a. 2 complete sets of blower and motor bearings for each size blower and

motor specified. b. 2 complete sets of gaskets and labyrinth ring seals. c. 1 complete coupling assembly. d. 1 spare expansion joint for each size blower specified.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Blower manufacturers: One of the following or equal: 1. Atlas Copco, Model ZM12608. 2. Gardner Denver-Hoffman and Lampson. 3. Continental Blowers. 4. Spencer.


5. HSI.

B. Motor manufacturers: As specified in Section 15170.

C. Blower VCP: 1. Furnished and supplied by blower manufacturer.

D. Blower MCP: 1. Furnished and supplied by blower manufacturer.

2.02 MATERIALS

A. Blower casings: Cast iron.

B. Blower impellers: High strength aluminum alloy.

C. Blower shafts: High Carbon Steel AISI 4140.

D. Blower and motor frame: Welded steel.

2.03 EQUIPMENT

A. Blowers: 1. Blower casings:

a. Design blower housing to be cylindrical in shape, and comprised of vertically split rigid sections fitted with rabbet joints held securely between rigid inlet and outlet heads with steel tie rods.

b. Design blower shaft penetration at the inlet and outlet heads with carbon rings or labyrinth shaft seals to prevent air leakage.

c. Design inlet and outlet connections with ANSI Class 125 pound drilled and tapped flanges to match diameter and arrangement of piping indicated on the Drawings.

2. Impellers: a. Provide impellers which are statically and dynamically balanced prior to

assembly of blower unit. b. Design impellers to be keyed to the shaft, and held in position with a

locknut and lockwasher. c. Design impeller hubs to butt against one another directly or through a

1 piece metal spacer. d. Design blower impellers so that not less than a 0.050 inch clearance

exists between the impellers and stationary blower parts. 3. Diffusing vanes:

a. Design diffusing vanes to receive air from 1 impeller and direct air to the next impeller. 1) One set of diffusing vanes shall be located between each impeller.

b. Design diffusing vanes to be integrally cast with the intermediate sections of the blower housing.

4. Shafts: a. Design and furnish blower shaft of sufficient diameter to operate

20 percent below the first critical speed, or 20 percent above the first critical speed.

b. The second critical speed shall be at least 20 percent over the maximum continuous operating speed of the blower.


5. Couplings: a. Provide a flexible disc, 5-inch minimum spacer type coupling for the motor

to blower connection as recommended by the blower manufacturer. b. Design coupling to allow for inspection and removal of the drive end

bearing without moving the blower, motor, or piping. c. Design coupling to absorb shock and vibration, and compensate for

misalignment. d. Design coupling to transmit the increased torque due to starting of the

blower. 6. Supports:

a. Design and furnish an equipment support on a common base of structural steel for the blower and motor capable of accurately positioning and leveling the blower and motor system on the concrete pad.

b. Incorporate suitable mounting provisions for power factor correction capacitors (if required). 1) Controls, sensors, switches, and other devices requiring connection

to remote panels shall be prewired to a blower terminal box mounted on the frame.

c. Position blower unit on antivibration strips. 1) Positively restrain unit from horizontal creep by anchor bolts

anchored in the concrete equipment pad. 7. Guards:

a. Design and furnish guards as specified in Section 15050. 8. Blower bearings:

a. Design blower to be provided with 2 oil-lubricated anti-friction bearings contained in outboard housings to isolate bearings from heat. Outboard housings shall allow for inspection and/or replacement of the bearings without disconnecting piping or disassembling the blower casing.

b. Design blower bearings for an ABMA 9 or 11, L10 life of not less than 100,000 hours at design rated pressure and flow rate.

c. Design and provide an external constant level oiler for visual indication of oil reservoir level.

d. Provide blower bearings vibration transducers on inboard and outboard bearings with monitoring.

e. Provide resistance temperature detectors on each bearing for thermal protection.

9. Lifting provisions: a. Provide lifting eyes on blowers, motors, and frames so that each major

component of the blower system or entire unit may be removed. 10. Finishes:

a. Equipment, where applicable, shall be finished as specified in Section 09960.

B. Drivers: 1. Horsepower:

a. As scheduled. b. Listed driver horsepower is the minimum to be supplied.

1) Increase driver horsepower if required to prevent driver overload while operating at any point of the supplied blower operating pressure-capacity curve including runout.

2) When scheduled driver is a motor, increase motor horsepower if required to prevent operation in the service factor.


3) Make all structural, mechanical, and electrical changes required to accommodate increased horsepower.

2. Motors: Provide motors as specified in Section 15170 and as specified in this Section: a. Revolutions per minute: As scheduled: b. Enclosure: As scheduled. c. Electrical characteristics: As scheduled. d. Efficiency, service factor, insulation, and other motor characteristics: As

specified in Section 15170. e. Motor accessories: As specified in Section 15170 and in this Section. f. Motor winding temperature detectors as specified in this Section. g. Motor current transformer mounted in the motor high voltage wiring

terminal box, as specified in this Section. 3. Noise level, unloaded, not to exceed 88 dBA when measured in accordance

with IEEE 85. a. Mean sound pressure levels measured 5 feet from machine surface.

4. Bearing grease lubricated, ball anti-friction rated for an ABMA 9 or 11, L10 life of not less than 100,000 hours. a. Double shielded. b. Rotor assembly statically and dynamically balanced.

5. Vibration levels shall not exceed 1.0 mils peak-to-peak at 3,600 revolutions per minute.

6. Provide current transformer installed in the motor high voltage wiring terminal box for monitoring blower motor amperage for surge protection. Provide shorting terminal block installed in the Blower VCP for connection to the current transformer.

C. Blower Vendor Control Panels (VCP) tagged "STB-CP-PAB1", "STB-CP-PAB2", "STB-CP-PAB3"AD2: 1. Design blower VCP to be delivered to jobsite as individual, prewired,

coordinated units ready for installation and field wiring. a. Panels suitable for wall or floor mounting as indicated on the Drawings. b. VCP shall comply with the requirements of Section 13390 "Packaged

Control Systems". 2. VCP will be connected to the Owner's distributed control system as indicated.

Provide all components within the VCP to achieve the connectivity as indicated and specified.

3. VCP shall be programmable logic controller driven system capable of communicating with owner's distributed control system as indicated on the Drawings. a. The blower manufacturer shall inspect, test, and certify interconnections

between the VCP and owner's distributed control system, remote sensors, switches, and other instrumentation and controls.

4. Surge/overload protection systems: a. Provide a surge/overload protection system with each blower unit. b. Each surge/overload protection system shall monitor blower motor

amperage, and energize separate alarms, and shut down the blower when motor current corresponds to blower surge or to amperage equivalent to motor nameplate horsepower (except at start-up). 1) Provide adjustable timed start-up override and alarm response delay.


c. Each surge protection system shall include a current transformer, shorting terminal block, necessary contacts, adjustable time delay, and shall control the blow off butterfly valve.

d. The current transformer shall be installed in the motor high voltage wiring terminal box.

e. The operator interface of the VCP shall indicate motor amps, the surge region, the standard cubic feet per minute and the maximum operating limit of the blower (full load amps).

f. Both conditions shall be indicated at the VCP, at the owner's distributed control system, and remotely as indicated on the Drawings. 1) Upon pre-surge condition, a signal from the VCP shall open the blow

off valve. 2) Upon surge, the motor shall shut down. 3) Motor overamp shall shut down the motor and indicate an alarm at

the VCP, at the owner's distributed control system, and remotely as indicated on the Drawings.

g. Surge control logic shall be provided by the VCP mounted programmable logic controller.

h. Pre-surge current shall limit blower inlet valve from closing. 1) Pre-overload current shall limit inlet valve from opening. 2) These conditions shall override external inputs from controlling inlet

valve position. 5. Blower bearing vibration detection and monitoring systems:

a. Provide three 100-ohm platinum resistance temperature detectors (one per phase winding) on each motor for thermal protection.

b. Provide with each blower system a vibration detection and monitoring system which will detect, display, and alarm the vibration of the inboard and outboard bearings of the blower.

c. The blower manufacturer shall mount its standard vibration transducers on the inboard and outboard bearings of each blower.

d. Signals from the transducers shall be displayed at the operator interface of the VCP, at owner's distributed control system and remotely as indicated on the Drawings.

e. Each vibration set point shall be field adjustable over the range of 1 to 5 mils and shall be field adjustable for time delay over the range of 2 to 15 seconds.

f. Excess blower bearing vibration shall shut down the motor and activate an alarm at the VCP, in owner's distributed control system, and remotely as indicated on the Drawings.

g. Provide interlocks, communication, and controls as indicated on the Drawings.

6. Motor windings temperature detectors: a. The blower bearings shall be provide with 100-ohm platinum resistance

temperature detectors on each bearing for thermal protection. b. Temperature measured by resistance temperature detectors shall be

displayed on the operator interface of the VCP, at owner's distributed control system, and remotely as indicated on the Drawings.

c. The temperature alarm shall be adjustable from the operator interface over range as recommended by the blower manufacturer. 1) The motor shall shut down upon excessive winding temperature and

an alarm indicated on the blower VCP, owner's distributed control system, and remotely as indicated on the Drawings.


7. Blower bearings temperature detectors: a. The blower bearings shall be provided with resistance temperature

detectors on each bearing for thermal protection. b. The resistance temperature detectors leads shall be terminated in the

frame-mounted terminal box for connection to the VCP. c. The temperature alarm shall be field adjustable over range as

recommended by the blower manufacturer. 1) The motor shall shut down upon excessive blower bearing

temperature and an alarm indicated on the blower VCP, at owner's distributed control system, and remotely as indicated on the Drawings.

8. Blower inlet valve: a. The blower programmable logic controller shall provide PID control loop to

maintain desired position of the inlet valve. b. Set point to the valve position controller shall be adjusted locally from the

operator interface of the VCP, from owner's distributed control system, and remotely from blower the control room.

c. Valve set point minimum and maximum shall be based on pre-surge current and pre-overload current. 1) These valve positions shall not be overridden. 2) Valve position shall be indicated at the VCP, owner's distributed

control system and remotely. 9. Master Blow-off Valve:

a. The blower blow-off valve shall be mechanically triggered by excessive pressure in the discharge header.

b. The Master Blow-off Valve will have an attached silencer, designed to function outdoors.AD2

10. Inlet filter differential pressure alarm: a. The inlet filter for each blower shall be equipped with a differential

pressure switch that activates a high differential pressure alarm at the VCP, at owner's distributed control system, and remotely as indicated on the Drawings.

11. The blower VCP shall be provided with MANUAL and AUTO modes of operation: a. In the MANUAL mode, blower START-STOP sequence shall be initiated

from the VCP. 1) Position of the inlet valve shall be adjustable from the VCP. 2) The blowoff valve OPEN/CLOSE control shall be controlled from the

VCP. b. In the AUTO mode, blowers shall be controlled as specified in

Section 17100.

D. Master Control Panel (MCP) tagged"STB-CP-PAB"AD2: 1. The following items are required as specified herein:

a. Space heating system per Section 13390, paragraph 2.02.H.3. b. Furnish and install one 120VAC, 1P-20A GFI convenience receptacle and

1 Cat 5e Ethernet data port receptacle with Nema 4X rated hinged UV resistant clear polycarbonate cover. Receptacles shall be accessible from control panel exterior without requiring access to internal control panel components. Wire receptacles to Ethernet switch and control power supply of internal control panel. Furnish and install receptacles as


manufactured by Hubbell "Panel-Safe", model PR4X205E or approved equal.

c. Main circuit breaker per Section 13390, paragraphs 2.01.A.2 and 2.04. d. Redundant 24 Volts DC power supply, per Section 17200. e. Three (3) Type 2 Ethernet switches and two (2) Type 5 Ethernet switches,

per Section 17600, which includes spare parts. f. Two (2) fiber patch panels per Section 17600.

2.04 ACCESSORIES

A. Rubber expansion joints: 1. Provide rubber expansion joints in suction and discharge piping at blower

flanges for each blower unit. 2. Provide rubber expansion joints as specified in Section 15120.

B. Check valves: 1. Provide each blower with a flanged discharge check valve of the dual, flat

plate type with center hinge, spring closure, cast iron body, Viton® B seal and 316 stainless steel plates and trims, Inkonel 600 springs, and rated for temperatures up to 400 degrees F. The valves shall have flat surfaces with the resilient seat facing on the body. The two plates shall be independently supported on the hinge pin and have separate closure springs. Seating shall be against a flat recess within the valve body, and valves wherein seating is against the cylindrical inner bore of the body will not be allowed. Check valves should be suitable for installation in the horizontal or vertical position as indicated on the Drawings. Valves shall be manufactured by Crane, Duo-Check II model, or equal.

2. Check valves shall be especially designed and suitable for use with centrifugal blowers, and shall retain positive sealing capability at 300 degrees F.

C. Butterfly valves: 1. Provide butterfly valves on the inlet, discharge, and the blow off line for each

blower unit. 2. Butterfly valves as specified in Sections 13446, 13447, 15112, 15117, and as

specified below: a. Configuration: Short body. b. Connections: Flanged. c. Differential pressure rating: 20 pounds per square inch gauge.

3. Valve operators shall be manual geared operators or motor operated with limit switches as specified in Sections 13446 13447 and indicated on the Electrical Drawings and P&IDs.

D. Air pressure and temperature gauges: 1. Provide pressure gauges for each blower on the suction and discharge piping

as indicated on the Drawings. a. Pressure gauges as specified in Section 17380 and as indicated on the

Drawings. 2. Provide temperature gauge on the discharge piping immediately downstream

of Blower Number 1. a. Temperature gauge as specified in Section 17380.

E. Air filters: As specified in this Section.


F. Inlet, discharge, and blow-off silencers: As specified in this Section.

2.05 INLET FILTERS

A. Each blower shall be provided with an inlet designed for maximum airflow at absolute minimum pressure drop.

B. Filters shall connect to the inlet of the blower. The coarse pre-filter shall have a removal efficiency of 93 percent on 10 micron. The final filter element shall have a removal efficiency of 99.5 percent on 3 micron. The filters shall be sized for a maximum face velocity of 500 feet per minute at peak airflow.

C. Maximum clean pressure loss across the filter shall be less than 0.12 psig.

D. The inlet filter shall be suitable for indoor installation and shall be integrally mounted to the blower inlet. The filter shall be removable without completely disconnecting it from the inlet.

2.06 AD2NAMEPLATE DATA

A. Provide stainless steel nameplate on blower. Include the following information: 1. Blower nameplate shall be stainless steel. 2. Mount blower nameplate for easy visibility. 3. Information and data provided:

a. Blower tag number. b. Vendor's name. c. Model and serial number. d. Size and type. e. First critical speed. f. Rated capacity. g. Rated inlet pressure. h. Rated inlet temperature. i. Rated discharge pressure. j. Horsepower at rated point. k. Efficiency at rated point.

4. Revolutions per minute at rated point: a. Maximum continuous speed. b. Maximum housing design pressure. c. Maximum allowable temperature.

B. Provide direction of rotation arrow on blower.


A. Certified factory tests: 1. General:

a. Tests shall be conducted using the actual blowers and motors to be furnished or calibrated lab motors.

2. Test results must be submitted and accepted prior to shipping equipment to jobsite. a. All tests shall be conducted at the blower manufacturer's factory, or at a

designated testing facility acceptable to the Engineer.


b. If the certified factory tests indicate noncompliance with the requirements of these Contract Documents, the blowers shall be reworked and retested at the manufacturer's full expense until compliance with the specifications is attained.

3. Acoustical analysis: a. Conduct level 2 acoustical analysis on each blower and motor assembly

as specified in Section 15050. 4. Test shall meet specified standard specified.

a. Submit certified acoustical test results for each blower and motor assembly furnished.

5. Housing hydrostatic tests: a. Conduct hydrostatic testing of each complete blower housing at

15 pounds per square inch gauge for not less than 30 minutes. b. Hydrostatic testing shall be conducted in accordance with API 617. c. Submit certified housing hydrostatic test results for each blower.

6. Impeller balancing/vibration test: a. Conduct static balancing of impeller units prior to blower shaft assembly. b. Conduct dynamic balancing of complete blower rotary assembly. c. Impeller balancing shall be conducted in accordance with API 617.

1) The double amplitude of vibration in every plane measured on the blower bearing housing adjacent and relative to each radial bearing shall not exceed API 617 limits.

d. Perform vibration test as specified in Section 15958 level 2. e. Provide in certified test report for each unit, including:

1) Date and place of the dynamic balancing. 2) Type of balancing machine used (make and model). 3) Balance machine weight rating. 4) Final balanced part weight. 5) Final balance quality (center of gravity displacement in inches). 6) Methods used to achieve final balance (grinding, drilling, end milling,

etc.). 7) A sketch showing relative locations of modification required to

achieve balancing. 8) Maximum vibration amplitude at the bearings when operating at

design speed after final balancing. f. Submit certified static and dynamic balancing test results for each blower.

7. Mechanical compliance tests: a. Provide shaft critical speed calculations. b. Conduct test as specified in Section 15958 test code with tests at full

speed only. c. Submit certified mechanical compliance test results for each blower.

8. Motor tests: a. Factory test motors as specified in Section 15170, except for efficiency.

9. Performance tests: a. Perform performance tests at the factory using the same tolerances and

clearances between aerodynamic surfaces as are recommended for actual continuous field operation. 1) A written statement of compliance to this requirement shall be

included as a part of this certified test report. b. Conduct performance testing in conformance with ASME PTC-10 and as

supplemented by the requirements specified: 1) Run minimum 3 test points on each blower.


a) Two of these points shall bracket the rated point within the allowable test condition tolerances of PTC-l0.

2) Run additional points at test conditions equivalent to the full range between specified blower operating limits.

c. In addition to the data specified above, each test report shall contain the following: 1) A copy of certified efficiency curves from 75 percent to 100 percent

full load for the drive motors to be furnished. 2) Curves and supporting calculations showing polytropic head and

polytropic efficiency at rated speed for flow at inlet conditions (ICFM) at the rated point.

3) Calculations showing the power input to the drive motor to be furnished, at the rated point.

4) Curves showing performance at rated speed and for discharge pressure from lower system pressure to surge pressure. a) The performance shall be shown in terms of standard cubic feet

per minute and brake horsepower required at the input shaft of the blower.

b) The curves shall be for the inlet conditions specified under Performance Requirements, and corresponding to operation at rated inlet conditions and minimum and maximum inlet density. Surge points shall be indicated.

d. Prior to conducting the tests, submit the proposed test procedure for review as required by ASME PTC-10.

e. After successful completion of the certified performance test, submit test results for each blower.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect components for shipping damage, conformance to these Specifications, and proper torques and tightness of fasteners.

3.02 INSTALLATION

A. General: Follow manufacturer's written instructions for installation and adjustment of components.

B. Leveling: 1. Level the blower system components as recommended by the manufacturer.

a. Unless the manufacturer recommends otherwise in writing, level leaving a 0.75- to 1.5-inch gap between the component base plate or support feet and the foundation for grouting after alignment.

2. After alignment, grout between the base plate or support and foundation.

C. Alignment: 1. Preliminary alignment: Align blower components and piping in accordance with

manufacturer's recommendations. a. When alignment correct, tighten anchor bolts snug, then grout between

base and foundation.


b. After grout hardens (48 hours minimum), fully tighten anchor bolts and recheck alignment.

c. Correct alignment as required. 2. Final alignment:

a. After piping has been connected, operate blower and check alignments again.

b. Correct as necessary.

D. Lubrication: 1. Clean bearings and housings and install lubricants in accordance with

manufacturer's recommendations. 2. Consolidate lubricant brands and types with other mechanical equipment as


E. Installation tolerances: In accordance with manufacturer's recommendations with enhancements as required to meet performance and vibration specifications.

F. Field finishes: Provide factory prime coat compatible with final field coating as specified in Section 09960 requirements.


A. Inspection and check-out: Prior to operating the blower, finish complete inspection, testing, and check-out of supporting systems, including but not limited to power systems, control systems, piping systems, and safety systems: 1. Complete electrical system testing as specified in Section 16800. 2. Instrumentation and controls:

a. Testing: As specified in Section 17100. b. Individual loop tests:

1) Test each instrumentation loop from field drive to intermediate terminations to controller and back to controlled element.

2) Provide signed and dated loop test sheets for each loop. c. End-to-end test: Perform tend to ends tests of each instrumentation loop

to demonstrate functionally by simulating an input at the field drive and observing the control system response at the final field control element.

d. Set operational limits (START/STOP, etc.) and alarm and shutdown limits as directed by the Engineer.

3. Piping: Test and cleaning as specified in Section 15052. 4. Motor rotation: Test motor rotation direction with blower coupling disconnected

(bump test).

B. Equipment performance test: Level 2 General Performance Test as specified in Section 15050 with additional requirements as follows: 1. Record temperature, pressure, and flow. 2. Verify manufacturer's curve.

C. Vibration test: Level 1 Vibration Test as specified in Section 15050.

D. Noise test: None required.

E. Operational testing: As specified in Section 01650. 1. Acceptable tests:


a. Test success: Blower operates as intended without failures for the specified duration.

b. Test failure: 1) Unintended shutdowns, the failure of the control system to respond

as required, vibration exceeding specified limits, or bearing temperatures exceeding manufacturer's recommended limits.

2) Minor on-line adjustments and tuning of instrumentation are not considered a failure.

c. Retesting: After a failure, correct, repair, or replace the causative components and repeat the testing for the full specified duration.

F. Manufacturer's field service: 1. Start-up:

a. Factory authorized representative shall check and inspect the system installation before the initial start-up and certify that the system has been correctly installed and prepared for start-up.

b. Factory representative shall insure proper operation of blower protection devices including vibration, temperature, and current alarms as well as interlocks with pre-surge and pre-overload current with inlet throttling valve.

c. Factory representative shall be on site a minimum of 2 days (16 hours) exclusive of travel time for start-up and functional checkout services.

2. Training: a. Technical representatives shall provide 2 days of on-site instruction to the

Owner regarding operation and maintenance of the blower systems. b. Operating instructions shall cover both normal operation and alarm

conditions. c. Both "classroom" and "hands-on" instruction shall be provided.

END OF SECTION

AD2 Addendum No. 2

March 1, 2019 - CONFORMED 11378A-1 9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/11378A (CONFORMED)

SECTION 11378A

MEMBRANE DISK FINE BUBBLE DIFFUSED AERATION SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Specification of a membrane disk fine bubble diffused aeration system for

installation in activated sludge aeration basins. 2. Includes, but not limited to:

a. Air distribution piping (including manifolds, and laterals). b. Piping supports. c. Air diffuser assembly (including membrane diffuser element, baseplate,

diffuser holder, retainer ring, and airflow control orifice). d. Moisture blowoff system. e. Fasteners and hardware.

B. Related sections: 1. Section 01140 - Work Restrictions. 2. Section 01300 - Submittals. 3. Section 01610 - Project Design Requirements. 4. Section 01650 – Facility Startup/Commissioning. 5. Section 01730 - Operation and Maintenance Data. 6. Section 15050 - Common Work Results for Mechanical Equipment. 7. Section 15286 - Stainless Steel Pipe.

1.02 REFERENCES

A. American Society of Civil Engineers (ASCE): 1. 2-91 - Measurement of Oxygen Transfer in Clean Water. 2. Standard Guidelines for In-Process Oxygen Transfer Testing.

B. ASTM International (ASTM): 1. A 240 - Standard Specification for Chromium and Chromium-Nickel Stainless

Steel Plate, Sheet, and Strip for Pressure Vessels and for General Application. 2. A 380 - Standard Practice for Cleaning, Descaling, and Passivation of

Stainless Steel Parts, Equipment, and Systems. 3. A 480 - Standard Specification for General Requirements for Flat-Rolled

Stainless and Heat-Resisting Steel Plate, Sheet, and Strip. 4. A 530 - Standard Specification for General Requirements for Specialized

Carbon and Alloy Steel Pipe. 5. A 554 - Standard Specification for Welded Stainless Steel Mechanical Tubing. 6. A 774 - Standard Specification for As-Welded Wrought Austenitic Stainless

Steel Fittings for General Corrosive Service at Low and Moderate Temperatures.

7. A 778 - Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products.

8. D 395 - Standard Test methods for Rubber Property - Compression Set.


9. D 412 - Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension.

10. D 573 - Standard Test Method for Rubber - Deterioration in an Air Oven. 11. D 1171 - Standard Test Method for Rubber Deterioration - Surface Ozone

Cracking Outdoors or Chamber (Triangular Specimens). 12. D 1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC)

Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. 13. D 2240 - Standard Test Method for Rubber Property - Durometer Hardness. 14. D 2241 - Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure -

Rated Pipe (SDR Series). 15. D 2564 - Standard Specification for Solvent Cements for Poly(Vinyl Chloride)

(PVC) Plastic Piping Systems. 16. D 2855 - Standard Practice for Making Solvent-Cemented Joints with

Poly(Vinyl Chloride) (PVC) Pipe and Fittings. 17. D 3034 - Standard Specification for Type PSM Poly(Vinyl Chloride) PVC

Sewer Pipe and Fittings.

1.03 DEFINITIONS

A. SOTR: Standard Oxygen Transfer Rate, expressed as pounds of oxygen per day; the rate of transfer of oxygen from air into tap water at standard conditions of temperature (20 degrees Celsius) and pressure (1 atmosphere), with zero dissolved oxygen concentration.

B. SOTE: Standard Oxygen Transfer Efficiency, expressed as a percentage; the efficiency of oxygen transfer under standard conditions (20 degrees Celsius, 1 atmosphere), determined as the fraction of oxygen in an injected gas stream dissolved under standard conditions.

C. DO: Dissolved Oxygen concentration in the mixed liquor, in milligrams per liter (mg/L).

D. MLSS: Mixed liquor suspended solids concentration, in mg/L.

E. Zone: Section or compartment of each aeration basin that contains at least 1 individual diffuser grid and aeration air dropleg, as indicated on the Drawings.


A. System configuration: 1. 1 existing aeration basin with layout and dimensions as indicated on the

Drawings and specified. 2. Nominal basin dimensions, including side water depths in units of feet of water

for each zone at different operating conditions, are indicated below:


Zone Length (ft) Width (ft) Side Water Depth (ft)

Minimum Average Peak Aeration Basin Dropleg 1 35.08 50.50 14.92 14.95 15.04

Dropleg 2 35.08 50.50 14.92 14.95 15.04

Dropleg 3 35.08 50.50 14.92 14.95 15.04

Dropleg 4 35.08 50.50 14.92 14.95 15.04 Notes: 1) None.

B. Design requirements: 1. General:

a. The fine bubble diffused aeration system furnished under this Section is designed to supply the aeration required to maintain a DO concentration of 2.0 mg/L in each aeration basin, and to maintain suspension of a mixed liquor with a MLSS concentration ranging from 1,000 to 3,000 mg/L.

b. The airflow to the fine bubble diffused aeration system will be supplied by multi-stage centrifugal blowers, and the airflow rate varied independently to maintain the desired DO concentration in the mixed liquor.

2. Mechanical: a. The fine bubble diffused aeration system includes the air distribution

piping excluding drop legs (manifolds, and laterals), piping supports, the air diffuser assemblies (diffuser disks, baseplates, diffuser holders, retainer rings, and flow control orifices), the moisture blowoff system, fasteners, hardware, and all accessories required for a complete installation and as required by the performance requirements in this Section.

b. The aeration system shall be compatible with hydrochloric acid, formic acid, and hydrogen chloride gas.

c. Joints in the aeration system piping which are factory solvent welded shall conform to the standard practice described in accordance with ASTM D 2855.

d. PVC solvent cement shall conform to all requirements in accordance with ASTM D 2564.

3. Operating parameters: a. Process airflows: Process airflows, in units of standard cubic feet per

minute (scfm), for each zone at different operating conditions are indicated below:


Zone Operating Condition

Minimum (scfm) Average (scfm) Peak (scfm) Aeration Basin

Dropleg 1 400 800 1,600

Dropleg 2 400 800 1,600

Dropleg 3 400 800 1,600

Dropleg 4 400 800 1,600 Notes: (1) None.

b. Maximum allowable pressure in the air piping at the dropleg connection for any of the specified conditions shall not exceed: 1) Aeration basin: 8.0 pounds per square inch gauge.

c. System to be designed to withstand the maximum allowable pressure plus a surge factor of 1.25.

d. Air temperature at dropleg during operation: ambient to 230 degrees Fahrenheit.

4. Diffuser layout: a. Provide manifolds, laterals, and diffusers with general arrangement as

indicated on the Drawings and as required by the performance requirements in this Section.

b. Provide diffuser quantities as required to meet performance requirements specified.

c. The diffuser layout shall be subject to the approval of the Engineer. The Engineer shall determine compliance with the stated requirements.

d. Design the diffuser grid layout to satisfy the following minimum requirements: 1) Minimum clearance of 12 inches from any wall to edge of diffuser. 2) Maximum clearance of 36 inches from any wall to edge of diffuser. 3) A minimum clear spacing of 2 inches between adjacent diffusers

(including blank diffusers) on the same lateral. 4) A maximum clear spacing of 48 inches between adjacent diffusers

(including blank diffusers) on the same lateral. 5) A minimum clear spacing of 6 inches between diffusers (including

blank diffusers) on adjacent laterals. 6) A maximum clear spacing of 48 inches between diffusers (including

blank diffusers) on adjacent laterals. 7) Make provisions for ladder placement to allow entry into each zone

from the top of the basin. 8) Access-ways shall be provided between groups of laterals and have

a minimum clear spacing of 24 inches (edge-to-edge) between diffusers. Sufficient clearance shall be provided to move from one access-way to another.

9) It shall not be necessary for a person to reach across more than 1 diffuser lateral to access any diffuser from an access-way; therefore, no more than 4 laterals may be placed in a group between access-ways and no more than 2 laterals between a wall and the first access way.


e. Droplegs: 1) A fixed number of droplegs on the main air header piping have been

provided and additional droplegs are not available. 2) The location of these droplegs is fixed and changes in dropleg

location are not allowed unless approved in writing by the Engineer. 3) The diffuser manufacturer shall refer to the grid layout and dropleg

locations indicated on the Drawings during design of the diffuser system.

C. Performance requirements: 1. System performance requirements (minimum) are as follows:

Zone SOTR, lbs/day SOTE, %

Airflow Rate, scfm

Minimum Active

Diffuser Count

Number of Blank

Diffusers, % Aeration Basin

Dropleg 1 11,700 29.0% 1,600 800 0

Dropleg 2 11,700 29.0% 1,600 800 0

Dropleg 3 11,700 29.0% 1,600 800 0

Dropleg 4 11,700 29.0% 1,600 800 0 Notes:

(1) Based on mixing limited conditions. 2. Demonstrate compliance with the minimum SOTE requirements specified

above through Factory Standard Oxygen Transfer Testing. a. The Test shall be based on the Zone 1 configuration specified above. b. Additional diffuser requirements for the remaining zones shall be

determined by proration of the Test Zone results based on the estimated active diffusers specified for each zone. 1) The estimated active diffuser counts specified in the preceding table

are included solely for the purposes of this proration. 2) Actual active diffuser requirements may be higher depending on the

results of the Factory Test. c. If the Factory Test determines that the specified minimum SOTE for the

Test Zone can only be achieved by using more diffusers than estimated above for the Test Zone, then the active diffuser count in each of the other zones shall be proportionately increased over their respective estimated active diffuser counts.

d. In no case shall the diffuser count in each zone be less than the counts listed in the tables above.

3. Size manifolds, and lateral piping as required to provide air distribution uniformity values in each zone as follows: a. 98 percent at average conditions. b. 95 percent at peak conditions.

1.05 SUBMITTALS

A. Submit product data and shop drawings, operation and maintenance manuals, and test reports to the Engineer for review as specified in Section 01300 and as detailed in this Section.


B. Product data and shop drawings: Include the following as part of the Product Data and Shop Drawing Submittals: 1. Descriptive literature and dimensional drawings for all equipment proposed,

including views of the air manifold and diffuser assemblies indicating materials of construction, material product specification for all components, and number, location, and spacing of diffusers, and size and layout of air piping. a. Include weights, center of gravity, and lifting diagrams, as required.

2. Pipe support layout describing methods for supporting and preventing uncontrolled movement of the air manifold and diffuser lateral grid pipe resulting from flotation dynamic forces, thermal expansion, fluid forces developed by mixers and flow from process pipe inlets/outlets forces, and other external forces.

3. Methods for compensating for thermal expansion and construction and design criteria employed.

4. Methods for draining the air distribution systems. 5. Air diffuser assemblies:

a. Number of diffuser elements. b. Complete materials list, material specifications, dimensions, and

tolerances of all parts of the diffuser assemblies. c. Curve showing head loss versus airflow rate for the flow control orifice

and diffuser element. d. Testing and sampling plans for Source Quality Control of the diffuser

elements. e. A full-size, completely assembled, representative sample of the proposed

diffuser assembly, mounted on 4-inch PVC pipe, including diffuser, gaskets, element holder, retaining ring, pipe supports, and expansion joint on 1 end, and all appurtenances for the particular diffuser system.

6. Diffuser grid piping: a. Complete materials list and specifications, dimensions, critical tolerances

of piping, fittings, expansion joints, and accessories. b. Layout of grid piping, diffuser holders, expansion joints, and pipe

supports. c. Identification of the installed location of the solvent welded pipe. d. Indicate diffuser-free areas required by the submersible mixer.

7. Manifold piping: a. Complete material list, material specifications, dimensions, thickness of

piping, fittings, expansion joints, and accessories. b. Layout of air manifolds.

8. Pipe supports: a. Complete design criteria, material list, material specifications, and

dimensions of all parts of the pipe supports and extensions. b. Include drawings showing proposed support design including anchor

locations and details. c. Include calculations for supports for thermal expansion in air from

30 degrees Fahrenheit to 95 degrees Fahrenheit. 9. Moisture blow-off systems:

a. Complete materials list, material specifications, and dimensions of all parts of the system.

b. Location of the system and layout of the piping, including joints, pipe supports, and valves.

c. Specifications for the ball valve.


10. Storage and protection of material: a. Certification that special shipping and storage containers shall be utilized

to protect the material from sun deterioration, handling damage, and heat warpage.

b. Packing, shipping, and storage procedures. 11. Certified efficiency curve:

a. Curve of SOTE versus air flux rate (defined as airflow in scfm per active diffuser area) at the design submergence, prepared, sealed, and signed by a registered professional engineer.

12. Air manifold piping factory leak test certification: a. Certification that air manifold piping has successfully passed the leak test

specified in air manifold piping testing. b. Submit this certification prior to shipment.

13. Design calculations: a. Design calculations documenting air head loss from the top of the dropleg

to the farthest diffuser for all conditions specified in System Description. b. Design calculations verifying uniform air distribution through the manifold

header and diffusers under all conditions specified in System Description. c. Design calculations showing loading conditions on piping and support

components. Include fluid forces developed by mixers and flow from process pipe inlets/outlets.

d. Design calculations showing mechanical strength capabilities of diffuser mounting system.

e. Design calculations showing normal buoyancy uplift forces and structural calculations to meet the requirements of piping supports.

f. Design calculations for piping supports for thermal expansion in air from 30 degrees Fahrenheit to 95 degrees Fahrenheit.

g. Seismic calculations. h. Calculations demonstrating adequacy of submerged stainless steel

cooling piping to provide necessary cooling of airflow to diffusers. 14. Spare parts list. 15. Qualifications and resume of installation engineer. 16. Training course outlines. 17. Manufacturer's experience and reference list as specified in Quality

Assurance. 18. Provide membrane longevity test reports:

a. Longevity of the proposed membrane diffusers shall have been demonstrated in at least 3 full-scale municipal installations operating continuously for a minimum of 3 years.

b. Test reports, prepared by an independent testing agency, shall confirm membrane longevity through compliance with the following maximum allowed percent (within) change in each membrane property. 1) Tests conducted in-house by the Supplier shall not be acceptable.


c. Data for a minimum of 3 diffusers from each installation shall be provided. Property Maximum Percent Change

Durometer 5 percent

Weight 5 percent

Permanent Set 0.5 percent

C. Operation and Maintenance Manuals: Furnish copies of operation and maintenance manuals as specified in Sections 01730 and 15050.

D. Factory Standard Oxygen Transfer Testing: 1. Use historical data:

a. Submit data from at least 5 previous oxygen transfer tests performed at approximately the same diffuser densities (within 1 AT/AD) and diffuser side water (within 0.5 feet) depths as the densities and side water depths proposed for this project.

E. As-built set of diffuser drawings: 1. A maximum of 30 days following the successful completion of the field 7-day

test, provide an as-built set of diffuser drawings showing the installed diffuser configuration with all pertinent details including: a. Installed number and location of diffusers and air distribution piping. b. Installed configuration of the air distribution piping including valves and

fittings, the location of the access ways. c. Location of the moisture blowoff piping.

1.06 QUALITY ASSURANCE:

A. Experience: Demonstrate minimum 5 years experience in the manufacture of fine bubble diffused aeration systems which have been successfully utilized in domestic wastewater applications.

B. Reference information: Provide the following: 1. List of at least 5 installations in domestic wastewater treatment plants located

in the Continental United States of not less than 2 million gallons per day (mgd) and with aeration equipment utilizing a quantity of diffusers equal to or greater than the number of diffusers proposed for this installation, with at least 5 years of successful continual operation, where the manufacturer has supplied equipment similar in design and characteristics to that proposed here. Include names, addresses, and telephone numbers of the Owners.

2. Name, address, and telephone number of contact person at each referenced installation.

3. Location of manufacturer’s diffuser production facility. 4. Location and description of manufacturer’s oxygen transfer testing facility and

equipment.


A. Environmental project conditions: 1. As specified in Section 01610. 2. Exposure to industrial solvents and petroleum products. 3. Intermittently submerged and exposed to atmosphere.


4. Wastewater temperatures: a. Maximum: 90 degrees Fahrenheit. b. Minimum: 50 degrees Fahrenheit.




any and all damage until the equipment is delivered to the job site. 3. Accessories shall be packaged separately in containers clearly marked,

“ACCESSORIES ONLY.” 4. A packing list, listing the contents of each container, shall be placed in a



conformance with the Contractor's construction schedule, to minimize handling and on-site storage of equipment.

2. Materials shall be unloaded and stored at a location on-site or directly into the aeration basins, and covered in accordance with the manufacturer's recommendations. Covering system shall protect the materials from UV radiation.

C. Storage and protection: Protect the system components at the site and during installation prior to project completion. As a minimum, provide cover, ventilation, and proper stacking to prevent warping of all aeration system piping stored on-site.


A. Coordinate work with restrictions specified in Section 01140.

1.10 WARRANTY

A. The manufacturer shall provide a 3-year extended warranty on all parts and materials. The extended warranty shall provide for replacement of all membranes which physically fail, tear, or pull out of mounting systems in the first 3 years of operation.

B. Owner shall receive an executed copy of the written warranty prior to final payment to the Contractor.

C. This warranty shall commence upon final acceptance of the aeration system by the Owner.

1.11 MAINTENANCE

A. Spare equipment: 1. 5 percent of the total diffuser membranes utilized on the project. 2. 1 percent of the total retainer rings and baseplates utilized on the project. 3. 5 percent of each of the different supports utilized on the project. 4. 1 spare moisture blowoff system complete with fittings and fasteners. 5. A minimum of 3 spanner wrenches for mounting of diffusers.


B. All spare parts shall be suitably packaged and clearly identified with indelible marking on the containers. Tools and spare parts shall be supplied in a tool chest for long-term storage and marked, “Tools and Parts for Aeration Basins".

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Furnish complete fine bubble aeration system by following manufacturer, or equal: 1. Sanitaire manufactured by ITT Industries, Inc. 2. Aquarius Technologies, Inc. 3. SSI Aeration Inc.

B. The complete fine bubble aeration system shall be furnished by a single manufacturer who is fully experienced in the design and manufacture of such equipment.

C. Use identical diffusers of the same model, type, and manufacturer, throughout the installation.

2.02 MATERIALS

A. General: For all components except where specifically modified in Equipment, use the materials of construction specified below: 1. Stainless steel:

a. Fabricate all welded parts and assemblies from sheets and plates of Type 304L stainless steel in accordance with ASTM A 240 with a No. 2D finish in accordance with ASTM A 480. Welds in accordance with ASTM A 774.

b. Fabricate all non-welded parts and assemblies from sheets and plates of Type 304 stainless steel in accordance with ASTM A 240, with a No. 2D finish in accordance with ASTM A 480.

c. Use Type 304L stainless steel in accordance with ASTM A 240 in the fabrication of all stainless steel pipe. In accordance with ASTM A 530, ASTM A 554, and ASTM A 778 in the fabrication of all stainless steel pipe.

d. Use Type 304L stainless steel in accordance with ASTM A 240 in the fabrication of all stainless steel pipefittings. In accordance with ASTM A 774 in the fabrication of all stainless steel pipefittings.

e. Use Type 304 stainless steel in accordance with ASTM A 240 in the fabrication of all stainless steel bolts, nuts, and washers.

f. Pickle all stainless steel assemblies and parts after welding, fabrication, and wire brushing by complete immersion in an acid solution in accordance with ASTM A 380. 1) Corrosion protection techniques not employing full immersion

methods shall not be acceptable. g. Do not field weld any stainless steel pipe, fittings, fabrications or

assemblies. 2. PVC:

a. Fabricate all PVC moldings and extrusions from PVC compound in accordance with ASTM D 1784, cell classification 12454-B.

b. Fabricate all PVC droplegs, manifolds, piping from PVC material in accordance with ASTM D 2241, with a hydrostatic design stress of 2,000 pounds per square inch.


c. Use PVC pipefittings in accordance with ASTM D 3034. d. Add a minimum of 2 percent titanium dioxide to all PVC compounds. e. Shop fabricate all solvent welded PVC joints in accordance with

ASTM D 2855. 3. Membranes:

a. Manufacture all membranes of EPDM synthetic rubber compound with precision die formed slits.

b. Do not use thermoplastic materials such as plasticized PVC or polyurethane.

c. The EPDM rubber compound shall be tested by a certified laboratory and have the following characteristics:

Parameter Standard Value / Unit Base Compound EPDM w/ Carbon Black for

UV Protection

Tensile Strength (Unperforated) ASTM D 412 1,200 psi

Elongation at Break ASTM D 412 350 percent

Hardness (Durometer) ASTM D 2240 58 within 5, Shore A

Accelerated Aging Compression Set @ 70 degree Celsius, 22 hours

ASTM D 395

40 percent

Elongation (percent retained) @ 100 degree Celsius, 70 hours

ASTM D 573

75 percent

Ozone Resistance ASTM D 1171

Pass

Modulus of Elongation @ 300 percent

ASTM D 412 500 psi

Material Thickness 0.08 inches

2.03 EQUIPMENT

A. General: 1. Supply products that are units of the manufacturer's standard production,

modified as necessary to satisfy the requirements of the Contract Documents, and specially fabricated for this project. Do not use products manufactured for another project.

2. The manufacturer shall supply a complete fine bubble diffuser system, ready for installation by the Contractor. No field modification of headers or field drilling or threading of headers shall be required.

3. Contractor shall provide all valves, air main piping, wall sleeves with seals, wall pipes, and concrete pedestals as necessary to complete the system as shown on the plans.

4. All equipment and appurtenances shall comply with the requirements as specified in Section 01612. a. Design mechanical equipment and piping and their supports to prevent

sliding or overturning. b. Provide brackets and anchors of ductile material capable of absorbing

energy and continuing to carry load.


c. Submit seismic calculations as specified in Section 01300.

B. Air distribution piping: 1. General:

a. The air distribution piping includes the stainless steel cooling loop (if needed), the manifolds that supply air from the dropleg to the laterals, and the laterals on which the diffusers are mounted.

b. Use only stainless steel or PVC for all air distribution piping as specified. c. Account for stresses due to temperature variation and provide suitable

systems to permit non-destructive relief of piping stresses. d. Install piping plumb with walls and make up all changes in direction using

standard fittings. e. Fabricate all piping assemblies to be field installed using flange-type joints

or positive fixed threaded union joints. 1) Push on, bell in spigot, or expansion type joints will not be

acceptable. f. Field welding of pipe sections, fittings, or flanges is not acceptable, except

for the lower PVC dropleg connection to the manifold. 2. Joints:

a. Threaded union joints shall consist of a spigot section solvent welded to 1 end of the pipe, a threaded socket section solvent welded to the mating pipe, an O-ring gasket, and a threaded screw on a retainer ring.

b. Positive fixed threaded union joints shall also have a spline and groove feature that will prevent rotation of adjacent header sections.

c. Flange joints shall have standard 125 pound drilling. d. Band couplings shall not be considered a fixed joint.

1. Dropleg Connection: a. Provide at least 1 dropleg connection for each Zone as indicated on the

Drawings. b. Connect CONTRACTOR provided dropleg to the Schedule 80 PVC

manifold with a Type 304 stainless steel flexible transition coupling. c. Install piping plumb with walls and make up all changes in direction with

standard pipefittings. 2. Manifolds:

a. Provide Schedule 80 PVC manifolds with PVC compound cell classification as specified in Materials.

b. Shop fabricate the manifolds in sections of 20 feet or less to conform with the accepted layout for the equipment supplied.

c. Maintain a constant bottom elevation of the manifolds throughout the basin.

d. Provide removable blind flanges or threaded end caps at the ends of all manifolds to allow purging of debris prior to system start-up.

3. Laterals: a. Lateral grid piping includes all submerged piping other than the droplegs,

manifolds, and the moisture blowoff piping. b. Provide lateral grid piping in accordance with ASTM D 2241 and sized for

SDR 35 or thicker. All fittings shall have pressure ratings not less than the attached piping and shall in accordance with ASTM D 3034 with a maximum SDR of 35.

c. Shop fabricate the laterals in sections of 20 feet or less. d. Field join lateral sections using flanged joints with gaskets. Connections

shall permit rotation of each section independent of adjacent sections.


C. Piping supports: 1. General:

a. Provide supports of both guide and fixed type to allow for expansion of the system. 1) Submit proposed pipe support layout and design for Engineer's

review and acceptance prior to manufacture. 2) Include all details outlined in Submittals.

b. For the welded parts of the pipe supports, use Type 304L stainless steel in accordance with ASTM A 240 with a No. 2D finish and a maximum carbon content of 0.030 percent.

c. For the non-welded parts of the supports, such as concrete anchors, nuts, and washers, use Type 304 stainless steel in accordance with ASTM A 240.

d. Fabricate the supports using flat stock of at least 18-gauge by 1-1/2 inches and rods of at least 5/16-inch diameter.

e. Supports shall be adjustable to allow movement of pipe and to compensate for a minimum variation in tank floor elevation of approximately 3 inches. 1) All adjusting devices shall lock in place after piping has been

installed and leveled. f. Attach supports to the tank floor using expansion type concrete anchors

designed for embedment in 3,000 pounds per square inch concrete. 1) Size anchors for pullout strength against calculated buoyant forces,

based on a design safety factor of 5 or more. g. Design supports to allow for complete removal from the tank (less

anchors) to facilitate cleaning and maintenance of tank bottom. 2. Dropleg supports:

a. Provide a mounting support at the midpoint of each dropleg. b. Design the support to restrain horizontal movement of drop.

1) Weight of the dropleg shall be supported by a wall support. 3. Manifold supports:

a. Provide a minimum of 2 supports with a maximum spacing between supports of 8 feet.

b. Design support system to resist thrust generated by expansion or contraction of pipe.

c. Design the manifold supports to include a manifold hold-down, guide straps, anchor bolts, and supporting structure. Use minimum 2-inch wide guide straps. Provide supports with a mechanism allowing for within 1.5 inches adjustment for alignment of the manifold in the field.

4. Lateral supports: a. Provide supports with a mechanism allowing for within 1.5 inches vertical

adjustment for alignment of the laterals in the field. b. Adjusting and aligning mechanism shall be infinitely adjustable within its

limits to allow precise leveling of the laterals and diffuser assemblies to within 1/4 inch of a common horizontal plane without removing the lateral from the support.

D. Diffuser assembly: 1. General:

a. With each complete air diffuser assembly, include a membrane diffuser element with matching baseplate, diffuser holder, threaded retainer ring, and an airflow control orifice.


b. Diffusers elements utilizing ceramic or plastic type diffusion media elements or ones that require a center bolt to limit membrane deflection will not be acceptable.

c. With each blank diffuser assembly, include a baseplate, threaded retainer ring, and an airflow control orifice.

d. Design, manufacture, and install the entire system in such a manner that all the diffuser elements are within 1/4 inch of a common horizontal plane.

e. Air distribution shall be uniform throughout the entire system as specified in performance requirements.

2. Membrane diffuser element: a. Type: Membrane disk. b. Size: 9-inch diameter. c. Material: Provide membrane material specifications as outlined in

Materials. d. Manufacture the membrane as a seamless, single extrusion or molding

without defects or repairs and integral sealing ring on periphery of diffuser element. 1) Surface of the membrane shall be smooth to prevent attachment of

biological growth. e. Design the membrane diffuser element to collapse and seal on the

supporting baseplate to prevent backflow of mixed liquor into the air piping when aeration air is turned off.

f. Design for the membranes to be replaceable in the field without needing to remove the diffuser assembly from the basin.

3. Baseplate: a. Provide PVC baseplate to completely support membrane diffuser element

and prevent reverse flexing. b. Baseplate shall include air release port centered in the baseplate.

4. Diffuser holder: a. Each diffuser shall incorporate a saddle type diffuser holder. Diffuser

holder shall either be integrally bonded to the piping system or attached with a saddle clip as per the following for each approved MANUFACTURER: 1) Sanitaire: Model 1633 2) SSI: Saddle Mount 3) Aquarius: Standard Mount

b. Diffuser holders attached via mechanical fasteners, such as rivets, shall not be acceptable.

c. Solvent weld each diffuser holder to the lateral grid piping in the factory or attach with retaining ring in the field such that the flat surface of all diffuser holders lie in the same plane along the length of the lateral grid piping; warping of this planar surface shall not be permitted. 1) Diffuser elements shall be located directly above the centerline of the

lateral pipes. 2) Elements that are offset or cantilevered shall not be allowed.

d. Secure the membrane diffuser element to the diffuser holder using a PVC retainer ring screwed on to the diffuser holder with the outer edge of the membrane diffuser element located in the groove provided. 1) Use a hold-down ring of sufficient length to allow engaging a

minimum of 1 full thread before compression of the membrane outer edge begins.


2) Strictly adhere to MANUFACTURER's recommendations during installation and tightening of the hold-down ring

3) Take precautions to avoid over tightening of the hold-down rings. 5. Airflow control orifice:

a. Each diffuser assembly shall incorporate a flow control orifice sized to provide equal air distribution throughout the grid. Should a diffuser element break, the flow control orifice shall be capable of maintaining uniform distribution of air throughout the system.

b. Design the airflow control orifice to be capable of being completely sealed. c. Factory drill the flow control orifices under controlled shop conditions prior

to shipment of the diffuser assemblies to the job site. d. No field drilling of flow control orifices is allowed. e. Provide removable orifice plugs for specified blank air diffuser assemblies:

1) Design plugs to be capable of preventing any airflow leakage throughout the specified range of flows.

2) Design plugs to allow removal using pliers.

E. Moisture blowoff system: 1. Provide a minimum of 1 moisture blowoff system per grid including all required

pipe, fittings, valves, and accessories. 2. Design the moisture blowoff system to be capable of effectively removing any

liquid that has entered the piping system. a. Include a sump in the piping at the location of the purge pipe to allow the

purge pipe to extend below the invert of the manifold and completely remove moisture from the manifold.

b. This fitting shall be a cross or a tee with a factory-solvent welded cap installed on the downward facing branch.

c. Locate the sump at the side of the grid opposite the dropleg to allow accumulated moisture to migrate with the airflow towards the sump.

3. Provide Schedule 80 PVC for all moisture blowoff piping, except for a short length of flexible, reinforced EPDM hose from the header/lateral purge pipe connection to the rigid blower piping mounted on the tank wall. a. The use of lengths of EPDM hose greater than 4 feet or extending to the

surface of the basin is not acceptable. b. All hose and fittings to have a pressure rating of no less than the attached

pipe, except that the cross fitting used for the sump may be Schedule 40 PVC.

4. Solvent welds may be used to join fittings to PVC pipe. a. A union shall be required in each blowoff line. b. Properly support the systems and allow for expansion and contraction of

the piping over a temperature range of 160 degrees Fahrenheit with no stress buildup in the piping.

c. Provide stainless steel hose clamps at each end of the flexible hose. 5. Attach moisture blowoff piping to wall of basin with Type 304 stainless steel

clips. a. The use of hose clamps or plastic ties to support blowoff piping from

dropleg piping (or other piping) is not acceptable. 6. Locate the valves in the blowoff piping in an easily accessible location above

the water surface adjacent to the wall and just above the grid system. a. The valve shall be a socket end type, PVC ball valve.


F. Fasteners and hardware: 1. Provide all bolts, nuts, and washers of Type 304 stainless steel.


A. Diffuser physical performance testing: 1. General:

a. The fine bubble aeration equipment shall be shop tested as specified. 1) No corrections shall be made to the measured values of any

parameter for possible errors due to instrument calibration, method of measurements, data observation, reduction of data, or measurement accuracy.

b. Perform oven age testing on the membranes as part of the quality control testing. 1) Results of the Accelerated Aging Test shall meet the criteria

specified in Materials. c. Sample and test the membrane diffuser elements for air distribution

uniformity, dynamic wet pressure (DWP), and dimensional tolerance as specified.

d. Submit a testing and sampling plan designed to insure consistently good quality of the diffuser assemblies from each membrane lot.

e. All tests shall be witnessed by a representative of an independent, certified testing laboratory engaged by the Contractor and approved by the Owner, and may be observed by the Engineer and Owner.

f. All costs for inspection and testing, exclusive of the costs for the presence of witnesses from the Engineer and Owner, shall be borne by the Contractor.

g. Notify the Engineer at least 30 days prior to the scheduled testing dates, and confirm the testing schedule at least 3 days prior to the testing date, to allow the Owner to witness the sampling and testing procedure for the diffusers.

2. Uniformity: a. Test diffusers in a plan to show that 95 percent of the diffusers within a

given lot meet the uniformity requirement. Uniformity is defined as a substantially even distribution of air bubbles across the diffuser surface when the diffuser is operating submerged in water.

b. The uniformity testing apparatus shall consist of a container for testing the elements individually and calibrated instruments for the measurement of all variables. 1) Provide a container or test box with suitable clamping devices for

holding the membrane element in position and completely sealing the element against the passage of air except through the exposed face. a) The holding device shall be such that the air is distributed

uniformly across the surface of the element. 2) Use a nonpulsating air supply. 3) If necessary, use a reservoir to dampen pulsation in the blower

discharge piping. c. Membrane elements to be tested for uniformity:

1) Saturate with tap water, clamped in position, and submerged in a depth of 2 inches of tap water.


2) Air shall then be diffused through the element at a rate of 12 standard cubic feet per minute per square foot of effective surface area for 1 minute.

3) The airflow rate shall then be reduced to 1.0 standard cubic feet per minute per square foot of effective surface area, and the uniformity of diffusion observed and recorded as satisfactory or rejected.

d. All diffusers not satisfying the uniformity requirement shall be rejected. e. If the uniformity tests do not show substantial uniformity, additional tests

shall be made as necessary to assure that elements with uniform permeability are being obtained. 1) The cost of any additional tests shall be borne by the Contractor.

3. Dynamic wet pressure (DWP): a. Test diffusers in a plan to show that 95 percent of the diffusers within a

given lot fall within 10 percent of the average DWP. DWP is defined as the pressure to operate at the specified conditions minus diffuser submergence and flow control losses.

b. Test diffusers in a room maintained at 70 degrees Fahrenheit within 5 degrees Fahrenheit and 10 to 50 percent humidity.

c. Use the same apparatus for the DWP test as was used for the uniformity test. 1) Provide a means of measuring the pressure under the diffuser

element. 2) Submerge the diffusers at least 2 inches of water and operate at an

airflow rate of 3.5 scfm per square foot of active diffuser area within 10 percent.

3) The DWP is the pressure head under the diffuser in inches of water minus the submergence depth in inches.

d. All measured DWP values shall be within 10 percent of the average DWP. e. All diffusers tested and found outside the acceptable range shall be

rejected. 1) If the lot is found to have a greater variability than specified, all

elements of the lot shall be tested and only individual diffusers which meet the variability requirement shall be accepted.

2) The cost of any additional tests shall be borne by the Contractor. 4. Dimensional tolerances:

a. Test diffuser elements and baseplates for dimensions and trueness of surfaces.

b. All elements with appreciable warping of surfaces shall be rejected. Appreciable warp is defined as irregularities greater than within 0.03 inch.

c. Maintain the following tolerances: 1) Membrane thickness: 0.08 inch within 0.01 inch. 2) Membrane disk diameter: 9 inch within 0.10 inch (9-inch diameter

disk). d. The criteria used to determine the acceptance of the dimensional

tolerances shall be the same as for uniformity and DWP.

B. Air manifold piping testing: 1. Factory assemble and test the air manifold piping for leaks to a pressure of

10 pounds per square inch, or 1.25 times the maximum allowable pressure, whichever is higher, prior to shipment.

2. Provide written certification per requirements of product data and shop drawings.


PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect all components for shipping damage and conformance to the specifications.

3.02 INSTALLATION

A. Contractor shall remove and dispose of all existing diffusers in the existing Aeration Basin.

B. Contractor shall install the specified fine bubble diffused aeration system in accordance with the equipment manufacturer's instructions and recommendations furnished with the equipment, approved shop drawings, and as indicated on the Drawings and Specifications.

C. Contractor shall furnish and install all piping, valves, fittings, anchors, interconnections, and accessories as required to make the system complete and functional. 1. Include in the bid all labor, materials, and equipment required to install the

diffuser system and to make the complete system operate satisfactorily.

D. Install all diffusers at an identical elevation within 0.25 inches of a common horizontal plane.


A. Cleaning of air piping: 1. After installation of the new aeration piping, it is to be cleaned with either a

water flush or air purge. The air pipe must be cleaned before diffusers are installed. a. Water Flush

1) To water flush the system, connect a water supply to the air header. It is imperative that the header be isolated with valving such that water does not flow back to the blowers.

2) Clean water must be employed. It is not necessary to use potable water but the hush water must be free of silt or debris.

3) Cap laterals and flush the air header water at least two feet per second (if possible).

4) The laterals are to be individually flushed next. A flush velocity of five to six feet per second is recommended for lateral cleaning. Removing the lateral end cap of individual laterals will produce a significant flushing action in the lateral as water is pumped through the header.

b. Air Purge 1) Open all lateral valves prior to opening the basin isolation valve.

Provide an opening at the end of the air laterals to allow air and foreign materials to be discharged from the system. The opening may be made at the end of the air lateral by leaving the end cap off at the end of the lateral.

2) In order to increase the velocity of air through the header and air laterals, it may be desirable to operate at maximum blower capacity. A high velocity is required in order to blow out any accumulated foreign matter.


3) Run the air purge for at least 10 minutes, but for no longer than 15 minutes. Running compressed air through the diffuser grid when it isn’t submerged in water can damage the piping.

c. These operations shall be coordinated with the needs of plant operations through the Engineer.

2. Do not install the diffuser elements until all cleaning operations are complete. 3. Thoroughly clean all new air piping immediately prior to installation. 4. Swab each unassembled piece of grid piping prior to installation. 5. After installation, protect all surfaces from contamination by dust, dirt,

construction debris, and moisture, including atmospheric moisture, in a manner satisfactory to the Engineer.

6. Whether or not the pipe upstream has been cleaned, all openings in partially completed work shall be temporarily sealed off except where installation is actively in progress. a. Seal off openings where installation is in progress at the end of each day's

work, or whenever the work is temporarily stopped for any reason. 7. Suspend work whenever inclement weather is imminent. 8. Thoroughly clean any surfaces which become contaminated prior to

acceptance to the satisfaction of the Engineer.

B. Inspection and checkout: 1. After installation, test the fine bubble diffusion equipment for mounting,

levelness, air uniformity, and leakage. a. Notify the Engineer at least 1 week prior to the scheduled testing date,

and confirm the testing schedule at least 2 days prior to the testing date, to allow the Engineer or his representatives to witness the field-testing.

b. Replace all items found to be defective. 2. Prior to initiating any field-testing, inspect all piping for proper joints, supports

and tie-downs, plugs, and moisture blowoff valves. 3. Provide a field service engineer to monitor the installation, leveling, and testing

of the aeration equipment. 4. Flood the aeration tank with water to the top of the diffusers.

a. Check the level of the diffusers to insure that they are at the same elevation within 0.25 inch of a common horizontal plane.

C. Field performance tests: 1. Notify the Engineer at least 1 week prior to the scheduled testing date, and

confirm the testing schedule at least 2 days prior to the testing date. 2. Introduce water into the aeration basins until the water level just reaches the

top of the diffusers. a. The level of the diffusers shall then be checked to insure that they are at

the same elevation, within the limits specified. 3. After completion of the leveling test, add water to the aeration basins to cover

the diffusers with about 3 inches of water. 4. Pass air through the diffusers, and check operation of the diffusers. 5. Visually inspect the surface of the water above the diffusers to ensure that

airflow is uniformly distributed across the tank, as well as uniformly distributed across the surface of each diffuser.

6. All diffusers, which in the opinion of the Engineer do not produce a uniformly distributed flow pattern, or do not produce a flow pattern consistent with the majority of the diffusers, shall be replaced.


7. Check all air manifold, moisture blow-off, and drop piping above the water surface for leaks with soapsuds after covering the diffusers with water. a. All leaks shall be repaired either with heavy bodied glue around

connections according to the glue manufacturer's instructions, or a method approved by the Engineer. Testing shall continue until the systems show no visual signs of leakage.

8. The Contractor is responsible for filling and emptying aeration basins with water as required for his testing activities. a. Water used shall be from the Owner's plant effluent water system. b. Contractor shall be responsible for conveying water between the plant

effluent water system and the aeration basins. c. Provide written notification to the Engineer a minimum of 5 days in

advance of any such use of the plant effluent water.

D. 3-day test: 1. Conduct the 3-day test following successful completion of the field

performance tests. 2. Fill the aeration basins with plant water to normal operating levels. 3. Operate at normal airflow rates for a minimum of 3 days. 4. If any diffuser system failures occur during this period, drain the basin(s),

make repairs/modifications, and then re-run the 3-day test. 5. Owner will provide a source of water and electrical energy. 6. Contractor shall pay for all costs of testing other than the cost of water and

energy at their sources. 7. At the end of the test or retest, leave the basins full of plant water.

E. 7-day test: 1. Following successful completion of the 3-day test, coordinate with the plant

operations personnel in placing the basins in operation. 2. Provide a minimum of 1 week for the Owner to establish operational conditions

in the aeration basins. 3. Upon notice that the aeration basins have achieved operational conditions,

begin the 7-day test. 4. Submit a written procedure for approval prior to beginning the 7-day test.

a. Correct any deficiencies found during the 7-day test and at the Owner's option, run the 7-day test again at no additional cost.

3.04 MANUFACTURER’S FIELD SERVICES

A. Provide manufacturer's factory-trained field service engineer, specifically trained in the installation and testing of the specific equipment. The field service engineer shall provide the following services: 1. Supervising equipment installation. 2. Providing start-up and testing assistance and making adjustments, repairs,

and corrections. 3. Training plant operating personnel.

B. Include a minimum of two 8-hour days of the field engineer's time on the site. 1. Training shall count for 1 day of the total required time. 2. Include a minimum of 3 trips.


C. Schedule in advance with the Owner, training for the fine bubble diffused aeration system operation and maintenance. 1. Submit a training schedule based upon the projected installation schedule.

D. Furnish a certificate stating that the equipment has been tested, is correctly installed, properly aligned, and ready to be placed in regular operation.

E. A maximum of 30 days following the successful completion of the field 7-day test, provide as-built drawings of the diffuser installation including all information outlined in Factory Standard Oxygen Transfer Testing Data.

F. Refer to Section 01650 for additional training requirements.

END OF SECTION


SECTION 11510

SAFETY EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: The following safety equipment: 1. First aid kit. 2. Safety rope. 3. Life preserver.

1.02 REFERENCES

A. National Institute for Occupational Safety and Health (NIOSH): 1. Schedule 13F - Self-Contained Breathing Apparatus (SCBA).

B. Occupational Safety and Health Administration (OSHA).

1.03 SUBMITTALS

A. Shop drawings.

B. Product data: 1. Submit manufacturer's product literature information for products specified. 2. Manufacturer's installation instructions.

C. Samples.

D. Operation and maintenance data.

E. Warranty.


A. Manufacturer qualifications: Show evidence that the firm has been engaged in producing such materials and products for at least 5 years and that the product submitted has a satisfactory performance record of at least 5 years.

B. Installer qualifications: Installer shall have 3 years experience in installing these materials for similar projects and shall be approved by the manufacturer prior to bidding of the project.

C. Regulatory requirements: As applicable, equipment of this Section shall comply with requirements of public agencies of the state where the project is located including OSHA, ULNFPA, U.S. Coast Guard.


A. Packing and shipping: Deliver to the job site in manufacturer's original containers.


B. Delivery: After wet operations in building are completed.

C. Storage and protection: Store materials in original, unopened containers in compliance with manufacturer's printed instructions.

D. Keep materials dry until ready for use.

E. Keep packages of material off the ground, under cover, and away from sweating walls and other damp surfaces.

F. Protect finished surfaces from soiling and damage during handling and installation. Keep covered with a protective covering.

PART 2 PRODUCTS

2.01 FIRST AID KIT

A. Manufacturers: One of the following or equal: 1. VWR Scientific, 56613-216. 2. Fire Safety Source, 223UFAO.

B. Features/characteristics: 1. Prefinished, wall-mounted metal cabinet. 2. Standard medical supplies capable of serving up to 25 people. 3. Meets OSHA requirements.

2.02 SAFETY ROPE

A. Manufacturers: One of the following or equal: 1. Mine Safety Appliances Company. 2. California Safety.

B. Characteristics: 1. Diameter: 9/16 inch. 2. Length: 50 feet. 3. Accessories: Snap hook on one end.

2.03 LIFE PRESERVER

A. Type: Doughnut-shaped, 30 inches diameter, with mounting brackets; U.S. Coast Guard approved.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install products in accordance with manufacturers' recommendations.

B. Install fixed equipment in accordance with manufacturer's instructions.

C. Replace any equipment found defective with new.


3.02 SCHEDULE

A. First Aid Kit - One (1) in Blower Building Office.

B. Safety Rope & Life Preserver - Two (2) at Aeration Basin Extension.

END OF SECTION


SECTION 11635

AUTOMATIC SAMPLERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Automatic samplers and accessories. 1. Tag numbers:

a. SST-SAFP-001-A b. SST-SAFP-002-A

B. Related sections: 1. Section 01300 – Submittals.


A. Automatic sequential/composite sampler unit, complete with weatherproof insulated fiberglass enclosure, integral programmable controllers, and accessories.

B. Unit shall be designed for use in highly corrosive environments and shall be corrosion resistant.

1.03 SUBMITTALS

A. Submittals shall be as specified in Section 01300.

B. Shop drawings: 1. Detail drawings or manufacturer's literature to indicate compliance with the

specified requirements. 2. Dimensional drawings.

C. Product Data.

D. Operation and Maintenance Manuals.

E. Warranties.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Teledyne ISCO, Model 5800. 2. Sigma, equivalent model. 3. Manning, equivalent model.


2.02 AUTOMATIC SAMPLER

A. Enclosure: 1. The sampling units shall have a weatherproof-insulated fiberglass enclosure. 2. Sampler shall be capable of operating in an ambient temperature range of -20

to 120 degrees Fahrenheit. 3. Provide a heater with electronic thermostat integral with the sampler.

B. Sampler shall be capable of both sequential or composite sampling. 1. Sampler shall be configured for composite sampling.

C. The samples shall be automatically composited in a 5-gallon polyethylene container located in a refrigerated compartment maintained between 0 and 4 degrees Celsius.

D. Controls: 1. The sampler shall operate on a flow proportional basis paced by 4 to 20 mA

signal. 2. The sampler shall have a built-in unit for converting the 4 to 20 mA signal to

contact closure input.

E. Sampling intervals: Capable of taking samples at intervals selectable in single increments from 1 to 9,999 flow pulses or timed intervals selectable in 1 minute intervals up to 5,999 minutes between consecutive uniform time intervals or up to 999 minutes for non-uniform time intervals.

F. Sample volume: Selectable in 1.0 milliliter increments from 10 milliliter to 9,990 milliliter.

G. A positive purge shall be provided before and after each sampling to prevent clogging and cross-connection.

H. Suction lift: Sampler shall be capable of drawing a sample to a minimum vertical height of 26 feet.

I. Pumping rate: Minimum pumping rate shall be 2.0 feet per second through 3/8-inch inside diameter tubing at 15 feet of vertical lift.

J. Power: 120 volt, single-phase, 60 Hertz.

2.03 ACCESSORIES

A. Provide 1 set of the following for each sampler furnished: 1. Spare sample tube: 1. 2. Spare strainer: 1. 3. 24 extra 1,000 ml polyethylene bottles with rack. 4. 1 extra 5-gallon polyethylene container.


PART 3 EXECUTION

3.01 INSTALLATION

A. Provide, store and install automatic samplers in accordance with the recommendations of the manufacturer.

END OF SECTION


SECTION 12310

MANUFACTURED METAL CASEWORK

PART 1 GENERAL

1.01 SUMMARY

A. Section includes metal cabinets; counter tops; chairs; casework hardware, connection to utilities; and service fittings and outlets.

1.02 REFERENCES

A. American National Standards Institute: 1. ANSI A156.9 – Cabinet Hardware.

B. ASTM International: 1. ASTM A653/A653M – Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process.

2. ASTM A666 – Standard Specification for Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar.

3. ASTM C1036 – Standard Specification for Flat Glass. 4. ASTM C1048 – Standard Specification for Heat-Treated Flat Glass-Kind HS,

Kind FT Coated and Uncoated Glass.

C. Consumer Product Safety Commission: 1. CPSC 16 CFR 1201; Safety Standard for Architectural Glazing.

D. National Electrical Manufacturers Association: 1. NEMA LD 3 – High Pressure Decorative Laminates.

1.03 SUBMITTALS

A. Section 01300 – Submittals.

B. Shop Drawings: Indicate casework locations, large scale plans, elevations, cross sections, rough-in and anchor placement dimensions and tolerances, clearances required.

C. Product Data: Submit component dimensions, configurations, construction details, joint details, and attachments, utility and service requirements and locations.

D. Samples: Submit two samples, minimum size 3 x 6 inches of each color of base material, metal, plastic laminate, or other finish.

E. Manufacturer's Installation Instructions: Submit special installation requirements.


1.04 QUALIFICATIONS

A. Installer: Company specializing in performing Work of this section with minimum three years documented experience.

B. Manufacturer: Company specializing in manufacturing products specified in this section with minimum three years documented experience.


A. Section 01600 – Product Requirements: Product warranties and product bonds.

B. Accept casework on site. Inspect on arrival for damage.

C. Coordinate size of access and route to place of installation.

1.06 COORDINATION

A. Coordinate casework installation with size, location and installation of service utilities.

B. Sequence installation to accommodate required utility connections.

PART 2 PRODUCTS

2.01 METAL CASEWORK

A. Manufacturers: 1. Steelcase 2. Lyon 3. LOC Solentific.

2.02 HARDWARE COMPONENTS

A. Hardware: Manufacturer's standard.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify adequacy of support framing and anchors.

3.02 INSTALLATION

A. Install casework, components and accessories.

B. Use anchoring devices to suit conditions and substrate materials encountered.

C. Set casework items plumb and square, securely anchored to building structure.

D. Insulate to prevent electrolysis between dissimilar metals.


E. Scribe to abutting surfaces and align adjoining components. Apply matching filler pieces where casework abuts dissimilar construction.

F. Field touch-up blemishes to original finish.

3.03 ADJUSTING

A. Section 01770 – Closeout Procedures: Testing, adjusting, and balancing.

B. Adjust doors, drawers, hardware, fixtures, and other moving or operating parts to function smoothly.

3.04 CLEANING

A. Section 01770 – Closeout Procedures: Final cleaning.

B. Clean casework, counters, shelves, legs, hardware, fittings and fixtures.

3.05 PROTECTION OF INSTALLED CONSTRUCTION

A. Section 01770 – Closeout Procedures: Protecting installed construction.

B. Do not permit finished casework to be exposed to continued construction activity.

3.06 SCHEDULES

A. Blower Building Office 102:Furniture within this room consists of –

ITEM QUANTITY 1. Steelcase 46216179 2

Leap, Chair, Upholstered Plastic: 6205 Black Upholstery: 5S26 Licorice Casters Soft Casters Arms: Standard H/W/P/D Arms Lumbar Opts: Standard Lumbar Seat Height: Standard 5” Pneumatic Seat Height Range Headrest Opts: Omit Headrest

2. Steelcase Currency Editor Desk 1

Worksurface-Straight, Full Depth 30”Dx72”Wx28 1/2"H Top Surface: Chocolate Walnut (LPL) (264L) Options- 2 Drawer-Left Hand

END OF SECTION


SECTION 13122

METAL BUILDING SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Prefabricated metal building systems.

B. Related sections: 1. Section 01610 – Project Design Criteria. 2. Section 01612 - Seismic Design Criteria. 3. Section 01614 - Wind Design Criteria. 4. Section 01770 - Closeout Procedures. 5. Section 03600 - Grouting. 6. Section 05190 - Mechanical Anchoring And Fastening To Concrete And

Masonry. 7. Section 08522 - Horizontal Sliding Aluminum Windows. 8. Section 08800 - Glazing. 9. Section 09960 - High-Performance Coatings.

1.02 REFERENCES

A. American Concrete Institute (ACI): 1. 318 - Building Code Requirements for Structural Concrete and Commentary.

B. American Institute of Steel Construction (AISC): 1. 303 - Code of Standard Practice for Steel Buildings and Bridges. 2. 360 - Specification for Structural Steel Buildings.

C. American Iron and Steel Institute (AISI): 1. SG02 - North American Specification for the Design of Cold-Formed Steel

Structural Members.

D. ASTM International (ASTM): 1. A 123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron

and Steel Products. 2. A 153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware. 3. A 325 – Standard Specification for Structural Bolts, Steel, Heat Treated,

120/105 ksi Minimum Tensile Strength. 4. A 490 - Standard Specification for Structural Bolts, Alloy Steel, Heat Treated,

150 ksi Minimum Tensile Strength. 5. A 653 - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or

Zinc-Iron Alloy Coated (Galvannealed) by the Hot-Dip Process. 6. A 780 - Standard Practice for Repair of Damaged and Uncoated Areas of

Hot-Dip Galvanized Coatings. 7. A 792 – Standard Specification for Steel Sheet, 55% Aluminum-Zinc Alloy-

Coated by the Hot-Dip Process.


8. B 187 - Standard Specification for Copper, Bus Bar, Rod, and Shapes and General Purpose Rod, Bar, and Shapes.

9. B 633 - Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel.

10. D 1494 - Standard Test Method for Diffuse Light Transmission Factor of Reinforced Plastics Panels.

11. F 959 - Standard Specification for Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners.

12. F 436 - Standard Specification for Hardened Steel Washers. 13. F 1852 - Standard Specification for “Twist Off” Type Tension Control Structural

Bolt/Nut/Washer Assemblies, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

E. American Welding Society (AWS): 1. D1.1 - Structural Welding Code - Steel. 2. D1.3 - Structural Welding Code - Sheet Steel.

F. FM Global (FM).

G. International Accreditation Service (IAS): 1. AC472 - Accreditation Criteria for Inspection Programs for Manufacturers of

Metal Building Systems.

H. International Building Code (IBC): 1. 2015 with amendments adapted by City Ordinance.

I. Metal Building Manufacturing Association (MBMA): 1. Metal Building Systems Manual.

J. Occupational Safety and Health Administration (OSHA): 1. Occupational Safety and Health Standards:

a. 1910.23 - Guarding floor and wall openings and holes.

K. Research Council on Structural Connections (RCSC): 1. Specification for Structural Joints Using High Strength Bolts.

L. Society for Protective Coatings (SSPC): 1. SSPC-SP2 - Hand Tool Cleaning.

M. Steel Door Institute (SDI): 1. A250.8 - Recommended Specifications for Standard Steel Doors and Frames.

N. Underwriters’ Laboratories, Inc. (UL). 1. 580 - Tests for Uplift Resistance of Roof Assemblies.

1.03 DEFINITIONS

A. Primary framing: An assemblage of beams and columns that support the secondary framing members, and that collects loads to transfer to the building foundation.

B. Secondary framing: Members which directly support roof, wall, or floor surfaces and convey loads to the primary framing.



A. System: 1. Design: Furnish metal building with vertical walls, gable roof, and with column

layout as indicated on the Drawings. 2. Size:

a. Furnish metal building of the size and configuration indicated on the Drawings.

b. Coordinate manufacturer's design dimensions for metal building system components, including columns, with equipment foundations, and details indicated on the Drawings.

3. Roof slope: Use a roof slope of 1 inch vertical in 12 inches horizontal or steeper.

4. Provide building with horizontal and vertical bracing where indicated on the Drawings.

5. Column reactions shall be vertical and horizontal only. a. No bending moments shall be transferred at column bases.

6. The building roofing system will be listed for a UL 580, Class 60 designation. 7. Openings: Frame openings for doors, windows, louvers, equipment with

structural framing to replace panels and secondary framing cut for opening. a. Provide curbs to suit roof-mounted equipment compatible with roof

sheathing.

B. Performance requirements: 1. General:

a. Design of the metal building structure and its appurtenances shall conform to the requirements of the IBC, the Metal Building Systems Manual, and the requirements of this Section. 1) Where the Metal Building Systems Manual conflicts with the

requirements of this Section, the more restrictive requirements will govern.

b. Do not include collateral or auxiliary loads in load combinations where dead loads offset other load effects (for example, uplift due to wind loads).

c. Hot-rolled structural steel sections or welded-up plate sections: Design in accordance with AISC 360.

d. Cold-formed steel structural members: Design in accordance with the AISI North American Specification for the Design of Cold-Formed Steel Structural Members.

2. Loading: a. General:

1) Design building for dead load, live loads, and combinations of loads including unbalanced loads in accordance with the IBC 2015 with amendments adopted by City Ordinance and the MBMA Metal Building Systems Manual, except as modified in this Section.

2) Reduction in wind, live, or snow loads based on tributary loaded area will not be permitted.

b . Roof loading requirements: 1) Live load: Minimum 20 pounds per square foot assumed to act

vertically on horizontal projected area of roof.


c. Collateral loading: Uniform roof load of 5 pounds per square foot assumed to act vertically on horizontal projected area of roof to account for miscellaneous accessories supported from the structure. 1) Collateral loading shall be considered a live load. 2) Design primary and secondary framing to support the additional

weight of mechanical equipment such as fans, air conditioners, etc. shown on plans. a) Mechanical equipment weights are in addition to collateral

loading. d. Auxiliary loading:

1) Structural members: Any single point along the secondary roof framing members shall be designed to carry a concentrated load of 200 pounds in addition to the roof live load.

2) Roof panels: Design panels to support a 200 pound load uniformly distributed over a 2 square foot area centered between supporting framing members, without exceeding a panel deflection to span ratio of 1/180 in a 2-span condition.

3) Auxiliary loading shall be considered a live load. 4) Auxiliary is to be considered concurrently with collateral loading.

e. Wind loading requirements: As specified in Section 01614. 1) Design roof purlins and structural frames for loads specified, but not

less that 30 pounds per square foot uplift on horizontally projected roof area.

f. Seismic loading requirements: As specified in Section 01612. 1) Bolted joints subject to seismic loading shall be designated

pretensioned joints. 3. Deflection limitations:

a. Primary frames: 1) Gravity deflection:

a) Live load deflection: L/240. b) Snow load deflection: L/240. c) Total load deflection: L/180.

2) Horizontal drift of rigid frames measured at eave: a) Wind drift limitation: H/60.

b. Secondary framing: 1) Gravity deflection:

a) Live load deflection: L/180. b) Snow load deflection: L/180. c) Total load deflection: L/150.

2) Horizontal deflection: L/120. c. Deflection of roof and wall panels: Span/180. d. Deflection calculations should be based on the wind loads presented in

AISC Design Guide 3. 1) Deflection calculations should be based on the unreduced wind loads

required in the IBC (50-year reoccurrence intervals). 4. Climatic conditions:

a. Gutters and downspouts: Design for a rainfall rate of 5 inches per hour. b. Temperature: Provide for movement (expansion or contraction) caused by

a range of ambient temperature of 120 degrees Fahrenheit without detrimental effects.


1.05 SUBMITTALS

A. Product Data: 1. Manufacturer’s installation instructions. 2. Manufacturer’s standard color charts and profiles:

a. Exterior wall and roof panels. b. Interior wall and roof liner panels. c. Gutters and downspout trim.

3. Manufacturer’s list of approved clamps that may be used to hang suspended items from roof purlins and details of acceptable methods of attachment to purlins.

B. Shop drawings: 1. Shop drawings: Catalog cuts; design and erection drawings; and other data

needed to clearly describe design, materials, construction details, fasteners, and erection. a. Erection drawings shall include building dimensions, required foundation

footprint, anchor bolt and base plate settings, bracing, main and secondary framing, and sections and details required to fully describe construction of building.

b. Indicate quantity, size, grade, embedment, and projection, and location of anchor bolts.

2. Calculations: Submit engineering design calculations for the complete structural system, including coverings and anchorages, sealed and signed by a Professional Engineer licensed in the state of Texas. a. Clearly indicate foundation reactions at all columns. Identify all applied

loads, load factors, and load combinations used to develop the reactions. b. Calculations will be submitted for record information only.

1) Engineer’s review of calculations will be for general conformance to the loading requirements of this Section.

2) The building manufacturer shall remain fully responsible for the structural design and adequacy of the metal building system.

3. Descriptive data: Submit data for the following items either on the shop drawings or separately: Accessories, each type of flashing, trim closures, caps and similar items, fasteners, doors, roof openings, gutters, and downspouts.

C. Quality control submittals: 1. Building manufacturer.

a. If requested by the Engineer, submit a record of manufacturer's metal building systems of similar design manufactured and erected in the 5-year period preceding the bid date for this project. 1) Include date of installation, location of metal building, and name and

address of Owner. b. Submit evidence of manufacturer’s certification under IAS AC472

Accreditation. 1) Certification must be valid for the facility at which the metal building

will be fabricated. c. Confirmation of UL 580 wind uplift rating.

2. Erector: a. Submit welder qualification certificates.


D. Record documents: 1. 1 set of reproducible “Record Drawings” for the erected structure.

a. Drawings shall bear the seal and signature of a Professional Engineer, registered in the state where the work is constructed and who provided responsible charge for the design.

E. Closeout submittals: Submit Contract Closeout Submittals as specified in Section 01770. 1. Operating and Maintenance Information. 2. Warranty. 3. Certificate of Compliance: At the completion of the metal building manufacture,

the manufacturer will furnish a letter to the Engineer stating that the work was performed in accordance with the approved construction documents.]


A. Manufacturer qualifications: Manufacturer shall have been engaged in the design, manufacture, and erection of metal building systems of the type specified for at least 5 years preceding the Bid Date of this Contract. 1. Building manufacturer shall be certified by IAS AC472 Accreditation. 2. The manufacturer’s Engineer of Record shall hold current license as a

Professional Engineer in the state where the work will be constructed.

B. Erector qualifications: Erectors shall be trained, approved, and certified by the manufacturer prior to Bidding of the Project. Erectors shall demonstrate at least 3 years experience in successfully erecting metal building systems of the type specified in Section 01610.


A. Packing and shipping: Deliver materials and fabrications to the job site in manufacturer's original containers with seals unbroken and labeled with manufacturer's identification and number.

B. Delivery: 1. Deliver materials dry and undamaged, and store out of contact with ground. 2. Cover materialswith weathertight coverings and keep dry. 3. Provide good air circulation and protection from surface staining for roof and

wall covering sheets.

C. Storage and protection: Store materials in original, unopened containers in compliance with manufacturer's printed instructions.

1.08 WARRANTY

A. Provide Owner with warranty that exterior finish system for metal panels shall be guaranteed against blister, peeling, cracking, chipping, or material rust-through for a period of 1 years from the date of Substantial Completion.


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Buildings: One of the following or equal: 1. American Buildings Company. 2. Red Dot Building System. 3. Butler Manufacturing Company.

2.02 MATERIALS

A. Primary framing (rigid frames): 1. Welded plates or hot-rolled steel columns and roof beams, complete with

necessary splice or connector plates for bolted field assembly. a. Minimum nominal thickness of structural shapes or their elements shall be

1/4-inch. 2. Welding procedures, welder qualifications, and welding quality standards shall

be in accordance with AWS D1.1 and AWS D1.3. 3. Base, cap, compression plates, and stiffener plates shall be factory-welded in

place, and shall have shop-fabricated connection holes. a. Provide minimum 4 anchor bolts per column base.

4. Columns and roof beams shall be fabricated complete with holes in webs and flanges for attaching bracing and roof and sidewall framing.

5. Shop finishing: a. Shop galvanized - hot-dipped:

1) Hot-dip galvanize members in accordance with ASTM A 123. 2) Provide a minimum zinc coating of not less than 1.4 ounces per

square foot.

B. Secondary framing (purlins, girts, framing at endwalls and openings, eave struts, bracing): 1. Hot rolled structural steel or cold-formed members. 2. Minimum thickness: 16-gage. 3. Bracing elements constructed of wire rope, stranded tendons, or other similar

material is not permitted. a. Rolled angle sections or solid steel bar is permitted.

4. Provide factory-punched holes for panel connections. 5. Shop finishing - hot rolled sections:

a. Galvanized - hot-dipped: 1) Hot-dip galvanize members in accordance with ASTM A 123. 2) Provide a minimum zinc coating of not less than 1.4 ounces per

square foot. 6. Shop finishing (cold-formed sections):

a. Galvanized - hot-dipped: 1) Hot-dip galvanize members in accordance with ASTM A 653 to G90

designation.

C. Roof and wall panels: 1. Roll-formed minimum 24 gauge steel, factory-finished each side. 2. Panels shall have interlocking side seams and shall be the manufacturer's

maximum standard width Factory cut to maximum possible length to minimize end laps.


3. Factory pre-punched for fastening. 4. Panel finish:

a. Factory pre-painted, pre-finished coating consisting of a UV light-resistant polyvinylidene diflouride (PVDF) resin based paint and primer system having a total thickness not less than 1.0 mil on an approximately 55 percent aluminum-43 percent zinc-1 percent silicone galvanized coating complying with ASTM A 792.

b. The galvanized coating shall be deposited at a minimum rate of 0.50 ounces/square foot.

c. Furnish manufacturer's standard color chart for Owner's selection. 5. Ridge panel: 1-piece, factory formed to match roof slope at each side, of same

material as roof panels, and capable of completely sealing roof ridge.

D. Bolted joint components: High-strength steel bolts used for steel-to-steel structural connections. 1. Galvanized in accordance with ASTM A 153. 2. Bolts: ASTM A 325 or A 490, Type 1. 3. Nuts: ASTM A 563, heavy hex. Grade and finish to match bolts as specified in

RCSC Specification for Structural Joints Using High Strength Bolts. 4. Washers: ASTM F 436; flat unless otherwise noted.

a. Load indicator devices: 1) Twist-off type tension-control bolt assemblies: ASTM F 1852, with

strength level in accordance with ASTM A 325. 2) Compressible washer direct tension indicators: ASTM F 959, Type

A 325 for ASTM A 325 bolts. 5. Bolts furnished for the project shall be a single size and grade.

E. Anchor bolts or anchor rods: As specified in Section 05190 except that material shall be Type 316 stainless steel unless otherwise indicated on the Drawings.

F. Fasteners and washers: 1. Fasteners and washers used for attachment of wall and roof panels. 2. Fasteners: Vinyl-coated steel or stainless steel. 3. Washers: Neoprene or other accepted type washer capable of being used to

assure watertightness at fastening locations.

G. Gutters and downspouts: 1. 24 gauge steel. 2. Galvanized in accordance with ASTM A 653 to G60 designation. 3. Field painted. Color to be selected by Owner to complement wall panels.

H. Doors and frames: 1. Provide hinged doors in accordance with Section 08110 and hardware in

accordance with Section 08710.

I. Windows and glazing: 1. Provide windows and glazing as indicated on the Drawings and as specified in

Sections08522 and 08800.

J. Touch-up painting materials: 1. For structural elements:

a. Shop primer: Manufacturer’s standard primer. b. Touch-up paint: Same as shop primer.


2. For sheet metal skin: a. Exterior finish paint: Match specified coating.

1) Color: Color as selected by the Engineer.

K. Insulation: 1. Thermal value:

a. Roof insulation: R-19 + R-11LS. As defined in Table 502.2(2) of the IECC. b. Wall insulation: R-13 + R6.5CI. As defined in Table 502.2(2) of the IECC.

L. Vapor Retarder: 1. WMP-50, 0.0015-inch minimum thickness, UV stablilized, white polypropylene,

laminated to 30-pound Kraft paper / metalized polyester and reinforced with glass fiber and polyester scrim. WMP-50, by LAMTEC, or equal, 0.0015-inch minimum thickness, UV stabilized, white polypropylene, laminated to 30-pound Kraft paper / metalized polyester and reinforced with glass fiber and polyester scrim. Basis weight: 32 lbs/1000 ft3.AD2

2. Perm Rating: 0.02. 2.3. Facing material shall be suitable for providing a clean, neat interior wall and

ceiling finish.AD2

M. Caulking material: Elastomer type, manufacturer's standard.

N. Roof vents: 1. 10-foot ridge vents with 9 inch or 12 inch throat opening at ridge. Vents shall

be pre-fabricated by a recognized manufacturer and shall include necessary flashing to make them weather tight.

2. Factory painted with color acceptable to Engineer and factory assembled units complete with bird screen and cord operated damper.

3. Each vent shall allow a minimum of 620 cubic feet per minute air movement at a temperature differential of 10 degrees.

4. Vents shall be fabricated by a recognized manufacturer shall include necessary flashing to make them weather tight.

O. Vent materials: 1. Steel: Minimum 20 gauge galvanized. 2. Screens: 1/8-inch mesh aluminum screen.

P. Ventilator accessories: 1. Bird Screen. 2. Flashing.

2.03 FABRICATION

A. Shop fabrication: 1. Structural elements:

a. Fabricate rigid frame of hot-rolled sections or continuously welded plate sections.

b. Field connections shall be bolted unless otherwise accepted by the Engineer.

2. Wall panels: a. Provide panels that are 1 piece from base to eave and have fasteners

located on inside of panels. b. Provide top and bottom closures and bottom supports.


3. Roof panels: a. Panel splicing: Panels may be spliced with minimum end overlap of

9 inches at purlins. b. Ridge panel: Provide 1 piece ridge panel, factory formed to match roof

slope, of same material as roof panel, and capable of completely sealing roof ridge.

c. Expansion of roof panels: Provide means to allow expansion of roof panels.

4. Fasteners for roof and wall panels: a. Fasteners: Secure with fasteners that assure maximum weathertightness,

proper bearing surface, and permanent seal at point of fastening. b. Washers: Use washers capable of assuring watertightness at fastening

locations. 5. Accessories:

a. Gutters, downspouts, and hangers: 1) Provide 4-inch gutters, downspouts, and hangers.

b. Vents: 1) Provide vents of size and location indicated on the Drawings. 2) Provide louvers that are operable and that have screens.

c. Ventilators: 1) Provide buildings with gravity vertical turbine ventilators with 12-inch

throats where indicated on the Drawings. 2) Provide ventilators that are gravity operated with damper. 3) Accessories: Provide hardware and accessories including bird

screen and flashing, as required to properly install ventilators in roof openings.

B. Tolerances: 1. Hot-rolled sections: In accordance with AISC 303. 2. Cold-formed and Built-up sections: In accordance with MBMA Metal Building

Systems Manual.


A. General. 1. Components of the metal building system fabricated in the manufacturer’s

shop will not be subject to special inspection, as specified in this Section. 2. The manufacturer shall communicate the proposed fabrication schedule to the

Contractor with sufficient notice and lead time to schedule the required inspections.

3. The manufacturer shall cooperate with the inspection agencies and personnel and shall facilitate access for the inspector to the components requiring inspection.

4. The inspector will verify that the manufacturer maintains detailed fabrication and quality control procedures that provide a basis for inspection control of the workmanship and the manufacturer’s ability to conform to approved construction documents and referenced standards. a. The inspector will review the procedures for completeness and adequacy

relative to the code requirements for the manufacturer’s scope of work.

B. Source inspection.


1. Special inspection of the metal building system components fabricated in the manufacturer’s shop will be performed at the time and frequency outlined in Schedule 13-1.

2. Components of the metal building system that will be subject to special inspection are as indicated in Attachment 13.1.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verification of conditions: 1. Verify site conditions prior to start of work. Unacceptable conditions shall be

reported to Engineer. 2. Starting of erection of metal building system work shall indicate acceptance of

existing conditions. a . Manufacturer or manufacturer’s trained erector shall review and examine

existing site conditions, foundation, and surface preparation, and adequacy of site-prepared components prior to commencing erection of the building.

a.3. Install all materials as per manufacturer recommendations.AD2

3.02 ERECTION

A. General: 1. Erect in accordance with the MBMA,Metal Building Systems Manual and

manufacturer’s instruction, except as modifled in this Section. 2. Separate dissimilar materials with gaskets or suitable insulating coatings. 3. Keep exposed surfaces clean and free from sealant, metal cuttings, and other

foreign materials.

B. Framing and structural members: 1. Set anchor rods by template and securely tie into formwork before concrete

placement. 2. Provide uniform bearing under baseplates and sills by filling using a

nonshrinking grout as specified in Section 03600.

C. Walls and roof: 1. Erect a structure that will be free from water leaks and meet design

requirements. 2. Direct side lap edges away from the prevailing winds at the site. 3. Do not exceed the maximum fastener spacings specified.

a. Space fasteners uniformly not to exceed: 8 inches on center at ends of covering, 12 inches on center at intermediate supports and at roof covering side laps, and 18 inches on center at wall covering side laps.

4. Install fasteners in straight lines within a tolerance of 1/2 inch per bay. 5. Seal side laps, ends of roof, wall coverings, and joints at accessories.

a. Drive fasteners to the surface and seat gasketed heads and washers. 6. Fasten accessories to framing members, except as otherwise accepted by the

Engineer. 7. Wall panels shall be isolated from concrete floor slab and/or foundation. 8. Flashing shall be provided at the base of wall panels to prevent wind-driven

rain from entering the building envelope.


D. Gutters and downspouts: 1. Attach securely to the building. 2. Install gutters sloped to drain with adequate provisions for expansion and

contraction.

E. Doors and roof openings: 1. Anchor securely to the supporting construction. 2. Install doors plumb and true and adjust to provide operation.


A. General. 1. Installation of metal building system will be subject to special inspection and

evaluation during construction, as specified in this Section.

B. Site inspection. 1. Special inspection of the metal building system components will be performed

at the time and frequency outlined in Schedule 13-1. 2. The elements of the metal building system construction that will be subject to

special inspection are as indicated in Attachment 13-1.

3.04 ADJUSTING

A. Touch-up factory finished surfaces of roof and wall panels with the manufacturer's recommended paint where damaged or abraded.

B. Where shop processes such as shearing or punching leave edges of galvanized steel unprotected by galvanization, touch up unprotected edges as specified in this Section.

C. Galvanized surfaces: Repair damaged galvanized surfaces in accordance with recommendations of the American Hot-Dip Galvanized Association.

3.05 CLEANING

A. Remove excess materials, equipment, and debris incidental to this work upon completion.

3.06 PROTECTION

A. During erection, the erector shall be responsible for the protection of this and all adjacent work from damage.

END OF SECTION

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SCHEDULE 13-1

METAL BUILDING SYSTEM CONSTRUCTION SPECIAL INSPECTION

IBC Table 1704.3 Inspection Task Frequency/Timing of Inspection

Criteria Reference

Prior to beginning installation of metal building, verify high-strength bolts, nuts, and washers:

1.a. Identification markings conform to ASTM standards required by approved design.

Periodic: Confirm from stockpile of materials delivered to site whether material furnished complies with the materials in the approved design.

1.b. Confirmation of manufacturer’s certificate of compliance

Periodic: Confirm that manufacturer has furnished the required Certificate of Compliance.

Inspection of high-strength bolted joints:

2.a. Joints designated bearing-type connections by the approved design.

Periodic: Provide continuous inspection of the initial installation of each type and size of joint. Subsequent installations of the same type and size of joint may be inspected on a periodic basis with inspections of a minimum of 20% of installations, or once per calendar week, whichever is more frequent.

2.b. Joints designated slip-critical connections by the approved design.

Continuous: Provide continuous inspection as specified in Section 01455.

Verification of structural steel material:

3.a. Identification markings conform to ASTM standards required by approved design.

Periodic:

3.b. Confirmation of manufacturer’s certified mill test reports.

Periodic:

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Criteria Reference

Prior to beginning installation of metal building, verify weld filler materials:

4.a. Identification markings conform to the AWS specification required by approved design.

Periodic:

4.b. Confirmation of manufacturer’s certificate of compliance

Periodic:

Inspection of structural steel welding:

5.a.1. Complete and partial penetration groove welds.


5.a.2. Multipass fillet welds. Continuous: Provide continuous inspection as specified in Section 01455.

5.a.3. Single-pass fillet welds greater than 5/16 inch.


5.a.4. Single-pass fillet welds less than or equal to 5/16 inch.

Periodic: Provide continuous inspection of the initial production of each type and size of welded joint. Subsequent production of the same type and size of joint may be inspected on a periodic basis with inspections of a minimum of 20% of installations, or once per calendar week, whichever is more frequent.

5.a.5. Floor and roof deck welds.

Periodic: Provide continuous inspection of the initial production of each type and size of welded joint. Subsequent production of the same type and size of joint may be inspected on a periodic basis with inspections of a minimum of 20% of installations, or once per calendar week, whichever is more frequent.

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Criteria Reference

Inspection of steel frame joint construction for compliance with approved design.

6.a. Bracing and stiffening details.

Periodic: Provide periodic inspection of any bracing and stiffening details of construction. Inspection should include, as a minimum, verification of member sizes and proper orientation. A minimum of 15% of locations should be verified.

6.b. Member locations. Periodic: Provide periodic inspection of member locations. Inspection should include, as a minimum, verification of member sizes and proper spacing/location. A minimum of 15% of locations should be verified.

6.c. Connection joint details. Periodic: Provide periodic inspection of joint details of construction. Inspection should include, as a minimum, verification of miscellaneous steel detailing, including stiffener plates, concrete pourstops, gusset plates and similar miscellaneous steel framing.. A minimum of 15% of locations should be verified.


Attachment 13-1

METAL BUILDING CONSTRUCTION REPORT

[project name]

[owner]

Permit No.:

Structure:

Date: Weather:

Contractor: Min/Max Temp:

Dwg. Ref:

Location:

ELEMENT DESCRIPTION TABLE 1704.3

CONFORMS

High strength bolts, nuts, and washers

General:

Fastener components are protected in closed containers from dirt and corrosion.

1.a. Yes No

Fastener components that accumulate dirt or rust may not be cleaned and incorporated into work.

1.a. Yes No

Fasteners may not be reused. 1.a. Yes No

Material within the grip of the bolt is non-compressible steel. 1.a. Yes No

Burrs extending greater than 1/16 inch above the faying surface are removed.

1.a. Yes No

Materials:

Bolt grade: A325 A490 F1852 Other: ________________________

1.a. Yes No

Bolt size: 5/8 inch 3/4 inch 7/8 inch 1 inch 1 1/8 inch 1 1/4 inch Other __________

1.a. Yes No

Bolt finish: _______________________________________________________

1.a. Yes No

Nut grade: A194 A563 Other: ________________________________

1.a. Yes No

Nut finish: _______________________________________________________

1.a. Yes No

Washer grade: F436 F959 1.a. Yes No


ELEMENT DESCRIPTION TABLE 1704.3

CONFORMS

Washer finish: ____________________________________________________

1.a. Yes No

Hole: Standard Oversized Short-slotted Long-slotted Yes No

Bearing Type Joints:

Faying surfaces may be uncoated, coated, or galvanized. 2.a. Yes No

All plies of joint have been drawn into firm contact 2.a. Yes No

Pretensioned Joints:

Faying surfaces may be uncoated, coated, or galvanized. 2.a. Yes No

Pre-installation verification of fastener assembly and installation procedures

2.a. Yes No

Bolts tightened in joint in accordance with Section 8 of RCSC Specification for Structural Joints Using High Strength Bolts

2.a. Yes No

Yes No

Slip Critical Joints:

Faying surfaces are not coated 2.b. Yes No

Faying surfaces to be coated have been prepared in accordance with RCSC Specification for Structural Joints Using High Strength Bolts

2.b. Yes No

Galvanized faying surfaces have been prepared in accordance with RCSC Specification for Structural Joints Using High Strength Bolts

2.b. Yes No

Pre-installation verification of fastener assembly and installation procedures

2.b. Yes No

Bolts tightened in joint in accordance with Section 8 of RCSC Specification for Structural Joints Using High Strength Bolts

2.b. Yes No

Welding of Structural Steel

General:

Materials:

Welded Joints:


Remarks: Inspector Date

AD2 Addendum No. 2

March 1, 2019 – CONFORMED 13390–1 9080B11 Harutunian Engineering, Inc. TBPE Firm F-2408

SECTION 13390

PACKAGED CONTROL SYSTEMS

PART 1 GENERAL

1.01 SUMMARY

A. Scope of Work 1. Furnish, install, and place in service the packaged control systems as shown

on the PLANS and as specified hereinafter. 2. The subsequent document entitled “Appendix A – Packaged System PLCs

Programming Criteria” is hereto made part of this section and includes OWNER’S requirements associated with the programming of the packaged control system PLC(s) and other project requirements. Coordinate with the OWNER’S and comply with the OWNER’S latest programming requirements. The contents of “Appendix A” are not inclusive of all requirements of this Contract. Refer to the PLANS and other Sections of the Specifications for additional information

3. The subsequent document entitled “Appendix B – AW Host Pack Spreadsheets” is hereto made part of this section and includes OWNER’S requirements associated with the AW Host Pack spreadsheets. Coordinate with the OWNER and comply with the OWNER’S latest Host Pack spreadsheet requirements. The contents of “Appendix B” are not inclusive of all requirements of this Contract. Refer to the PLANS and other Sections of the Specifications for additional information.

4. The subsequent document entitled “Appendix C – AW Software Tagging Criteria” is hereto made part of this section and includes OWNER’S requirements associated with the software tagging within PLC/OIU programs. Coordinate with the OWNER and comply with the OWNER’S latest tagging criteria requirements. The contents of “Appendix C” are not inclusive of all requirements of this Contract Refer to the PLANS and other Sections of the Specifications for additional information.

1.02 RELATED WORK

A. The Procurement Documents are complementary; what is called for by one is as binding as if called for by all.

B. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work.

C. Related work as called for on the PLANS, as specified herein or in other Sections of the Specifications.


1.03 QUALIFICATIONS

A. Panels associated with the Packaged Control System (PCS) shall be designed, constructed, and tested in accordance with the latest applicable requirements of ISA, NEMA, ANSI, UL, and NEC standards.

B. Assemble panels in equipment manufacturer’s factories. Test panels for proper operation prior to shipment from the manufacturer’s factory.

1.04 DELIVERY, STORAGE AND HANDLING

A. Protection 1. The Contractor, and hence the PCS supplier, shall be responsible for safety of

the PCS during storage, transporting and handling. 2. The PCS equipment shall be environmentally protected and stored in climate

controlled (temperature and humidity, etc.) environment. 3. At all times the PCS equipment shall be housed inside a moisture free, non-

porous, extra heavy duty plastic weatherproof housing. 4. Interior and exterior of PCS equipment shall be kept clean at all times. 5. Energize the space heaters within the PCS and energize during storage and

installation for humidity control.

B. Additional project job site storage requirements: Upon delivery to the project site and prior to final installation, protect and store in accordance with the following: 1. Environmentally protected and stored in climate controlled (temperature,

humidity, and non-corrosive class) environment at the job site. Size, furnish and install temporary gaseous air scrubbers, air conditioners, and additional environmental control equipment complete with branch circuiting conduit/wire as required to maintain in a controlled environment at the following conditions: a. Ambient Dry Bulb Temperature:

1) Minimum: 68 degrees Fahrenheit. 2) Maximum: 85 degrees Fahrenheit.

b. Ambient Relative Humidity: Maximum: 50% c. Ambient Corrosion Level: International Society of Automation Class: G1

2. Every effort shall be made to provide all necessary electrical power connections ready for immediate connection to equipment upon arrival of equipment on jobsite.

3. Upon arrival of equipment onto job site, the Contractor shall provide proper transition of power to equipment, especially any 120 VAC powered equipment, to ensure all air conditioning, heating, and gaseous air scrubbing equipment are fully operational and that the equipment is in a conditioned space on the day the equipment arrives.

4. Furnish and install replacement air scrubber media, air filters, etc., as required for proper operation of the environmental control equipment.

1.05 SUBMITTALS

A. Submit shop drawings in accordance with the requirements of Section 01330 of the Contract Specifications. Include: 1. Dimensioned/scaled top and bottom enclosure views, front enclosure

elevations, and internal component/device layouts 2. One-line diagrams and wiring diagrams, as applicable,


3. Catalog cut sheets. Include protective device coordination curves and current limiting circuit breaker/fuse peak current let through curves, where applicable. Include color chart for control panel color selection by the OWNER.

4. Additional information as described in Appendix A – Packaged System PLCs Programming Criteria.

5. Where NEMA 4X aluminum control panel is provided per Section 13390.2.02.J.1.b, submit information regarding material composition, finish details, and chemical compatibility with H2S, H2SO4, and HCL as minimum to facilitate Owner review. Use of aluminum control panel material will not be permitted without submittal of this additional information.

B. Where Programmable Logic Controllers (PLCs) are provided as part of the PCS (refer to Section 2.03, this Section of the Specifications), submit PLC programming documentation in accordance with the requirements of Section 01330 of the Contract Specifications. Include: 1. PLC program input/output point listing, including all PLC software input/output

points obtained through all serial communication interfaces. Include points obtained from the OWNER’s Distributed Control System that are necessary for proper operation of the PCS. Multiple submittals of this listing will be required to facilitate the PLC programming coordination specified herein. The input/output point listing shall be provided electronically in Microsoft Excel format. The input/output point listing shall be submitted along with the product data. At minimum, the following shall be identified in the input/output point listing for each input/output point: a. Register Address: The PLC register address associated with the point b. Tag Name: the tag name as assigned in the PLC program for the data

point c. Description: the description of the data point d. Data Type: the data type as used in the PLC program (integer, floating

point, etc.) e. Origin. For those points transmitted via a serial communication network,

the PLC identifier and its associated register address f. Terminal block locations. g. Additional supplementary information as recommended by the packaged

control system manufacturer to enhance the understanding of the i/o listing.

2. Submit a Plant Control System interface table in electronic Microsoft Excel file format. The Plant Control System interface table is to consist of only those data points in the packaged system vendor’s PLC data registers that are to be shared with the OWNER’S Top-End computer system and/or PLC system via the Modbus/TCP communication with the packaged control system PLC. This plant control system interface table should consist of ONLY points that are intended to be shared with the plant control system (Plant PLC’s and plant SCADA computers). These data points should include, in particular, equipment status (e.g., on/off), process values (e.g., pressure, level, flow, etc.), equipment mode (e.g. manual/auto or lead/lag), alarms, data points associated with the protective relays/power monitoring units and telemetered through the Modbus/TCP communication data link connected to the PCS (minimum points as described hereinafter), and additional data points that are available to or can be developed by the PCS as requested by the Owner. The table should also include control commands and setpoints (if appropriate and as deemed fit


by the vendor). No other data points, e.g. internal/temporary registers, should be listed in this table. The quantity and type of input/output points to be made available to the OWNER’S Distributed Control System through the serial communication interfaces will be determined after Bid Award. Provide the input/output points as requested by the OWNER at No Additional Charge to the OWNER. The Plant Control System interface table is to consist of the following columns: a. Register Address: The PLC register address associated with the point b. Tag Name: the tag name as assigned in the PLC program for the data

point c. Description: the description of the data point d. Data Type: the data type as used in the PLC program (integer, floating

point, etc.) e. EGU Min: Minimum value for data point (for non-Boolean values). It is

assumed the point is scaled to the engineering units (EGU) value in the vendor PLC for use by the plant control system

f. EGU Max: Maximum value for the data point (for non-Boolean values). It is assumed the point is scaled to the engineering units (EGU) value in the vendor PLC for use by the plant control system.

g. EGU: engineering units used (for non-Boolean values). h. Bool 0 Desc: The description of the Boolean point when it is Boolean 0 i. Bool 1 Desc: The description of the Boolean point when it is Boolean 1 j. Alarm Priority: The alarm priority (for alarm points only) is to be one of H,

M, or L, where H = High priority alarm, M = Medium priority alarm, L = Low priority alarm

k. Direction: The direction is to be one of R, W, or RW, where: R = Data is read by the plant control system from the vendor PLC , W = Data is written by the plant control system to the vendor PLC, RW = Data is read and written by the plant control system from/to the vendor PLC

l. Discrete Commands from plant HMI to PLC: If any discrete command bits are required from the plant HMI control system to the PLC, then the PLC will reset the command bit to zero at the end of each PLC scan. The command is to take action in the vendor PLC on Boolean 1, and have no action in the vendor PLC on Boolean 0.

m. All alarms shall be Boolean such that 0 is then normal condition and 1 is the alarming condition

n. Heartbeat Register in each PLC: For each PLC, please provide a heartbeat register that increments once every 0.1 seconds, is of Type INT and has a range of 0 to 32767

o. Boolean Status Points: Map all 0x (%M) register Boolean points to 4x registers (%MW) words of WORD data type and provide indexing into the 4x register to attain the Boolean value. All equipment on/off statuses shall be Boolean such that 0 = OFF, 1 = ON

3. Completed AW Host Pack spreadsheets. The OWNER will furnish Host Pack spreadsheets electronically in Microsoft Excel format. Include effort to coordinate with the OWNER related with the Host Pack spreadsheets and submit the completed Host Pack spreadsheets in electronic Microsoft Excel file format. The formatting of the Host Pack spreadsheets may not be altered without prior approval from the OWNER. Refer to Appendix B – AW Host Pack Spreadsheets for additional requirements for bidding purposes.


4. Minimum data points to be telemetered by the PCS for protective relays/power monitoring units that are connected to the PCS are as follows: Voltage (average, A-B,B-C,C-A), Current (average, A, B, C, Ground), power factor, horsepower, kw, kvar, kva, mwh, and all alarms and trip conditions that are configured on the protective relay/power monitoring unit.

5. Electronic files of PLC program in editable electronic files and PDF on CD-ROM. Follow the file format as described hereinafter.

6. Electronic files of the OIU screens in editable electronic files (Schneider Electric Vijeo *.vdz file format) and PDF on CD-ROM. Follow the file format as described hereinafter.

7. Additional information as described in Appendix A – Packaged System PLCs Programming Criteria.

C. Sequence of operation. In addition to the operation of the PCS, include the OWNER’s process/mechanical equipment that shall also be monitored/controlled by the PCS, where applicable.

D. Testing Related Submittals: 1. Submit ORT test procedures and test results per Section 17100. 2. Submit PAT test procedures and test results per Section 17100.

E. Certified Report: Submit a report prepared by PCS Manufacturer’s technical representative certifying satisfactory installation, operation, and in service placement of entire PCS.

1.06 OPERATION AND MAINTENANCE MANUALS

A. Furnish Operation and Maintenance Manuals in accordance with the requirements of Section 01730 of the Contract Specifications. Include: 1. Installation and operation manuals. 2. Renewal parts bulletin. 3. As built drawings, including approved shop drawings. 4. Test data 5. Software program hardcopy (as applicable) for final as-built software. 6. Additional information as described in Appendix A – Packaged System PLCs

Programming Criteria.

1.07 TOOLS AND SPARE PARTS

A. Furnish the following spare parts with the equipment for each PCS in conformance with the specifications: 1. One (1) – Set of fuses (minimum 3) for each type and size used for fuses 110V

and greater. 2. One (1) – Set of starter contacts for every three (3) like starters used (a

minimum of 1 for each size used). If contacts are not replaceable a spare starter for each size used shall be supplied.

3. One (1) - Contactor coils for every NEMA size and type starter installed, a minimum of one coil per size.

4. One (1) - Spare control relay, complete with all accessories, for each relay type used.

5. One (1) - Spare timing relay. 6. One (1) – Sets of overload heaters for each size and type used.


7. One (1) – Selector switch, complete with 2 auxiliary contacts, of each type used (two position, three position, etc.).

8. One (1) – Pilot light, complete with auxiliary contact, of each type used. 9. One (1) - Push button, complete with auxiliary contact, of each type used 10. Ten percent - terminal blocks, of each type and color used. 11. Ten percent – PLC input/output modules, with minimum of two of each module

type used. 12. Ten percent – PLC CPU and Ethernet networking modules, with minimum of

one of each module type used 13. Ten percent – PLC CPU memory cards, with minimum of five of each type

used 14. Ten percent – Ethernet switches, minimum of one of each type used 15. Ten percent – OIU, with minimum of one of each type used 16. Two (2) sets of filters and media for gaseous scrubber unit.

1.08 SPECIAL MANUFACTURER SERVICES

A. Where PLCs are provided as part of the PCS (refer to Section 2.03, this Section of the Specifications): 1. The PCS Manufacturer shall include, at minimum, four (4) meetings dedicated

for the purpose of coordinating PLC programming development. The meetings shall be conducted to assist in the coordination effort needed to interface the PCS with the OWNER’s Distributed Control System, inclusive of all the OWNER’s PLCs and Top-End (host) computer system, and coordination of PCS PLC algorithm development where required to achieve the overall functional requirements of this Specification. The PCS Manufacturer shall provide a non-sales type representative to attend each meeting who is also intimately familiar with the PLC programming of the PCS. For bidding purposes, each meeting shall have a four hour duration and be held at the OWNER’S project site. At each meeting, the PCS Manufacturer shall also provide a submittal of the PLC program input/output point listing, sequence of operation, and electronic files of the PCS PLC program developed to date. Refer to the Submittals section of this Specification for minimum composition of input/output point listing, sequence of operation, and electronic PLC program files. The PCS Manufacturer shall include all necessary travel, submittal reproduction, and miscellaneous other expenses associated with their meeting attendance.

2. PLC software registers associated with the input/output point types (i.e., discrete input, discrete output, analog input, analog output) that are telemetered to the OWNER’s distributed control system shall be organized contiguously among each input/output point type.

3. In the software programming, adhere to the software tagging as described in “Appendix C – AW Software Tagging Criteria” to the extent practicable. Coordinate software tagging with the OWNER.

B. Furnish the services of a qualified, experienced, factory trained technical (non-sales type) representative to advise the Contractor in the installation of the equipment and assist in all PCS testing and start-up. Include checking alignment of parts, wiring connections, operation of all panels, parts (relays, starters, PLCs, etc.). Include time to correct and recheck any discrepancies which are discovered. Also include providing the OWNER with a report certifying that the equipment was installed,


properly tested, and set in accordance with the PCS manufacturer’s requirements and is in satisfactory operating condition. Format and quantity of reports shall be per the requirements of Section 01330 of the Contract Specifications.

C. Any problems encountered with the operation of equipment, parts, components, etc. installed within the PCS shall be repaired/remedied by the manufacturer's technical representative.

D. Manufacturer's technical representative is to set, adjust and test all circuit breakers, relays, motor circuit protectors, etc. in the presence of a representative of the OWNER. The settings will be based on coordination, short circuit, and motor starting studies performed in compliance with Section 16140 of the Specifications, “Switchboards”, paragraph 1.08 “Special Manufacturer’s Services”. 1. The Manufacturer shall furnish the protective device of the appropriate

characteristics that shall be the most suitable for the proper protection and coordination of the system at No Additional Cost to the OWNER. The Manufacturer shall select, set, and adjust the load side devices served by the main PCS protective device accordingly at No Additional Cost to the OWNER.

2. Provide the OWNER with a test report certified by the manufacturer. Include a record of all settings. Format and quantity of reports shall be per the requirements of Section 01330 and 01730 of the Contract Specifications.

PART 2 PRODUCTS

2.01 GENERAL

A. Furnish and install all necessary components and wiring for a complete and functional system. Furnish and install additional requirements as follows: 1. Furnish and install the enclosure as hereinafter specified. Mount and wire all

components inside of enclosure unless specified otherwise. The enclosure, with all components mounted and wired, complete with all accessories, shall be referred to hereinafter as the Control Panel.

2. Furnish and install the Control Panel configured for single point electrical feed that terminates on a dedicated main circuit breaker inside of the Control Panel. Refer to the PLANS and also the appropriate Division 11 Specification for which the PCS is provided for voltage and phase requirements. The Control Panel shall contain all necessary means, i.e. , control power transformer with primary and secondary short circuit protection/disconnects, uninterruptible power supply, associated wiring, short circuit protection, etc. to derive and distribute the needed control power at the necessary voltages for the entire PCS.

3. Furnish and install the control system Type as hereinafter specified. 4. Furnish and install motor starters/drives as specified herein, by other Sections

of the Specifications, and the PLANS. Size, furnish, and install motor starters/drives complete with all accessories as specified.

5. Furnish and install circuit breakers for branch circuits distributed from Control Panel as hereinafter specified. Coordinate operation of branch circuit breakers with corresponding main circuit breaker for proper circuit isolation and protection. Note, the main circuit breaker for the control panel per paragraph 2.01.A.2 shall not be considered a branch circuit breaker for the purposes of this Specification.


6. Furnish and install field devices that are fully corrosion resistant, water tight, and resistant to all chemicals associated with the process application. All field devices life cycle, operation, and accuracy shall not be affected by the process application. As a minimum, all field devices shall be U. L. Listed and NEMA 4X rated. The mounting arrangement shall include provisions to enhance operation and maintenance of the system in consideration of the process application.

7. Where devices are required for the functional operation of the PCS but are not specified under Division 17, furnish and install manufacturer’s standard.

8. Where process taps/connections are located higher than 5 feet above finished floor/grade, furnish and install remote mounted indicating transmitters and extend tubing as required to facilitate mounting transmitters no higher than 5 feet above finished floor/grade.

9. For additional construction notes and special requirements, refer to the PLANS and the Specifications.

B. Analog, Control, and Alarm Signaling Requirements 1. Refer to the PLANS and also the appropriate Division 11 Specification for

which the PCS is provided for minimum contacts to be connected to the OWNER’s Distributed Control System.

2. All control and alarm circuits shall be 120 volts A.C. Alarm signal contacts shall open to alarm and shall be isolated contacts rated for 5 ampere at 120 volts A.C.

3. The contact configuration (normally open/closed) required for proper interface to the OWNER’s Distributed Control System shall be furnished and installed at No Additional Cost to the OWNER. Under no circumstances shall contacts of pushbuttons and selector switches shall be connected to the OWNER’s Distributed Control System via interposing relays. Refer to Section 17600 for minimum interface requirements to the OWNER’s Distributed Control System.

4. All analog signals shall be 4 to 20 mA DC. Use “two-wire” type circuits where possible. Furnish and install loop current isolators for each analog signal circuit in which either the field device or Control Panel is located outdoors. Loop current isolators shall be per Section 17200.

5. All RTD signals shall be 100 ohm platinum type.

C. Selector Switches, Pilot Devices, Pushbuttons requirements: 1. For NEMA 12 rated enclosures: Furnish and install per Section 17200. 2. For NEMA 4X rated enclosures: Furnish and install per Section 16540. 3. Mount on enclosure door.

D. Wiring: Furnish and install as specified in Section 17200. Group conductors and route in wireways as specified in Section 17200. Wiring for 480 VAC circuits shall be per Section 16200.

E. Identification: Tag enclosure, terminal blocks, and devices (mounted interior and on the face of the enclosure) as specified in Section 17200. Tag all wiring per the requirements of Section 16200.

F. Grounding: Furnish and install grounding per Section 17200.

G. Miscellaneous Accessories:


1. Furnish and install lugs/ power distribution blocks /terminal blocks as required for the connection of the field wiring. Furnish and install terminal blocks per Section 17200. Furnish and install the necessary means for the termination of the field wiring at No Additional Cost to the OWNER.

2. Furnish and install a Type 2 surge protective device for the 120 VAC package control system control power circuitry. Wire, and mount inside the enclosure.

3. Furnish and install 24 volts DC power supply and all other power supplies per the PCS manufacturer’s requirements where not specified per Section 17200. Wire and mount inside the enclosure.

4. Where an uninterruptible power supply is needed for the application, furnish and install per Section 17200. Packaged control systems having PLCs shall also be furnished with uninterruptible power supplies per Section 17200.

5. Arrange the enclosure internal components to coordinate with the OWNER’s conduit entry requirements at No Additional Cost to the OWNER.

2.02 CONTROL PANEL ENCLOSURE REQUIREMENTS

A. Enclosure shall be the totally enclosed, dead front, suitable for back-to-wall mounting. Free standing and wall mounted enclosures may be used. Enclosure shall be adequately sized to contain all of devices required for the PCS in addition to facilitating the termination and routing of all associated PCS field interconnect conduit/wire systems.

B. Unless specifically noted otherwise elsewhere, enclosures shall be rated: 1. Enclosures located outdoors: NEMA Type 4X, Type 316 Stainless Steel

enclosures. 2. Enclosures located indoors in process/mechanical areas and storage areas

that are not environmentally and climate controlled: NEMA Type 4X, Type 316 Stainless Steel enclosures.

3. Enclosures located indoors in areas that are environmentally and climate controlled: Nema 12-gasketed, painted steel enclosures per Section 17200.

C. Enclosure shall have hinged, gasketed doors. Each door shall have an operating handle. At minimum, Furnish and install quarter turn door latch. Furnish and install three point door latch where available for the enclosure. Furnish and install pad locking means for the door/handle.

D. Enclosures shall have a door mounted variable depth disconnect operating mechanism for operating the main circuit breaker and providing access to the 480V compartment. Provide padlockable disconnect operating handle. Handle shall be mechanically interlocked with the door/barrier to prevent personnel from opening the door and accessing the 480V compartment when the unit disconnect is in the ON position. Furnish and install handle-door interlock defeating (bypass) feature. Disconnect operating mechanism shall be as manufactured by Square D Class 9421 or approved equal. Electric actuated door interlock means will not be accepted.

E. When sizing the enclosure, consideration shall be given to the enclosure installation location and the environmental aspects associated with the location (indoors, outdoors, etc.). Enclosures shall be sized to adequately dissipate heat generated by the equipment contained therein. Enclosures shall be provided with the necessary climate control devices, i.e. air conditioners, cooling fans,


thermostatically controlled heaters, as required, for proper PCS operation. All outdoor located enclosures containing PLCs shall have air conditioners as hereinafter specified.

F. Furnish and install enclosure manufacturer’s factory interior backpanels and sidepanels as required to facilitate interior device mounting. Panels shall be factory painted white.

G. For all PCS enclosures containing components rated greater than 120 VAC and components rated 120 VAC and less, the enclosure shall consist of two compartments. Each compartment shall have an independently operating door. A barrier shall extend the full height and depth of the enclosure to separate the two compartments and isolate power and control components rated 120 VAC and less from all components rated greater than 120 VAC.

H. The following are required for all outdoor enclosures containing PLCs and for indoor enclosures containing PLCs that are located in Process/Mechanical areas and Storage areas that are not environmentally and climate controlled: 1. Air Conditioner:

a. Sizing and Quantity: Provide the size and quantity of units as required for the application environment.

b. Type: Thermostatically controlled packaged closed-loop air conditioner climate control unit surface mounted to the exterior side of the control panel. Suitable for use in an outdoor corrosive environment and also rated Class 1 Division II.

c. Material: Nema 4X, Type 316 Stainless Steel enclosure suitable and rated for use in corrosive environment, 16-gauge minimum thickness. Internal components shall be coated for corrosion protection.

d. Electrical Service: Connect to the PCS single point electrical service via a dedicated circuit breaker.

e. Controls: 1) Provide air conditioner manufacturer’s standard air conditioning

system package control system for the air conditioner. The air conditioner shall have the capability to be controlled by the industrial thermostat specified hereinafter.

2) Each air conditioner shall include low ambient controls to allow the unit to operate down to 0 degrees Fahrenheit ambient conditions.

3) Provide a dedicated thermostat for each air conditioner. The thermostat shall be per Section 17200. The thermostat for each air conditioner unit shall be mounted inside the cabinet.

f. Accessories: 1) Condensate Management System: Each air conditioner unit shall

have a condensate management system that evaporates moisture from the enclosure into the condenser air stream and shall not require disposal of liquid condensate and shall not cause build-up or spillage of liquid condensate.

2) Air filters: Field replaceable aluminum filters. 3) Extension frame with self-contained Drip Pan Tray 4) Mounting gaskets and hardware for a complete installation 5) Reinforce the cabinet enclosure as required to support the air

conditioner.


g. Manufacturer: EIC Solutions, or approved equal. 2. Cabinet Interior Insulation:

a. General: 1) Provide insulation for interior of cabinet to the extent practicable to

reduce heat transfer. 2) Install in accordance to manufacturer requirements, minimize the

number of duct board sections and provide no gaps between sections

3) Install with cleanable aluminum foil (FRK) facing on exposed surface such that no bare fiberglass surface is exposed or visible. Install panels and other equipment onto cabinet such that insulation is not compressed.

4) Securely fasten duct board onto cabinet interior surface with adhesive with 100 percent coverage of adhesive at board fiber side contact with cabinet inner surface area.

5) Where heat dissipating device or other device is mounted onto cabinet panel, provide a 1-inch gap between duct board and device or as required to allow proper operation of device per device manufacturer requirements.

6) Neatly cut duct board to provide a clean finished appearance. b. Material: 1-inch thick fiberglass duct board having a rigid resin bonded

and flame retardant fibrous glass board with a damage-resistant reinforced aluminum foil (FRK) facing

c. Thermal Conductivity: (K at 75 degrees Fahrenheit) no greater that 0.23 BTU-inch per hour foot-squared degree Fahrenheit.

d. Adhesive, tape, and duct board installation shall comply with NFPA 90A or NFPA 90B and UL 181A and ASTM C 916.

e. Manufacturer: Owens Corning series QuietR or approved equal f. Accessories:

1) Tape: Aluminum foil / scrim / kraft (FSK) 3-inch minimum width non-tearable with diamond patterned backing, a rubber based adhesive system, and shall meet requirements of UL 723 and as manufactured by Shuretape or approved equal.

3. Space Heater: a. Sizing and Quantity: Provide the size and quantity of units as required for

the application environment. b. Type: Thermostatically controlled. Provide a dedicated thermostat for the

space heater. The thermostat shall be per Section 17200. The thermostat shall be mounted inside the enclosure.

4. Interior Enclosure Ambient Air Temperature Transmitter: Furnish and install a temperature transmitter to monitor the interior cabinet ambient air temperature. Transmitter shall be per Section 17380. Although not shown on the PLANS, connect the 4-20mADC analog output from the transmitter to the packaged control system PLC for remote monitoring by the OWNER’S Distributed Control System. The internal cabinet ambient air temperature shall be visible exterior of the cabinet, regardless if the temperature value is displayed on any OIU screen. Furnish and install a discrete digital indicator as required to display the internal cabinet ambient air temperature.

I. Furnish and install the following additional accessories for each enclosure: 1. For each door:


a. Grounding bonding jumper. b. Door stop kit . c. 12-inch door data pocket.

2. For free standing enclosures: a. Furnish and install light fixture per the requirements of Section 17200. b. Furnish and install wire convenience receptacle per the requirements of

Section 17200. c. Furnish and install lifting eyes.

3. Furnish and install all additional enclosure accessories, mounting hardware, 19 inch rack accessories, etc., as required for a functional PCS.

4. Additional requirements for indoor enclosures located in areas that are environmentally and climate controlled: Furnish and install enclosure complete with all accessories per Section 17200.

J. Enclosures shall be as manufactured by: 1. All outdoor enclosures and indoor enclosures located inside

process/mechanical areas and storage areas that are not environmentally and climate controlled: a. Wall mounted control panel: Hoffman Concept Stainless Steel 4X

Disconnect Wall Mounted Enclosure Series with CWHPTO Padlock Handle, or approved equal.

b. Free Standing control panel: Hoffman Free-Standing Single and Dual Access with 3-Point Latches and Lockable Powerglide® Handles, Type 4X Enclosures, or approved equal.

2. Indoor enclosures located inside environmentally and climate controlled areas: Furnish and install per the requirements of Section 17200.

2.03 PACKAGED CONTROL SYSTEM TYPES

A. The PCS shall use one of two types of control system types to implement the packaged control system functionality as follows: 1. Type A: At minimum, this type shall employ the use of PLCs as described

hereinafter. PLCs in combination with hardwired relay logic may be used at the PCS Manufacturer’s discretion.

2. Type B: This type shall only employ the use of hardwired relay logic. This control system type shall not include the use of PLCs whatsoever. Additionally, any type of micro-processor based programmable relay, any relay requiring software download, or any other type of similar programmable relay shall not be used. As technology advances over time, similar appearing devices are subject to review and approval by the OWNER after Bid Award and the PCS Manufacturer shall incorporate the OWNER’s request at No Additional Cost to the OWNER.

B. Additional requirements for Type A systems only: 1. General:

a. Furnish and install PLCs as specified in Section 17600. b. All equipment shall be furnished and installed complete with all necessary

software. c. As a minimum, the PCS shall communicate with the equipment as shown

on the control system architecture, in addition to the OWNER’S Top-End computer system. Program the PCS accordingly.


2. Operator Interface Unit (OIU): a. Type 1: Furnish and install Type 1 OIU as specified in Section 17600 b. If a specific type of OIU is not shown on the PLANS or Specifications, the

default type shall be Type 1. c. Furnish and install the additional quantities of OIUs as may be required by

the PLANS or Specifications. d. Mount OIU on enclosure door, providing additional enclosure accessories

(window kit, etc.) as needed to achieve appropriate NEMA rating. e. Furnish and install a sun shield as specified in Section 17380 for all OIUs

installed on enclosures located outdoors. 3. Miscellaneous:

a. Furnish and install the Ethernet switches, patch panels, and related hardware/accessories as specified in Section 17600 and as shown on the PLANS to facilitate the network data connections of the PCS to the OWNER’s Distributed Control System.

b. Although not shown on the PLANS, furnish and install one 120Vac, 1P-20A GFI convenience receptacle and 1 Cat 5e Ethernet data port receptacle with Nema 4X rated hinged UV resistant clear polycarbonate cover. Receptacles shall be accessible from control panel exterior without requiring access to internal control panel components. Wire receptacles to Ethernet switch and control power supply of internal control panel. Furnish and install receptacles as manufactured by Hubbell “Panel-Safe”, model PR4X205E or approved equal.

c. Furnish and install additional 25 percent excess capacity over the number of inputs, outputs, and other necessary functions.

C. Requirements common to Types A and B systems: 1. Refer to the PLANS and also the appropriate Division 11 Specification for

which the PCS is provided for the control system type. 2. Furnish and install relays as specified in Section 17200.

2.04 MAIN AND BRANCH FEEDER CIRCUIT BREAKERS

A. Furnish and install thermal magnetic molded case circuit breakers. Size per NEC. Circuit breakers shall have U.L. listed minimum RMS symmetrical short circuit current rating equal to or greater than that of the bus serving the equipment, unless noted otherwise on the PLANS or in the Division 11 Specifications. Unless shown otherwise, the minimum RMS symmetrical short circuit current rating shall be 42kA at 480 volts A.C.

B. Furnish and install where specifically shown on the PLANS or for proper circuit protection/coordination: 1. Current limiting circuit breaker. 2. Electronic trip attachment. Trip unit shall be solid state type with field

adjustable long time, short time, ground fault and pick up settings.

2.05 COMBINATION MOTOR STARTERS

A. Furnish and install per the requirements of Section 16120 with the following exceptions: 1. General:

a. Comply with the control logic requirements of the PCS manufacturer.


2. Circuit breakers: a. Shall have U.L. listed minimum RMS symmetrical short circuit current

rating equal to or greater than that of the bus serving the equipment, unless noted otherwise on the PLANS or in the Division 11 Specifications. Unless shown otherwise, the minimum RMS symmetrical short circuit current rating shall be 42kA at 480 volts A.C.

3. Starters: a. Size and configuration (full voltage non-reversing, full voltage reversing,

etc.) as required for the application. Size per NEC and provide minimum of NEMA Size 1.

4. Control Power Transformer: a. Dedicated control power transformer for each motor starter is not

required. Serve starter control power from PCS control power distribution per the manufacturer’s standard.

PART 3 EXECUTION

3.01 FACTORY INSPECTION AND TEST

A. Each control panel shall be completely assembled, wired, and adjusted at the factory and shall be given the manufacturer’s routine shop test and any other additional operational test to insure the functionality, workability and reliable operation of the equipment.

B. Size, furnish and install the overload relay heaters based on actual motor nameplate current. Set overload relay settings at maximum values permitted by the NEC 430-32.

C. Size, furnish and install the motor space heater fuses based on actual motor space heater load current.

3.02 FIELD INSTALLATION (BY CONTRACTOR)

A. Mount all PCS subcomponents as shown on the PLANS and as recommended by the PCS manufacturer.

B. All field wiring shall be tagged per the requirements of Section 16200. Secure wiring in control panel with plastic ties. Arrange wiring neatly, remove surplus wire, and install abrasion protection for wiring passing through holes or near edges of sheet metal.

C. Clean and vacuum all interior of the equipment. Touch-up and restore damaged surfaces to factory finish.

3.03 FIELD TESTING

A. After field installation of the PCS and prior to energizing any of the process/mechanical equipment controlled by the PCS: 1. Conduct an ORT for the PCS per Section 17100. Submit test results for

review and approval. Prior to conducting the ORT, meet all prerequisites associated with conducting the ORT as described in Section 17100. The


OWNER may elect to witness the ORT. Coordinate with the OWNER accordingly.

2. Conduct a PAT for the PCS per Section 17100. Submit test results for review and approval. Prior to conducting the PAT, meet all prerequisites associated with conducting the PAT as described in Section 17100. Exception: As the application software for the PCS is provided by the PCS manufacturer, the PCS manufacturer shall lead the PAT software test activity.

END OF SECTION

March 1, 2019 – CONFORMED 13390–16 9080B11 Austin Water SCADA Engineering and Support

SECTION 13390

APPENDIX A - PACKAGED SYSTEMS PLC PROGRAMMING CRITERIA

PART 4 PACKAGED SYSTEMS PLC PROGRAMMING CRITERIA

4.01 GENERAL

A. PLC Hardware to be used by packaged equipment Vendor shall be as specified in the contract bid specifications. As a minimum, the processor used to interface to the Owner’s SCADA system shall support the Schneider Electric Unity Pro programming software.

B. Vendor shall use latest version of Schneider Electric Unity Pro programming software, unless otherwise directed by Owner.

4.02 PROGRAM ORGANIZATION AND STRUCTURE

A. The overall program shall be broken down into meaningful sections of code related to the operations of the equipment. As a minimum, include the following program sections: 1. Communications - All registers that are being written to or being read from the

Vendor’s package system PLC from the Owner’s SCADA equipment shall be grouped into one section of the program. Register addresses used for interfacing to Owner’s SCADA system shall be placed in a contiguous block of registers to facilitate read and write operations

2. Section Control - (if code includes variables to enable/disable sections of code).

3. Process Control - If the process is complex and/or the section is very large, this section should be further broken down into permissive section(s), alarming section(s) and control section(s).

4. Input/Output (I/O) Processing – This section includes data manipulation of physical inputs and outputs such as analog scaling, totalizing, etc.

5. PLC Time Synchronization and Heartbeat – This section shows the registers that are to be used to synchronize the PLC’s clock with the Owner’s SCADA system and to determine whether the Vendor’s PLC logic is executing (heartbeat) to be monitored by the Owner’s SCADA system.

B. Vendor is to follow the Owner’s software tagging convention for all tags being read from or written into by the Owner’s SCADA system. If the Vendor elects to use their own software tagging convention in their programs that control the equipment within their own package system, then the PLC(s) that is used to interface with the Owner’s SCADA system needs to include a set of registers that will be labeled with the Owner’s software tagging convention and be “mapped” to the corresponding set of registers that are used by the Vendor’s software program. The mapping of these registers is to be clearly labeled in the program and indicated on the Field I/O spreadsheet to be provided at the end of the job.


C. All program sections are to be clearly labeled with text that describes what the section of code does. As a minimum, include the key wording for each section as described above.

D. Provide comment lines within the sections of code to describe what the various parts of the section do, especially for those areas where the function is performing is not evident or is complex to follow.

E. All software tags in the program are to follow a structured naming convention and be clearly labeled with meaningful text descriptions to make it easy to understand what the tag represents and what function it is performing in the program.

F. Ensure that none of the programs developed have security controls enabled, i.e. password protection on DFB’s, restrictions on uploading or editing program, etc.

4.03 PROGRAM DETAILS

A. Vendor is to use IEC programming languages supported by Unity Pro, and in general adopt the following guidelines. 1. Use Derived Function Blocks (DFB) language as much as practical to

standardize on process control functions. 2. Use Structured Text (ST) language for Calculations and I/O Mapping routines. 3. Use IEC Ladder Logic (LL) and Function Blocks (FB) for control logic and to

include in DFB’s.

B. Standardize the program sections and program elements (DFB, ST, etc.) as much as possible into modular and/or functional pieces of code for repetitive and often use sections of code to simplify the program and minimize its size.

C. Vendor is to set up a Custom Library for standard program elements like DFB’s and FB’s.

D. Use Topological (Unity Pro) Addressing on M340 PLCs for registers associated with physical I/O, i.e. %I1.3.2 and %Q1.4.3, instead of State Ram addressing (%M) since State Ram addressing convention does not reference the physical I/O location, but topological addressing does.

E. Use eBool variables if there may be a reason to keep track of previous values (history) or there is a need to look at a leading or falling edge in the signal.

F. Avoid using IEC BMDI function blocks on any of the PLC programs since Unity Pro is not able to search for registers contained within the range of that block.

G. Use IO Scanner for communication between PLC’s where possible to facilitate the set-up and troubleshooting of registers that are being moved from one PLC to another.

H. Code should be designed to avoid using force bits for the logic to execute properly. Inadvertent un-forcing of bits will cause the program to behave unexpectedly.


I. Do not initialize %MW values during a cold start or a program download. Doing so can cause stored values such as run time to be over written. Ensure this option is unchecked in the programming software if the option is available.

4.04 DOCUMENTATION AND DELIVERABLES

A. As part of their Operations and Maintenance Manual, Vendor is to include, but not be limited to the following: 1. Control Narratives that include:

a. The various control modes of operation; i.e. remote automatic, remote manual, local automatic, local manual, maintenance mode, etc.

b. Identification of and description of all permissive and shutdown signals that are required to operate the equipment or that will shut the equipment down.

c. Identification of all set points and process variables that are Operator adjustable with a description of what they do and how they affect the operation of the equipment.

2. Field I/O and Host Pack and Peer to Peer spreadsheets (example provided by Owner) to document the various software tags associated with the package equipment.

3. Instrument Index spreadsheet showing all instrumentation on their package equipment and calibration information including, but not limited to; instrument tag name, input range, units, control loop description, scaling, trip set points, etc.

B. Vendor is to provide a copy of all program files installed in the production system and source files of all documentation listed above.

END OF APPENDIX A


SECTION 13390

APPENDIX B – AW HOST PACK SPREADSHEETS

PART 5 AW HOST PACK SPREADSHEETS

5.01 FIELD I/O LIST DESCRIPTIONS NOTES

A. General 1. The Field Input/Output (I/O) lists only inputs or output connected to process

control equipment and devices, i.e. instrument, electrical equipment, etc.. It does not include logical inputs or outputs that are generated as part of the PLC/RTU program to do data manipulation, or data that is passed on to another controller or Host computer.

2. All inputs and outputs associated with a PLC/RTU, i.e. physical and logical points, are shown on the Host Pack list if they are being transmitted/received by a Host computer, or are shown in the Peer to Peer Data Communications List, if the values are being shared with another peer device.

B. Information required for each entry. 1. RACK NAME - The rack name as shown on the contract drawings. Note this

name is for cross-reference only. The actual drop, and rack number used in the software configuration will be as specified in the DROP, and RACK column of the Field I/O List.

2. FIELD DEVICE TAG - The name of the end device, in accordance with the INFOR (maintenance management system) naming convention and tagged in the field and/or on the contract drawings. This field is used as a cross-reference to the Host Pack table.

3. DESCRIPTION - The description of the signal. This description shall be used consistently throughout the application software.

4. CARD/MODULE TYPE - The Modicon model number located in the corresponding slot.

5. POINT TYPE - The point type indicates AI, AO, DI, or DO for analog input, analog output, discrete input, or discrete output, respectively.

6. DROP, RACK/BASE – The drop and rack number associated with the chassis. These fields define the required drop, rack assignment for the configuration of each chassis associated with the processor.

7. SLOT - This field defines the physical location of the module within a given chassis.

8. I/O POINT – This field defines the specific point on the module. 9. CARD/MODULE TERMINALS – Physical wiring termination points on the I/O

card/module. 10. FIELD I/O ADDR. - The software register address where the I/O module

places the data for the point. This field is used as a cross-reference to the Host Pack table.


11. BIT NO. - The bit within the register address where the I/O module places the data for the point, as required. This field is used as a cross-reference to the Host Pack table.

12. EGU LOW - The value of the signal at 4 mA in the specified engineering units. This information is only applicable to analog signals.

13. EGU HIGH - The value of the signal at 20 mA in the specified engineering units. This information is only applicable to analog signals.

14. EGU - The engineering units for the analog signal. This information is only applicable to analog signals.

15. SCALED IN PLC? – Defines whether or not the analog value is scaled in the PLC, or if scaling occurs at the top end. This information is only applicable to analog signals.

16. RAW LOW - The value of the signal at 4 mA in counts as written to the PLC register by the I/O module. This information is only applicable to analog signals.

17. RAW HIGH - The value of the signal at 20 mA in counts as written to the PLC register by the I/O module. This information is only applicable to analog signals.

18. SIGNAL TYPE – Electrical characteristics of the signal, i.e. 4-20 mA, 1-5 VDC, etc.

19. TERMINAL BLOCK - The name of the block of terminals where field wiring is terminated.

20. TERMINAL NO’S - The terminal numbers within the terminal block where the field wiring is terminated.

21. LOOP DIAG. – The number of the drawing where a loop drawing is shown for the signal loop. These could either be loop-specific drawings, or typical loop drawings.

22. P&ID No. – The number of the P&ID drawing where the I/O point is shown on the drawings.

23. NOTES - Miscellaneous notes to further describe the signal. This field contains information such as square root (SQRT) for analog inputs, analog alarm setpoints, shelf states for discrete inputs, etc.

5.02 HOST PACK FIELD DESCRIPTIONS NOTES

A. General Information 1. Physical Inputs and Outputs (I/O) refer to connections to instruments and/or

device/equipment including: motor status contacts, valve position switches, pump start/stop commands, etc.

2. There are two different tagging standards for physical I/O points, depending on whether they are instruments or signals coming from or going to equipment/devices other than instruments.

3. Instrument tags follow the ISA standards and are somewhat different from the other physical I/O points, i.e. equipment and devices, in that those tags include not only an equipment code, like the instruments, but it also includes a Function Descriptor Code that is up to four characters long. Since a piece of equipment/device may have multiple I/O points connected to it (such as a


motor starter) the Function Descriptor Code ensures uniqueness and clarifies the function performed by the specific I/O.

4. Software TagNames assigned to a PLC/RTU program are identical to the physical I/O points, i.e. Instrument Tags and Equipment/Device Tags.

5. Software TagNames that are generated by a controller or a host computer that are not tied directly to a physical I/O point, follow the same convention as the equipment and instrument tags, except a suffix is added to the end of the physical tag to indicate the origination/destination of that software tag, i.e. whether the point is logically created in the PLC/RTU or Host program and were it is sending its information to.

B. Information required for each entry. 1. Host SCADA Configuration Information – the fields in this section relate to

configuration of alarming and general point information for use in the SCADA Host database. a. HOST NODE NAME(S) - The computer name of PMCS SCADA Servers

which will be polling the PLC, including OIUs. b. HOST TAGNAME - The tagname used in the PMCS host software to

reference the input point. c. DB TYPE - The database point type used in the OIU and PMCS database

definition for the point. See Table 4-3 in the System Integration Design Guide for a list of available database point types.

d. HOST DESCRIPTION - A description of the signal. The description field is limited to 40 characters.

e. ACTIVE STATE (1) - The definition of the energized state for a discrete point.

f. INACTIVE STATE (0) - The definition of the de-energized state for a discrete point.

g. ALARM STATE – Defines if either the Active or Inactive states will be used to generate an alarm a discrete point.

h. LOLO ALARM - The setpoint for the low low alarm limit for an analog point.

i. LO ALARM - The setpoint for the low alarm limit for an analog point. j. HI ALARM - The setpoint for the high alarm limit for an analog point. k. HIHI ALARM - The setpoint for the high high alarm limit for an analog

point. l. ALARM PRIORITY - The alarm priority. The alarm priority shall be

defined as L, M, or H for low priority alarm, medium priority alarm, or high priority alarm, respectively. If the point does not require alarming, then this field shall be blank for the point. If multiple analog alarm setpoints are defined, alarm priorities shall be indicated for each alarm type.

2. PLC Host Read/Write Area – the fields in this section define the interface between the host database and the PLC/RTU. a. HOST I/O ADDR - The register address in the PLC which the host will

read to get the current value of the point. b. HOST BIT NO - The bit within the register address in the PLC which the

host will read to get the current value of the point.


c. HOST PLC DATA TYPE - The data type of the signal in the PLC register. This defines how the PMCS interprets the data in the PLC register(s). Options for this field are based on the data types used in the PLC/RTU.

d. PLC SOFTWARE TAGNAME - The name of the register(s) that the PMCS host will read to current value of the point, as defined in the PLC/RTU software.

3. PLC Intermediate Area – the fields in this section identify any intermediate registers used in the PLC/RTU to perform calculations or process the input signals from the I/O module. a. INT I/O ADDR - The register address in the PLC where the intermediate

data value is stored. b. INT BIT NO - The bit within the register address in the PLC where the

intermediate data value is stored. c. INT DATA TYPE - The data type of the signal in the intermediate PLC

register. Options for this field are based on the data types used in the PLC/RTU.

d. PLC SOFTWARE TAGNAME - The name of the register(s) in the PLC where the intermediate data value is stored, as defined in the PLC/RTU software.

4. Field Interface Area – the fields in this section identify information about the field devices and register locations written to by the I/O modules. a. PEER DEVICE – Indicates whether or not the point is transmitted from

anoter PLC, as opposed to being acquired from local I/O. b. FIELD DEVICE TAG - The name of the end device, in accordance with

the INFOR (maintenance management system) naming convention and tagged in the field and/or on the contract drawings. This field is used as a cross-reference to the Field I/O List table.

c. POINT TYPE - The point type indicates AI, AO, DI, or DO for analog input, analog output, discrete input, or discrete output, respectively.

d. FIELD I/O ADDR. - The software register address where the I/O module places the data for the point. This field is used as a cross-reference to the Field I/O List table.

e. FIELD BIT NO. - The bit within the register address where the I/O module places the data for the point, as required. This field is used as a cross-reference to the Field I/O List table.

5. Other fields a. PLC/RTU EQUIPMENT TAG - The name of the PLC or RTU device, in

accordance with the INFOR (maintenance management system) naming convention and tagged in the field and/or on the contract drawings. This field is used as a cross-reference to the Field I/O List table.

b. NOTES – Miscellaneous notes specific to the database point.

5.03 PEER TO PEER DATA COMMUNICATIONS DESCRIPTIONS NOTES

A. General 1. The Peer to Peer Data Communications list is intended to only show data

(inputs or outputs) that is shared between two peer devices such as PLC/RTU controllers. The list does not include any other physical I/O points connected to


the associated PLC/RTU or data points that are transmitted to or received from a Host computer.

2. For physical I/O points connected to a specific PLC/RTU, refer to the Field Input/Output (I/O) list.

3. For data points that are associated with a particular PLC/RTU that are transmitted to or received from a Host computer, please refer to the Host Pack list.

4. Information required for each entry. a. PLC SOFTWARE TAGNAME - The name of the register(s) that the PMCS

host will read to current value of the point, as defined in the PLC/RTU software.

b. DESCRIPTION - A description of the signal. The description field is limited to 40 characters.

c. HOST PLC DATA TYPE - The data type of the signal in the PLC register. This defines how the PMCS interprets the data in the PLC register(s). Options for this field are based on the data types used in the PLC/RTU.

d. ORIGINATION EQUIPMENT TAG - The name of the PLC or RTU device where the point data is coming from (source of the data), in accordance with the INFOR (maintenance management system) naming convention and tagged in the field and/or on the contract drawings. This field is used as a cross-reference to the Field I/O List table, Host Pack table, or other Peer to Peer tables.

e. ORIGINATION I/O ADDR - The register address in the source PLC which the destination peer device will read to get the current value of the point. This field is used as a cross-reference to the Field I/O List table, Host Pack table, or other Peer to Peer tables.

f. ORIG BIT NO - The bit within the register address in the source PLC which the destination peer device will read to get the current value of the point. This field is used as a cross-reference to the Field I/O List table, Host Pack table, or other Peer to Peer tables.

g. DESTINATION EQUIPMENT TAG - The name of the PLC or RTU device where the point data is being written to (consumer of the data), in accordance with the INFOR (maintenance management system) naming convention and tagged in the field and/or on the contract drawings. This field is used as a cross-reference to the Field I/O List table, Host Pack table, or other Peer to Peer tables.

h. DESTINATION I/O ADDR - The register address in the consumer PLC which the source peer device will write to provide the current value of the point. This field is used as a cross-reference to the Field I/O List table, Host Pack table, or other Peer to Peer tables.

i. DEST BIT NO - The bit within the register address in the consumer PLC which the source peer device will write to provide the current value of the point. This field is used as a cross-reference to the Field I/O List table, Host Pack table, or other Peer to Peer tables.

j. HOST INTERFACE? – Indicates whether the destination device passes the data to the PMCS host, or whether the data will be passed along to another peer device.


k. BLOCK MOVE TYPE – Indicates the function block or other method used to facilitate the transfer of peer data.

l. BLOCK MOVE DEVICE – The name of the PLC/RTU whose program includes the block move command. The Origination device can write the data to the Destination device, or the Destination device could read the data from the Origination device.

m. NETWORK PROTOCOL – The protocol used to transport the peer data. n. NOTES – Miscellaneous notes specific to the database point.

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Austin Water SCADA Tag Function Descriptor Standards


SECTION 13390

APPENDIX C – AW SOFTWARE TAGGING CRITERIA

For signals associated with a stand-alone instrument: PPPPPP_TTTTTT_IIII_QQ Where,

PPPPPP = Process Identifier (abbreviation for process fluid shown on P&IDs) TTTTTT = Function Descriptor (see Austin Water Software Tag Function Descriptors

table) IIII = Unique Identifier (Loop numbers for instrument - limited to 4 characters) QQ = Qualifier (see Table 3-4, AW Primary Qualifier Codes)

For signals associated with a piece of equipment: PPPPPP_TTTTTT_IIII_QQ Where,

PPPPPP = Equipment Code (as will be entered in INFOR) TTTTTT = Function Descriptor (see Austin Water Software Tag Function Descriptors

table) IIII = Unique Identifier (Equipment ID - limited to 4 characters) QQ = Qualifier (see Table 3-4, AW Primary Qualifier Codes)

Function Descriptor Codes

The function descriptor code is a four character code used to indicate the specific equipment data being represented by the software point. Examples of equipment data include motor status, motor fault, motor start/stop commands, etc. The following tables list the function descriptor code available for use.



11/12/2013

Austin Water Software Tag Function Descriptors Code Type Description AAH Input High Analyzer Concentration Alarm AAL Input Low Analyzer Concentration Alarm ACNC Input Active Concentration ACTP Input Analog Cell Temperature ACTV Input Active or in Progress AFB1 Input Auto Flow Pace - Flow Meter 1 AFB2 Input Auto Flow Pace - Flow Meter 2 AFBD Input Auto Flow Pace - Calculated Data AFBF Input Auto Flow Pace - Flow Meter ALCR Input Critical Alarm ALMN Input Maintenance Alarm ALARM Input Alarm ALRT Input Alert ALTSW Input Alternate Switch AMPH Input High Amp AMPL Input Low Amp AMPS Input Amps ASIL Input Motor Auto Stop Interlock ATPT Input Attempt (used for substation transfer attempt Counter) AUTO Input Auto AVG Input Average Selected BATA Input PLC Controller Battery A Alarm BATB Input PLC Controller Battery B Alarm BATGEN Input Generator Battery Alarm BFTC Input Breaker Fail to Close BFTO Input Breaker Fail to Open BKAC Input Breaker Ok to Close BKRC Input Breaker Closed BKRO Input Breaker Open BKWF Input Filter Backwash Sequence Failure Alarm BKWH Input Strainer in Backwash BKWM Input Filter in Manual Backwash Mode BLCB Input Level Control Band BYP Input Bypass (e.g., UPS) CAPC Input Metering Pump Capacity CALFLW Input Calculated Flow CALLFL Input Call Fail CBLA Input Global Communications Cable A Fault CBLB Input Global Communications Cable B Fault CFLA Input Communications Fail Channel A



Austin Water Software Tag Function Descriptors Code Type Description CFLB Input Communications Fail Channel B CHCK Input Check Valve Fail to Open CLFH Input Hypochlorite Generator High Cell Flow

CLFL Input Hypochlorite Generator Low Cell Flow

CLOCK Input PLC Clock

CLOS Input Close

CLRUN Input Call to Run

CLSD Input Limit Switch Closed

CLTP Input Hypochlorite Generator Cell Temperature

CMERAV Input Total Communication Errors Average

CMERLG Input Total Communication Good

CMERT Input Total Communication Errors

CMFL Input Communication Fail

CMPLD Input Last Poll Period

CMTRLT Input Total Comm Transmissions

CNRA Input Polymer Mixing Unit Centrifuge Not Run Alarm

COMERR Input Communication Error

CPRM Input Close Permissive

CPUSTA Input CPU Status Diagnostic

CRSW Input Current Switch

CRTM Input Time Until Next Cleaning

CYAC Input Cycle Timer Accumulated Time

CYCR Input Cycle Freq Timer

CYRM Input Remaining Time Until Next Cycle

CYSP Input Cycle Stop

CYST Input Cycle Start

DATAQL Input Data Quality

DAY Input PLC Clock Day of Month

DENS Input Chemical Density

DRAC Input Duration Timer Acc Val

DRRM Input Time Remaining Until Duration Ends

DRPS Input Duration Timer Reset

DSBL Input Disable

DSCH Input Discharge Rate

DSTC Input Discharge to Chlorine (App Point Chlorine Injection Vaults 1-4)

DSTF Input Discharge to Filters (App Point is Filtered Water Injection Vault)

DSTN Input Discharge to None (Application Point is Not Selected

DSWF Input Lime Slaker Discharge Weight Fault

EMRG Input Emergency (e.g., ATS in Emergency Power)



Austin Water Software Tag Function Descriptors Code Type Description ENAB Input Enable Control Status

ENAX Input Enable State X

ENBL Input Enabled (e.g., Auto Transfer at SUB enabled)

ESL Input Undervoltage Alarm

ESTP Input Emergency Stop

ET Input Voltage

EUH Input High Engineering Units

EUL Input Low Engineering Units

EXRNTM Input Extensive Run Time

EYEW Input Eyewash Station No. 1 Flow Switch High

FAIL Input Failure (e.g., PLC Fail

FAUL Input Fault (e.g., Lime Slurry Aging Tank Mixer Fault)

FAUT Input Motor Flow Pacing Auto Control Status

FDFA Input Flow Rate Difference Alarm (e.g., delta between calculated and actual flow)

FIT Input Flow Indicating Transmitter / Signal

FILFMX Input Lifetime Max Flow

FITOMX Input Today’s Max Flow

FIYEMC Input Yesterday’s Max Flow

FLOW Input Flow/Flow Mode

FLWO Input Flow Pacing Selection Reset

FLWC Input Hypochlorite Generator Cell Flow

FLWX Input Flow X Selected for Flow Pacing

FQAC Input Frequency Timer Accumulated Value

FQICUR Input Current Day Flow Total

FQILF Input Lifetime Flow Total

FQIPRE Input Previous Day Flow Total

FQITOT Input Calculated Flow Total

FQPS Input Frequency Timer Preset

FRDH Input Flow rate difference high (when instrument flow compared to calculated flow)

FRFS Input Fail to reach flow setpoint

FRPS Input Fail to reach position setpoint

FSL Input Low Flow Switch

FSP_ACC Input Accumulated Fail to Stop Time

FSRT Input Fail to Start

FSTP Input Fail to Stop

FTAC Input Fail Timer Accumulated Value

FTC Input Fail to Close

FTO Input Fail to Open

FTPS Input Fail Timer Preset

FUSB Input Fuse Blown



Austin Water Software Tag Function Descriptors Code Type Description FXRM Input Fixed Rate Mode (vs. Level Rate Mode)

GRND Input Ground Fault Alarm

HDLS Input Headloss (e.g., filters)

HDWR Input Hardware

HLTH Input PLC Power & Scan Health Status

HOLD Input Hold Calculation Command

HOPP Input Hopper

HOUR Input PLC Clock Hour (Military) from Host

HTBT Input Heartbeat (Used for communication check)

HRUN Input High Speed Running Status

HSTR Input Motor High Speed Start Command

HVR Input Voltage High (e.g., battery)

ILCK Input Interlock

INIT Input Total Run-time Alarm/Hours Reset

ISRV Input In Service Command

KILK Input Key Interlock

KQAH Input Motor Service Alarm

KQI Input Runtime

KQI1 Input Service Runtime

KQI2 Input Lifetime Runtime

KQI3 Input Runtime Since Start

KQILF Input Lifetime Runtime

KQIMN Input Monthly Runtime

KQIMP Input Previous Monthly Runtime

KQITO Input Today’s Runtime

KQIYE Input Yesterday’s Runtime

KWHMG Input KWH / MG Today

KWHMG Input KWH / MG Yesterday

LAUT Input Motor Local Auto Control Status

LAGPMP Input Lag Pump Run

LCRM Input Equipment in Local or Remote

LDRA Input Level Decline Rate Alarm

LDRD Input Level Decline Rate Difference

LEAD Input Equipment is Load

LEAK Input Leak indication (.g., high gas concentration)

LEVEL Input Level

LGPSTS Input Lag Pump Starts Today

LI2DMN Input Minimum Level from 2 Days ago

LI2MDX Input Maximum Level from 2 Days ago



Austin Water Software Tag Function Descriptors Code Type Description LIT Input Level Indicating Transmitter

LITOMN Input Today’s Level Minimum

LITOMX Input Today’s Level Maximum

LIWF Input Lime Slaker Lime Inlet Weight Fault

LIYEMN Input Yesterday’s Level Minimum

LIYEMX Input Yesterday’s Level Maximum

LMAN Input Motor Local Manual Control Status

LMWT Input Lime Weight

LOAL Input Lockout Alarm

LOCK Input Lockout

LOCL Input Local

LOGC Input Controller A/B Logic Mismatch

LRUN Input Low Speed Running Status

LSHH Input Level Switch Hi-Hi

LSH Input Level Switch Hi

LSLL Input Level Switch Lo-Lo

LSL Input Level Switch Lo

LSTR Input Motor Low Speed Start Command

LVHH Input Level Hi-Hi

LVLB Input Level of Brine

LVLL Input Level Lo-Lo

LVLN Input Level of Salt

LVLQAI Input Level Data Quality

LVLX Input Level X Selected

LVR Input Voltage Low (e.g., battery)

LVRM Input Level Rate Mode (vs. Fixed Rate Mode)

LY Input Bubbler / Level Transmitter Fail

MAN Input Manual

MDBBD Input Modbus Baud

MDBDL Input Modbus Data Length

MDBDP Input Modbus Data Parity

MDBRT Input Modbus Retries

MDBSB Input Modbus Stop Bit

MDBTO Input Modbus Timeout

MDFT Input Frequency Timer Mode

MDSP Input Sludge Pump Mode (UFC Residual)

MIN Input Clock Minute

MLR Input Motor Lockout Relay

MNFL Input Manual Flow

MNPS Input Manual Position Mode



Austin Water Software Tag Function Descriptors Code Type Description MNSP Input Manual Speed SP Mode

MNTN Input Maintenance Mode

MODALN Input Module (IO) Alarm

MODBD Input Modem Baud

MODDL Input Modem Data Length

MODDP Input Modem Data Parity

MODE Input Status or Mode

MODSB Input Modem Stop Bit

MONTH Input Clock Month

MPR Input Motor Protector Relay Alarm

MSIL Input Motor Manual Stop Interlock

NSH Input Hi Torque Alarm

NCR Input No Charge (e.g., battery)

NDST Input Output to No Destination (e.g., metering pumps)

NGR Input Negative Ground (e.g., battery)

NLRM Input None in Level Rate Mode Alarm (UFCs)

NMSTOP Input Normal Stop Cycle

NORM Input Normal (e.g., ATS Normal Power

NOTAVL Input Not Available

NOTK Input Standby Controller Not On LAN

NSH Input Hi Torque Switch

NSHH Input Hi-Hi Torque Alarm

NSHHH Input Drive Motor Cut Out Torque Alarm

NUMBR Input Telephone Number

OAAF Input Operator Adjustable Adjustment Factor (e.g., metering pump dose calculations)

OFAC Input Cycle Timer Off Accumulated Valve

OFF Input Off Status

OFFX Input Disable State X Command

OFLN Input Offline

OFPS Input Cycle Timer Off Preset

ON Input On / Running

ONAC Input Cycle Timer On Accumulated Value

OPEN Input Open Status

ONPS Input Cycle Timer On Preset

OPRM Input Open Permissive

OORAIX Input Out of Range for Analog Input Channel X

OORAOX Input Out of Range for Analog Output Channel X

OSRV Input Out of Service Command

OVLD Input Overload



Austin Water Software Tag Function Descriptors Code Type Description PBSP Input Push Button Stop (e.g., LSPS)

PBST Input Push Button Start (e.g., LSPS)

PDAH Input High Differential Alarm

PFLD Input Power Factor Lead

PFLG Input Power Factor Lag

PFOL Input Power Factor Capacitor Overload

PGR Input Positive Ground Detect (e.g., battery charger)

PICK Input Pickup Coil

PING Input PING (e.g., PLC PING status)

PIT Input Pressure Indicating Transmitter

PMPX Input Pump X Selected

PNLF Input Front Panel Open

POLLCD Input Poll Command

POLLST Input Last Poll Status

PRTY Input Chemical Purity

PRMA Input Controller A is Primary

PRMB Input Controller B is Primary

PROC Input Motor Process Permissive

PSAC Input Parallel Source Active (e.g., SUB1)

PSAL Input Parallel Source Alarm (e.g., SUB1)

PSH Input Pressure Switch High

PSL Input Pressure Switch Low

PSTR Input Motor Pending Startup Status

PWRA Input Power Fail A

PWRB Input Power Fail B

QFEF Input Filters Effluent Flow Dosage Point

QRWF Input Raw Water Flow to Clarifiers Dosage Point

RAIXHD Input RTU Analog Point ‘X’ Health Diagnostic

RALL Input Remote Auto Lead-Lag Control Mode

RALM Input Resettable Alarm

RAPR Input Remote Auto Percentage mode

RAUT Input Motor Remoter Auto Control Status

RDY Input Equipment Ready Status

REFVLP Input Reference Voltage Positive

REFVLN Input Reference Voltage Negative

RIOP Input Global Communications RIO Health Fault

RKXFLT Input Rack Fault for Rack No. ‘X’

RMDXHD Input RTU Module ‘X’ Health Diagnostic Status

RMOT Input Remote

RSET Input Alarm Reset



Austin Water Software Tag Function Descriptors Code Type Description RSME Input Resume Calculation Command

RTHI Input Runtime Hi Alarm

RTMH Input Rectifier High Temp Hi

RTODDT Input RTU Time Of Day – Date

RTODDY Input RTU Time Of Day – Day

RTODHR Input RTU Time Of Day – Hour

RTODMN Input RTU Time Of Day – Minute

RTODSC Input RTU Time Of Day – Second

RTODYR Input RTU Time Of Day – Year

RTS Input Return to Service

RUNA Input Running Alarm

RUNC Input Close Contactor is Energized (e.g., electric actuator)

RUNN Input Motor Running

RUNO Input Open Contactor is Energized (e.g., electric actuator)

RUNTIME Input Service Time Preset/Reset Value

RVSF Input RVSS (Reduced Voltage Solid-state Starter) Fault

RXXSTA Input Rack 0 Slot XX Status (OK)

S908 Input Global Communications Health Fault

SAFE Input Motor Safety Permissive (Future)

SALM Input Alarm Exists

SAUT Input Motor Speed Auto Control Status

SBYA Input Controller A is Standby

SBYB Input Controller B is Standby

SCAN Input PLC Scan Time

SCLB Input Scale Buildup (Lime Slaker)

SCLH Input Scale Buildup High Alarm (Lime Slaker)

SEC Input Clock Seconds

SELX Input State X Selected

SHDN Input Shutdown Alarm

SHOL Input Space Heater Overload

SILK Input Motor Stop Interlock

SLTL Input Salt Tank Low

SOFF Input Selector Switch in OFF

SON Input Selector Switch in ON

SPRM Input Start Permissive

SRAM Input PLC State RAM

ST Input Speed Feedback

STBY Input Stand-by Status

STDN Input Shutdown



Austin Water Software Tag Function Descriptors Code Type Description STEP Input Sequence Step

STLF Input Lifetime Starts

STRK Input Stroke

STRT Input Motor Start

STOP Input Motor / Valve Stop

STSEXD Input Starts Exceeded

STSEXB Input Starts Exceeded Bypassed

STTO Input Today’s Starts

STYE Input Yesterday’s Starts

SUCC Input Success

SURG Input Surge Alarm

SWAP Input PLC Swap Over Command

SYNC Input Sync Check Relay

TALM Input Temperature Alarm

TDAC Input Time Delay Off Accumulated Value

TEMP Input Temperature

TIMSTP Input Time Stamp

TGON Input Tagout On

TOC Input Truck Operated Contact (Vacuum Circuit Breaker)

TODFUL Input Time of Day Events Full

TODNUM Input Time of Day Events Number

TODSYN Input Synch RTU Clock to FEP

TOKN Input Token Rotation Time in secs

TOTL Input Total

TRBL Input Trouble (Malfunction) Alarm

TSH Input High Temperature Switch

TSL Input Low Temperature Switch

UFRV Input Unit Filter Run Volume

UPSB Input UPS Low Battery

UPSF Input UPS Fail

VFDA Input VFD Alarm

VFDT Input VFD Temperature Alarm

VFTC Input Valve Fail to close

VFTO Input Valve Fail to open

VSH Input High Vibration

VSHH Input High High Vibration

VSL Input Low Vibration

WALM Input Weight Alarm



Austin Water Software Tag Function Descriptors Code Type Description

WARN Input Warning

WIWF Input Water Inlet Weight Fault (Lime Slaker)

WSFL Input Weight Sensor Fault (e.g., Lime Slurry Aging Tank)

WY Input Weight Tared

XA Input Surge Suppressor Alarm

XFER Input Transfer Relay (e.g., initiates SUB1 transfer algorithm)

XHK Input Dosage Set point

XHLD Input Hold Calculation Status

XMTECD Input Transmit Error Code

XMTEND Input Transmit Error Node

XS Input General Switch Input

XSRV Input Filter In Service Status

XTND Input Filter Extend Backwash Notification

XTON Input Filter Extend Backwash On Status

XTOP Input Stop

XQI Input Current Day Start Count

XYSN Input Module Health Drop X Rack Y Slot N

YEAR Input Clock Year

ZA Input Valve Fail Alarm

ZDO Input Zero Dropout Value

ZS Input General Switch Input

ZSC Input Position switch close

ZSO Input Position switch open

ZT Input Position Feedback

AHK Output Remote Analyzer Setpoint

CLOS Output Equipment Close Coil

CYPS Output Cycle Preset Time Setpoint

DRPS Output Duration Preset Time Setpoint

FHK Output Flow Setpoint

FHKx Output Flow Setpoint, where x is a unique digit (when multiple setpoints used)

FIC Output Flow Controller Output

HSTR Output High Speed Start Coil

HXTP Output High Speed Stop Coil

KQC Output Runtime Reset Value

LHK Output Level Setpoint

LHKx Output Level Setpoint, where x is a unique digit (e.g., used in multi-level setpoints for tanks)



Austin Water Software Tag Function Descriptors Code Type Description

LSTR Output Low Speed Start Coil

LXTP Output Low Speed Stop Coil

MNRTSP Output Minimum Pump Runtime Setpoints

OFFSP Output Off Setpoint

ONFR Output Online Fixed Rate Mode Command

ONLR Output Online Level Rate Mode Command

ONSP Output On Setpoint

OPEN Output Equipment Open Coil

RNTRST Output Runtime Reset

RSET Output Reset Command

RST1 Output Reset Service Runtime Command

RST2 Output Reset Life Runtime Command

RVAL Output Equipment Runtime Preset Value

SHK Output Speed Setpoint

SHKx Output Speed Setpoint, where x is a unique digit (when multiple setpoints used)

SPBD Output Stop Blowdown Command

SRINSP Output Service Alarm Interval Setpoint

STBD Output Start Blowdown Command

STOP Output Stop Command

STRT Output Start Command

TGDT Output Tagout Date Setpoit

TGRN Output Tagout Reason Setpoint

TGRS Output Tagout Reset Command

TGST Output Tagout Set Command

TGTM Output Tagout Time Setpoint

TGUS Output Tagout User Setpoint

XFER Output Transfer Coil

XHK Output Dosage Setpoint

XHKx Output Dosage Setpoint, where x is a unique digit (when multiple setpoints used)

XRUN Output Motor Run / Stop Coil

XTOP Output Motor Stop Coil

ZHK Output Position Setpoint

ZHKx Output Position Setpoint, where x is a unique digit (when multiple setpoints used)

ZVC Output Valve Close Command

ZVO Output Valve Open Command

ZVC Output Valve Open / Close Coil



Table 3-4 Primary Qualifier Codes

Qualifier Code

Description

I Field inputs to PLC.

O Field outputs from PLC.

F Filtered values/coils (used for existing software tag names only).

HI Host inputs read from PLC.

HR Host register read from/written to PLC.

M Logic modified values/coils.

P Peer-to-Peer points.

S Scaled values.

DW Host write to data source.

DR Host read from data source.

PB Primary Block.

CSB Secondary Block.

LHI Local Host (OIU) inputs read from PLC.

LHO Local Host (OIU) outputs written to PLC.

LHR Local Host (OIU) register read / wire to PLC


SECTION 13446

MANUAL ACTUATORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Valve and gate actuators. 2. Handwheel actuators. 3. Hand-cranked geared actuators. 4. Floor Boxes. 5. Floor stands. 6. Key operated valves. 7. Bench stands. 8. Accessory equipment and floor boxes.

B. Related sections: 1. Section 05190 - Mechanical Anchoring And Fastening To Concrete And

Masonry. 2. Section 09960 - High-Performance Coatings. 3. Section 13446 - Manual Actuators. 4. Section 13447 - Electric Motorized Actuators.

1.02 REFERENCES

A. Aluminum Association (AA): 1. DAF-45 - Designation System for Aluminum Finishes.

B. American Water Works Association (AWWA).

C. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

D. National Electrical Code (NEC).

1.03 DEFINITIONS


1.04 SUBMITTALS

A. Shop drawings: Include shop drawings and product data with associated gate or valve as an integrated unit.



A. Provide valve actuators integral with valve or gate, except for valve actuators utilizing T-wrenches or keys, and portable actuators intended to operate more than 1 valve.

B. Provide similar actuators by 1 manufacturer.

C. Provide gates and hand operating lifts by 1 manufacturer.

D. Provide hydraulic gate lifts by 1 manufacturer.

E. Provide hydraulic valve actuators and motorized actuators by 1 manufacturer.

1.06 MAINTENANCE

A. Extra materials: 1. Key operated valve keys or wrenches: Furnish a minimum 4 keys with 4-foot

shafts and 3-foot pipe handles or wrenches with 4-foot shafts and 3-foot handles for operating key operated valves.

PART 2 PRODUCTS

2.01 VALVE AND GATE ACTUATORS

A. Valve actuators: 1. Cylinder actuators, motorized actuators, and portable actuators are specified

in Sections 13447. 2. Manual actuators:

a. Material: Type 316 stainless steel. b. Design: Hand lever c. Spring release handle: 12-inch. d. Notch plate: 10 position. e. Secure with mounting bolts. f. Locking device so that valve can be locked in any position with a wing nut.

3. Stem and cover: a. For submerged valves, provide extension stem as indicated on the

Drawings. 4. Limit switches: Provide limit switches on manually actuated valves where

indicated on the Drawings: a. Limit switches: Heavy-duty, industrial grade, oiltight, with not less than

2 auxiliary contacts. b. Rating: Rated for 10 amps, 120 volts alternating current. c. Enclosure: NEMA Type 4X enclosure and with stainless steel levers and

arms. Provide switch with NEMA Type 7 enclosure when switch is located within areas with NEC Class 1, Division 1 or Class 1, Division 2 designations as indicated on the Drawings.

B. Stem covers: 1. Aluminum pipe: 2. Threaded cap on top. 3. Bolted aluminum flange on bottom.


4. Slots cut 1- by 12-inch at 18 inches on center in front and back of pipe. 5. Capable of covering threaded portion of greased stems that project above

actuators when gates or valves are opened or closed. 6. Ultraviolet light resistant, clear butyrate plastic or polycarbonate pipe:

a. Capped on the upper end. b. Either threaded into the top of the gate operators or held in place by

bolt-down aluminum brackets. c. Capable of covering threaded portion of greased stems that project above

actuators when gates or valves are opened or closed. 7. Staff gauges:

a. Adhesive-backed mylar, suitable for outdoor service. b. Calibrated in hundredths of feet. c. Read the weir crest elevations directly. d. Gauge range: 1.5 feet minimum. e. Indicate the following elevations on each staff gauge:

1) -0.75, -0.50, -0.25, 0.0, 0.25, 0.50, 0.75. f. Supplement with a stem-mounted pointer or indicator that permits direct

observation of the weir gate crest elevation. g. Apply staff gauges to each stem cover after installation of the cover and

after calibration and testing of the weir gates. h. Set gauges precisely by a survey crew using instruments acceptable to

the Engineer.

C. Stem cover flanges, pipes and caps: 1. After fabrication, etch and anodize to produce the following chemical finishes

in accordance with AA publication DAF-45: a. A 41 - Clear Anodic Coating. b. C 22 - Medium Matte Finish.

D. Gate stem covers: Concentric with stem.

E. Position indicators: 1. For all aboveground worm gear or traveling nut manual actuators, provide

position indication on the actuator enclosure. 2. Tail rods on hydraulic cylinders, or dial indicators with clear full-open and

closed position indicators, calibrated in number of turns or percentage of opening.

F. Manual or power actuator size: 1. Sized to deliver maximum force required under most severe specified

operating condition, including static and dynamic forces, seat and wedge friction, and seating and unseating forces with safety factor of 5, unless otherwise specified.

G. Actuator size: Capable of supporting weight of suspended shafting unless carried by bottom thrust bearings; shaft guides with wall mounting brackets.

H. Provisions for alternate operation: Where specified or indicated on the Drawings, position and equip crank or handwheel operated geared valve actuators or lifts for alternate operation with tripod mounted portable gate actuators.


I. Operation: Counterclockwise to open with suitable and adequate stops, capable of resisting at least twice normal operating force to prevent overrun of valve or gate in open or closed position.

J. Open direction indicator: Cast arrow and legend indicating direction to rotate actuator on handwheel, chain wheel rim, crank, or other prominent place.

K. Buried actuator housing: Oil and watertight, specifically designed for buried service, factory packed with suitable grease, completely enclosed space between actuator housing and valve body so that no moving parts are exposed to soil; provide actuators with 2-inch square AWWA operating nut.

L. Worm gear actuators: Provide gearing on worm gear actuators that is self-locking with gear ratio such that torque in excess of 160 foot-pounds will not need to be applied to operate valve at most adverse conditions for which valve is designed.

M. Traveling nut actuators: Capable of requiring maximum 100 foot-pounds of torque when operating valve under most adverse condition; limit stops on input shaft of manual actuators for fully open and closed positions; non-moving vertical axis of operating nut when opening or closing valve.

2.02 HANDWHEEL ACTUATORS

A. Manufacturers: One of the following or equal: 1. Rodney Hunt Company. 2. Waterman Industries, Incorporated.

B. Coating: Handwheel as specified in Section 09960.

C. Mounting: Floor stand or bench stand. Unless otherwise indicated on the Drawings position actuator 36 inches (nominal) above top of walkway surface.

D. Bearings above and below finished threaded bronze operating nut: Ball or roller.

E. Wheel diameter: Minimum 24 inches.

F. Indicator: Counterclockwise opening with arrow, and word OPEN cast on top of handwheel indicating direction for opening.

G. Pull to operate: Maximum 40 pounds pull at most adverse design condition.

H. Stem travel limiting device: Setscrew locked stop nuts above and below lift nut.

I. Grease fittings: Suitable for lubrication of bearings.

2.03 HAND-CRANKED GEARED ACTUATORS

A. Type: Single removable crank; fully enclosed.

B. Mounting: Floor and bench stand. Unless otherwise indicated on the Drawings position actuator 36 inches (nominal) above top of walkway surface.

C. Operating nut: When scheduled for portable actuators.


D. Geared lifts: 2-speed with minimum ratio of 4 to 1.

E. Teeth on gears, spur pinions, bevel gears, and bevel pinions: Cut.

F. Lift nuts: Cast manganese bronze.

G. Exterior surfaces on cast-iron lift parts: Smooth.

H. Bearings above and below flange on lift nuts: Ball or roller; capable of taking thrust developed by opening and closing of gates under maximum operating head; with bronze sleeve bearings and sufficient grease fittings for lubrication of moving parts, including bearings and gears.

I. Crank rotation indicator: Cast arrow with word OPEN in prominent location readily visible indicating correct rotation of crank to open gate.

J. Hand cranks: 15-inch radius; requiring maximum 25 pounds pull to operate gate at maximum operating head; with: 1. Revolving brass sleeves. 2. Gears, spur pinions, bevel gears, and bevel pinions with cut teeth. 3. Cast manganese bronze lift nuts. 4. Cast-iron lift parts with smooth exterior surfaces.

K. Indicator: Dial position type mounted on gear actuator; enclosed in cast-iron or aluminum housing with clear plastic cover; marked with fully open, 3/4, 1/2, 1/4, and closed positions.

2.04 FLOOR BOXES

A. Manufacturers: One of the following or equal: 1. Waterman industries, Inc.

B. Floor boxes: Cast-iron; with: 1. Counter type indicator. 2. Hinged, lockable lid with directional arrow. 3. 2-inch square AWWA operating nut. 4. Packing gland providing drip-tight seal around valve shaft.

2.05 FLOOR STAND

A. Manufacturers: One of the following or equal: 1. Rodney Hunt Company. 2. Waterman industries, Inc.

B. Floor stand assemblies: Heavy-duty cast-iron, suitable for mounting specified actuator.

2.06 BENCH STANDS

A. Manufacturers: One of the following or equal: 1. Rodney Hunt Company. 2. Waterman industries, Inc.


B. Bench stands: Handwheel actuators or hand crank, geared actuators conforming to hand-cranked geared actuator requirements, except capacity to be mounted on haunch, wall bracket, or self-contained gate yoke.

2.07 ACCESSORY EQUIPMENT

A. Wall brackets or haunches: As indicated on the Drawings.

B. Stems: Stainless steel; sized to match output of actuator; minimum gate or valve operating stem diameter; maximum 200 slenderness ratio.

C. Stem couplings: Stainless steel; internally threaded to match stem; lockable to stem by set screw.

D. Stem guides: Cast-iron with silicon bronze bushing; maximum 200 slenderness ratio; capable of being mounted with wall bracket; adjustable in 2 directions.

E. Wall brackets: Cast-iron, capable of withstanding output of actuator, adjustable in 2 directions.

F. Stem stuffing boxes: Cast-iron, with adjustable gland and packing.

G. Fasteners: Type 316 stainless steel.

H. Anchor bolts: As specified in Section 05190 except that the material shall be Type 316 stainless steel.

I. Geared valve actuators: Provided with cut gears, either spur or worm; sized to operate valves at most adverse design condition; with maximum 40-pound pull at handwheel or chain wheel rim.

J. Geared valve traveling nut actuators: Acceptable only where specified or indicated on the Drawings.

K. Accessory equipment for valves and gates requiring remote actuators: Operating stems, stem couplings, stem guides, wall brackets, and stem stuffing boxes.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install floor boxes in concrete floor with lid flush with floor.

B. After installation of gate and stem covers, mark stem covers at point where top of stems are at full-open position and at closed position.

C. Attach floor stand to structure with anchor bolts.

D. Install stem stuffing boxes where operating stems pass through intermediate concrete floor slabs.


3.02 SCHEDULES

A. Geared actuators: Provide geared actuators for following valves: 1. Butterfly valves larger than 6 inches, nominal size, on liquid service. 2. Butterfly valves larger than 10 inches, nominal size, on gas and air service. 3. Plug valves 6 inches, nominal size, and larger.

B. Handwheel actuators: Provide handwheel actuators for valves mounted 6 feet or less above floors.

C. Chain wheel actuators: Provide chain wheel actuators for valves mounted more than 6 feet to centerline above floors.

END OF SECTION


SECTION 13447

ELECTRIC ACTUATORS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Electric motor-driven actuators for valves and gates as identified in the valves and gates schedule as EAM, EDM, OR EDR.

B. Related sections: 1. Section 15112 - Butterfly Valves.

1.02 REFERENCES

A. American Water Works Association (AWWA): 1. C504 - AWWA Standard for Rubber-Seated Butterfly Valves. 2. C540 - AWWA Standard for Power-Actuating Devices for Valves and Slide

Gates.

B. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS:

A. NEMA: 1. Type 4X enclosure in accordance with NEMA 250.

1.04 SUBMITTALS

A. Provide a complete list/schedule of all actuators being provided with their associated tag names as indicated on the design drawings and/or specifications, service process area and the size of the valve they are actuating.

B. Clearly identify any exceptions in terms of quantities and/or quality of actuator(s) being submitted.

C. Product data: 1. Electrical ratings:

a. Voltage and number of phases. b. Starting and running current. c. Voltage levels and source for control and status.

2. Description of integral control interface. 3. Environmental ratings, including NEMA enclosure rating and submergence

capabilities. 4. Gear ratios for both manual and motorized actuation. 5. Opening and closing directions. 6. Allowable starts per hour. 7. List of all included options and accessories. 8. Full travel times.


9. Gearbox data including gear ratio, and gearbox efficiency. 10. Affidavit in accordance with AWWA C540.

D. Shop drawings: 1. Wiring diagrams:

a. Include all options and expansion cards furnished with each actuator. 2. Dimensioned drawings of each valve and actuator combination. 3. Dimensioned drawings of each valve gearbox. 4. Electric motor data.

E. Calculations: Submit the following for each valve/gate size and class: 1. Operating torque calculations. 2. Maximum torque calculations for seating and unseating. 3. Maximum operating torque at starting and normal operation.

F. Test reports: 1. Factory test report and certificate. 2. Each actuator must be performance tested with a simulated load at the factory

and individual test certificates and detailed test reports shall be provided. a. The test equipment used should simulate a typical valve load.

G. Manufacturer's instructions: 1. Include manufacturer's instructions, description of system operation, start-up

data, and troubleshooting checklist.

H. Operations and maintenance data: 1. Include manufacturer's literature; cleaning procedures, replacement part lists,

wiring diagrams, and repair data. 2. Include a list of all configurable parameters, and the final values for each. 3. List of recommended spare parts. 4. List of special tools necessary for proper operation and/or maintenance. 5. Exploded view drawings that illustrate all assemblies, sub-assemblies, and

components. 6. Routine test procedures for all electronic and electrical circuits. 7. Troubleshooting chart covering the complete valve and controls/electrical

power systems, showing description of trouble, probable cause, and suggested remedy.

8. Certified factory and field-test results.


A. Obtain required information from the valve/gate supplier, including but not limited to: 1. Interface to gate or valve. 2. Operating range (In degrees). 3. Quarter turn or multi-turn. 4. Required turns for full travel on multi-turn applications. 5. Direction of rotation for opening and closing. 6. Maximum and normal torque requirements. 7. Additional sizing requirements indicated in the following Specifications:

a. Section 15112 - Butterfly Valves.


B. All motorized, intelligent actuators shall be the product of a single manufacturer for all valve and gate applications on this project, regardless of gate or valve type, manufacturer, or supplier.

1.06 SPARE PARTS

A. Provide the following spare parts (minimum 10 percent of total number of actuators of each model type furnished, but not less than 1 for each model of actuator furnished): 1. Stem nut. 2. Worm shaft subassembly. 3. Drive sleeve subassembly. 4. Complete actuator seal kit. 5. Actuator gearbox oil (sufficient quantity to fill 4 gearboxes). 6. Encoder. 7. Control module.

B. Provide 1 spare motor for each size motor furnished.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Acceptable manufacturers for lines 4 inch and larger: a. EIM; Limitorque; or approved equal.

2.02 CHARACTERISTICS FOR ACTUATORS ON LINES 4 INCHES AND LARGER

A. Provide actuators complete and operable with all components and accessories required for operation.

B. Power supply: 1. Voltage and phases as indicated in the Schedule. 2. Valve or gate motion independent of power supply phase rotation. 3. Provide an internal backup power source to maintain settings and track valve

position when main power is off. 4. The actuators shall incorporate all major components such as the motor,

starter, local controls, terminals etc. housed within a self-contained, sealed enclosure.

C. Size actuator to move gates or valves from full open to closed position within the time indicated in the Schedule: 1. If an operating time is not indicated on the Schedule, size the actuator to move

gates or valves at minimum 12 inches per minute under maximum load. Measure rate of closure for valves at maximum diameter of disc, plug, or ball.

2. Size actuators so that gear boxes are not required where possible.

D. Control interface: 1. Provide actuator with controls and interface as indicated in the wiring

schematics. Refer to wiring schematics.


2. Local interface, integral to actuator: a. Furnish and install selector switches control devices, refer to wiring

schematics: 1) Actuator shall include a "LOCAL", "OFF", and "REMOTE" selector

switch and "OPEN", "CLOSE", "STOP" pushbuttons. Refer to control wiring schematics.

b. Local display: 1) Valve fully open and fully closed LED indicating lights for position

indication. 3. Remote control station - (VCP):

a. Provide remote control stations for all actuators located more than 5 feet above finished floor/grade or where indicated on the Drawings or Intelligent Actuator Schedule. 1) NEMA rating as listed in the Intelligent Actuator Schedule.

a) Where the rating is not listed, use NEMA Type 4X enclosures for non-hazardous areas, and explosion proof (XP) Class I Division 1 for hazardous areas.

b) All pilot devices shall 30 mm and pilot lights shall be illuminated by LEDs.

2) “LOCAL”, “OFF”, and “REMOTE” selector switch and "OPEN", "CLOSE", “STOP” pushbuttons. Refer to control wiring schematics.

3) LED indicating lights to indicate valve position: a) Fully open. b) Fully closed.

4. Control inputs: a. Capable of using 120 VAC or 24 VDC inputs. b. Controls the valve when LOCAL-STOP-REMOTE is in REMOTE. c. Isolated inputs capable of operating from external control voltage source

or internal power supply: 1) Furnish 120 VAC and 24 VDC control power supplies within the

actuator. d. Provide the following inputs:

1) OPEN. 2) CLOSE. 3) STOP.

e. OPEN and CLOSE inputs configurable between maintained (actuator runs until end of travel, high torque, or a STOP input) and momentary (actuator stops when command is removed).

5. Status outputs: a. Monitor relay output: Dry contact, normally closed, opens when actuator is

not in REMOTE or in the event of any internal fault or alarm condition. b. Dry contact outputs configured for the functions indicated on the

Drawings. Refer to Control Wiring Schematics for additional detail regarding the actuator wiring.

c. All dry contacts provided shall be rated 120VAC, minimum 2A inductive. Refer to control wiring schematics.

6. Analog outputs: a. Provide an isolated 4-20 milliampere analog output[s] when indicated on

the Drawings. 1) Loop power sourced from the actuator power supply. 2) Capable of driving into a load up to 500 ohms. 3) Output proportional to process value(s) indicated on the Drawings.


4) Valve or gate position. 5) Operating torque.

7. Network communications: a. Communications and control between the actuator and plant’s control

system shall utilize the following protocol: 1) Profibus PA. 2) Profibus DP. 3) Foundation Fieldbus. 4) DeviceNet. 5) Modbus RTU (RS-485). 6) Pakscan.

E. Features: 1. Time delay on reversal: Incorporate time delay between stopping actuator and

starting in opposite direction to limit excessive current, torque, and heating from instantaneous reversal.

2. Data logging: a. Store diagnostic data and reference data. b. Time-stamped historical operating data, including number of operations

and most recent operations. c. Torque profiles showing actual torque at each valve position through the

operating range. 1) Store reference data (recorded during commissioning) and data from

last operation. 3. Provide display of logged data on the actuator, or provisions to download to a

personal computer.

F. Materials: 1. Construct motorized actuators of materials suitable for the environment in

which the valve or gate is to be installed.

G. Components: 1. Motors: 2. Specifically designed for valve actuator service with high starting torque, totally

enclosed non-ventilated construction. 3. Torque ratings equal to or greater than that required for valve seating and

dynamic torques with a 25 percent factor of safety. a. Design requirements for rubber-seated AWWA butterfly valves:

1) Design actuators for maximum gate or valve operating torque, in accordance with and using safety factors required in AWWA C504 and AWWA C540. a) Valve actuator torque requirement for open-close service: Not

less than the required valve-seating and dynamic torques under design operating conditions in accordance with AWWA C504.

b) Valve actuator torque requirement for modulating service: Not less than twice the required valve dynamic torque under design operating conditions in accordance with AWWA C504.

b. Design requirements for slide gates, gate valves, knife gate valves, globe valves, and diaphragm valves: 1) Design valves and actuators for maximum operating torque, in

accordance with and using safety factors required in AWWA C540.


2) Design for the maximum torque and thrust running load over the full cycle.

3) Maximum torque or thrust rating: The actuator stall torque or maximum thrust output shall not exceed the torque or thrust capability of the valve or gate, as determined by the valve or gate manufacturer.

4. Capable of being removed and replaced without draining the actuator gear case.

5. Motor bearings shall be amply proportioned of the anti-friction type and permanently lubricated.

6. Rated for operating under the following conditions without exceeding temperature limits with ambient temperature of 40 degrees Celsius. a. Continuous duty operation at normal operating torque or 33 percent of

maximum torque (whichever is greater). Fifteen minute duty cycle motors are NOT acceptable.

b. 1,200 starts per hour for modulating service. 7. Provide the following motor protection features:

a. Jammed valve (no valve motion detected through a time delay). b. High motor temperature (sensed by an embedded thermostats). c. High torque. d. Single phasing protection.

H. Enclosures: 1. Actuator housing ratings as indicated in the Schedule. 2. Stainless steel external fasteners. 3. Provide 'O' ring seals for each of the following areas:

a. Between the terminal compartment and the internal electrical elements. b. Between the mechanical and electrical portions to protect from the ingress

of oil, and to protect the mechanical components of oil from dust and moisture when the electrical terminal is open.

4. Provide the following minimum enclosure ratings: a. NEMA Type 4X enclosure for general applications.

I. Position sensing: 1. Provide, at minimum, the gear limit switches and configuration of the gear limit

switches as shown on the limit switch development diagram on the control wiring schematics. a. All valve limit switches shall be rated 120VAC, minimum 2A inductive.

J. Torque sensing: 1. Torque shutdown setting: 40 percent to 100 percent rated torque.

a. Adjustable in 1 percent increments. 2. Capable of interrupting control circuit during both opening and closing and

when valve torque overload occurs. 3. Electrical or electronic torque sensing: 4. Independent of variations in frequency, voltage, or temperature. 5. Provide a temporary inhibit of the torque sensing system during unseating or

during starting in mid-travel against high inertia loads. 6. Provide visible verification of torque switch status without any housing

disassembly.


K. Manual actuators: 1. Hand wheel for manual operation.

a. Maximum 80 pound pull on rim when operating gate or valve under maximum load.

b. Provide pull chain when motorized actuator is located more than 6 feet above floor surface. 1) Chain shall be of sufficient length to reach approximately 4 feet

above the operating level. 2) Where the chain obstructs an aisle or walkway, provide holdback or

other means to ensure chain does not create a nuisance or hazard to operating personnel.

2. Declutch lever: Padlockable, capable of mechanically disengaging motor and related gearing and freeing hand wheel for manual operation.

L. Gearing: Hardened alloy steel spur or helical gears and self-locking, alloy bronze worm gear set. 1. Accurately cut to assure minimum backlash.

M. Bearings: 1. Anti-friction bearing with caged balls or rollers throughout. 2. Sealed-for-life type thrust bearings housed in a separate thrust base.

N. Drive bushing: 1. Easily detachable for machining to suit the valve stem or gearbox input shaft. 2. Positioned in a detachable base of the actuator.

O. Lubrication: 1. Provide totally enclosed actuator gearing with oil filled gear case suitable for

operation at any angle. 2. Suitable for standard SAE80EP gear oil. 3. Actuators requiring special or exotic lubricants are not acceptable.

2.03 ACCESSORIES

A. Setting tool: 1. If required for setting or configuring the actuator, provide a hand-held setting

tool. a. Furnish 1 setting tool for every 10 actuators.

B. Termination module cover: 1. For actuators on a valve network provide a means to keep the valve network in

service, in the event where the actuator must be removed. 2. Provide sunshades for all outdoor installations of remote control stations that

use a LCD or similar screen. Regular pushbutton, sector switches, and pilot light control stations will not require a sunshade.


A. Factory test: 1. Test each actuator in the factory, and submit an individual test certificate for

each actuator. 2. Perform a high potential test and record the following information:

a. Test voltage.


3. Simulate a maximum and typical valve loads and record the following information: a. Current and power factor at maximum and set torque values. b. Torque as measured by the actuator. c. Actuator output speed or operating time.

4. Performance testing: Conduct performance test for each actuator simulating valve operating torque from full-open to full-close and from full-close to full-open. The following information shall be recorded during each performance test: a. Torque at maximum torque setting. b. Current at maximum torque setting. c. Test voltage and frequency. d. Actuator output speed and operating time for full-open to full-close. e. Amperage draw on motors at breakaway and under normal operation.

B. Field verify characteristics prior to sizing motor actuator.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install actuators in accordance with manufacturer's instructions.

3.02 MOTORIZED ACTUATOR SCHEDULE

A. Provide all actuators indicated on the Drawings. 1. Major process actuators are listed in the Intelligent Actuator Schedule in this

section. 2. The schedule does not include all number and types of actuators required for

the Project.

B. Abbreviations relating to type: 1. BFV = Butterfly Valve. 2. BV = Ball Valve. 3. PV = Plug Valve. 4. SG = Slide Gate.

C. Abbreviations relating to actuator type: 1. O/C = Open and Close Service. 2. MOD = Modulating Service.

D. Abbreviations relating to controls: 1. PA = Profibus PA. 2. DP = Profibus DP. 3. DN = DeviceNet. 4. FF = Foundation Fieldbus H1. 5. MB = Modbus RTU (RS-485). 6. NET = Manufacturer’s proprietary network. 7. A = Analog (4-20mA) control, modulating duty. 8. D = Discrete control, modulating duty. 9. D-O/C = Discrete Open/Close.


INTELLIGENT ACTUATOR SCHEDULEAD2

Item Reference

DWG Type Size Actuator

Type NEMA Rating

Voltage /Phase

/Hz Notes Open Time Controls

Aeration Basin BFV No. 1 05M03 BFV 12” MOD 4x 480/3/60 1 30 s A

Blower No. 1 BFV 09M01 BFV 12” MOD 4x 480/3/60 -- 15s A

Blower No. 2 BFV 09M01 BFV 12” MOD 4x 480/3/60 -- 15s A

Blower No. 3 BFV 09M01 BFV 12” MOD 4x 480/3/60 -- 15s A Notes: (1) Provide actuators with remote control station. (2) New motorized actuator to be installed on existing equipment. (3) Provide Battery Backup Unit.

END OF SECTION

AD2 Addendum No. 2


SECTION 14612

DAVIT CRANES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Portable davit cranes with worm gear hand winch.

B. Related sections: 1. Section 05120 - Structural Steel. 2. Section 11225 - Portable Anoxic Submersible Mixers


A. Design requirements: 1. Davit crane and hoist load capacity: 1,000 pounds, minimum. 2. Boom reach: 23 to 66 inches. 3. Minimum clearance under boom: 30 inches. 4. Lift below base level: 19.00 feet. 5. Mount type: Pedestal.

1.03 SUBMITTALS

A. Product data: 1. Dimensional drawings or other construction details including materials of

construction, equipment weights and equipment finishes. 2. Manufacturers installation instructions.

B. Shop drawings and calculations. 1. Structural loads calculations for crane and supports stamped by an engineer

registered in Texas. 2. Anchor bolts design calculations and details as specified in Section 05120.

C. Certificate of testing to verify performance requirements of these specifications.

D. Operation and maintenance manuals: Provide prior to installation of the system.

E. Warranties.


A. The manufacturer of the equipment shall have successful operating installations of a similar type to the equipment specified at 5 or more separate facilities. Fulfillment of this experience requirement shall be a condition of acceptance.

1.05 WARRANTY

A. Provide manufacturer's standard warranty.


B. Warrant to correct defective products for minimum of 1 year after date of shipment.


A. Packing and Shipping: Unload and store cranes under direct supervision of manufacturer.

PART 2 PRODUCTS

2.01 PORTABLE DAVIT CRANE

A. Manufacturers: The following or equal: 1. Thern Model 5PA10.

B. Design davit crane in accordance with Specifications and Codes of the Steel Construction Manual.

C. The boom to be capable of rotating 360 degrees under load.

D. Locking pin adjustment: Boom angle to be vertically adjustable. Boom to lock in place at each position with a locking pin.

E. Provide a locking device to prevent boom swivel when desired.

F. Structural design calculations shall be signed by a professional engineer registered in the state of Texas.

G. Loads are lifted with a spur gear hand winch attached to the boom and equipped with a disk brake for load control.

H. Steel gear covers protect gears and help prevent injuries.

I. Crane and base to be constructed of stainless steel.

2.02 CRANE ACCESSORIES

A. Provide 5/16 inch by 25 foot stainless steel cable with swivel hook. The hoisting cable shall be specifically designed for service loads specified: 1. Manufacturers: The following or equal:

a. Thern

B. Provide flush bases by the same manufacturer as the davit crane: 1. Manufacturers: The following or equal:

a. Thern.

C. Provide plastic base cover to keep water from collecting in base when crane is removed. 1. Manufacturers: The following or equal:

a. Thern.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install per manufacturer’s written instruction.

3.02 FIELD TEST

A. After complete installation of the system, the equipment shall be tested to its rated capacity. 1. Load and slings shall be provided by the crane manufacturer and removed

when tests are complete. 2. The equipment shall be operated through 3 complete lift and lowering cycles. 3. No hoisting equipment shall be used until load testing is concluded.

B. Crane shall not be used by Contractor for the installation of equipment.

END OF SECTION


SECTION 15050

COMMON WORK RESULTS FOR MECHANICAL EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Basic design and performance requirements for building mechanical equipment and process mechanical equipment.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01610 - Project Design Criteria. 4. Section 01612 - Seismic Design Criteria. 5. Section 01650 - Facility Startup/Commissioning. 6. Section 01730 - Operating and Maintenance Data. 7. Section 01770 - Closeout Procedures. 8. Section 03600 - Grouting. 9. Section 05120 - Structural Steel. 10. Section 05140 - Structural Aluminum. 11. Section 05190 - Mechanical Anchoring and Fastening to Concrete and

Masonry. 12. Section 09960 - High-Performance Coatings. 13. Section 10400 - Signage. 14. Section 15052 - Common Work Results For General Piping. 15. Section 15082 - Piping Insulation. 16. Section 15110 - Common Work Results For Valves. 17. Section 15958 - Mechanical Equipment Testing.

1.02 REFERENCES

A. American Gear Manufacturer's Association (AGMA) Standards: 1. 6001-E08 – Design and Selection of Components for Enclosed Gear Drives.

B. American Bearing Manufactures Association (ABMA) Standards: 1. 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

C. American Petroleum Institute (API): 1. 682 - Shaft Sealing Systems for Centrifugal and Rotary Pumps.

D. ASTM International (ASTM): 1. A36 - Standard Specification for Carbon Structural Steel. 2. A48 - Standard Specification for Gray Iron Castings. 3. A125 - Standard Specification for Steel Springs, Helical, Heat-Treated. 4. A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for

High Temperature or High Pressure Service and Other Special Purpose Applications.


5. A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both.

6. A320 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for Low-Temperature Service.

7. A536 - Standard Specification for Ductile Iron Castings. 8. A653 - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or

Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process. 9. B61 - Standard Specification for Steam or Valve Bronze Castings. 10. B62 - Standard specification for Composition Bronze or Ounce Metal Castings. 11. B505 - Standard Specification for Copper Alloy Continuous Castings. 12. B584 - Standard Specification for Copper Alloy Sand Castings for General



E. Hydraulic Institute (HI).

F. Occupational Safety and Health Administration (OSHA).

G. Unified Numbering System (UNS).

1.03 DEFINITIONS

A. Resonant frequency: That frequency at which a small driving force produces an ever-larger vibration if no dampening exists.

B. Rotational frequency: The revolutions per unit of time usually expressed as revolutions per minute.

C. Critical frequency: Same as resonant frequency for the rotating elements or the installed machine and base.

D. Peak vibration velocity: The root mean square average of the peak velocity of the vibrational movement times the square root of 2 in inches per second.

E. Rotational speed: Same as rotational frequency.

F. Maximum excitation frequency: The excitation frequency with the highest vibration velocity of several excitation frequencies that are a function of the design of a particular machine.

G. Critical speed: Same as critical frequency.

H. Free field noise level: Noise measured without any reflective surfaces (an idealized situation); sound pressure levels at 3 feet from the source unless specified otherwise.

I. Operating weight: The weight of unit plus weight of fluids or solids normally contained in unit during operation.


1.04 DESIGN REQUIREMENTS

A. General: 1. Product requirements as specified in Section 01600. 2. Project conditions as specified in Section 01610. 3. Provisions specified under each technical equipment specification prevail over

and supersede conflicting provisions specified in this Section. 4. Equipment manufacturer's responsibility extends to selection and mounting of

gear drive units, motors or other prime movers, accessories, and auxiliaries required for proper operation.

5. Vibration considerations: a. Resonant frequency:

1) For single speed equipment, ensure there are no natural resonant frequencies within 25 percent above or below the operating rotational frequencies or multiples of the operating rotational frequencies that may be excited by the equipment design.

2) For variable speed equipment, ensure there are no natural resonant frequencies within 25 percent above or below the range of operating frequencies.

b. Design, balance, and align equipment to meet the vibration criteria specified in Section 15958.

6. Equipment units weighing 50 pounds or more: Provide with lifting lugs or eyes to allow removal with hoist or other lifting device.

B. Power transmission systems: 1. V-belts, sheaves, shaft couplings, chains, sprockets, mechanical variable-

speed drives, variable frequency drives, gear reducers, open and enclosed gearing, clutches, brakes, intermediate shafting, intermediate bearings, and U-joints are to be rated for 24 hour-a-day continuous service or frequent stops-and-starts intermittent service, whichever is most severe, and sized with a service factor of 1.5 or greater in accordance with manufacturer recommendations: a. Apply service factor to nameplate horsepower and torque of prime source

of power and not to actual equipment loading. b. Apply service factors in accordance with AGMA 6001-E08, other

applicable AGMA standards, or other applicable referenced standards.

C. Equipment mounting and anchoring: 1. Mount equipment on cast iron or welded steel bases with structural steel

support frames. a. Utilize continuous welds to seal seams and contact edges between steel

members. b. Grind welds smooth.

2. Provide bases and supports with machined support pads, dowels for alignment of mating of adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits.

3. Provide jacking screws in bases and supports for equipment weighing over 1,000 pounds.

4. Design equipment anchorage, supports, and connections for dead load, running loads, loads during start-up, seismic load specified in Section 01612, and other loads as required for proper operation of equipment.


a. For equipment with an operating weight of 400 pounds or greater and all equipment that is supported higher than 4 feet above the floor, provide calculations for: 1) The operating weight and location of the centroid of mass for the

equipment. 2) Forces and overturning moments. 3) Shear and tension forces in equipment anchorages, supports, and

connections. 4) The design of equipment anchorage, supports, and connections

based on calculated shear and tension forces. 5. Anchorage of equipment to concrete or masonry:

a. Perform calculations and determine number, size, type, strength, and location of anchor bolts or other connections.

b. Unless otherwise indicated on the Drawings, select and provide anchors from the types specified in Section 05190.

c. Provide bolt sleeves around cast-in anchor bolts for 400 pounds or greater equipment. 1) Adjust bolts to final location and secure the sleeve.

6. Anchorage of equipment to metal supports: a. Perform calculations and determine number, size, type, strength, and

location of bolts used to connect equipment to metal supports. 7. Unless otherwise indicated on the Drawings, install equipment supported on

concrete over non-shrink grout pads as specified in this Section.

1.05 SUBMITTALS


B. Product data: 1. For each item of equipment:

a. Design features. b. Load capacities. c. Efficiency ratings. d. Material designations by UNS alloy number or ASTM Specification and

Grade. e. Data needed to verify compliance with the Specifications. f. Catalog data. g. Name plate data. h. Clearly mark submittal information to show specific items, materials, and

accessories or options being furnished. 2. Gear reduction units:

a. Engineering information in accordance with applicable AGMA standards. b. Gear mesh frequencies.

C. Shop drawings: 1. Drawings for equipment:

a. Drawings that include cut-away drawings, parts lists, material specification lists, and other information required to substantiate that proposed equipment complies with specified requirements.


2. Outline drawings showing equipment, driver, driven equipment, pumps, seal, motor(s) or other specified drivers, variable frequency drive, shafting, U-joints, couplings, drive arrangement, gears, base plate or support dimensions, anchor bolt sizes and locations, bearings, and other furnished components.

3. Installation instructions including leveling and alignment tolerances, grouting, lubrication requirements, and initial Installation Testing procedures.

4. Wiring, control schematics, control logic diagrams and ladder logic or similar for computer based controls.

5. Recommended or normal operating parameters such as temperatures and pressures.

6. Alarm and shutdown set points for all controls furnished.

D. Calculations: 1. Structural:

a. Substantiate equipment base plates, supports, bolts, anchor bolts, and other connections meet minimum design requirements specified and seismic design criteria as specified in Section 01612.

2. Mechanical: a. ABMA 9 or ABMA 11 L10 life for bearings calculation methods for drivers,

pumps, gears, shafts, motors, and other driveline components with bearings.

b. Substantiate that operating rotational frequencies meet the requirements of this Section.

c. Torsional analysis of power transmission systems: When torsional analysis specified in the equipment sections, provide: 1) Sketch of system components identifying physical characteristics

including mass, diameter, thickness, and stiffness. 2) Results of analysis including first and second critical frequencies of

system components and complete system. d. Calculations shall be signed and stamped by a licensed engineer.

E. Operation and maintenance manuals: 1. As specified in Section 01730. 2. Equipment with bearings:

a. Include manufacturer and model number of every bearing. b. Include calculated ball pass frequencies of the installed equipment for

both the inner and outer raceways.

F. Commissioning submittals: As specified in Section 01650.

G. Project closeout documents: As specified in Section 01770.

PART 2 PRODUCTS

2.01 MATERIALS

A. Materials as specified in Section 01600 including special requirements for materials in contact with drinking water.

B. Ferrous materials: 1. Steel for members used in fabrication of assemblies: ASTM A36.


2. Iron castings: ASTM A48, tough, close-grained gray iron, free from blowholes, flaws, and other imperfections.

3. Ductile iron castings: ASTM A536, Grade 65-45-12, free from flaws and imperfections.

4. Galvanized steel sheet: ASTM A653, minimum 0.0635 inch (16 gauge). 5. Expanded metal: ASTM A36, 13 gauge, 1/2-inch flat pattern expanded metal. 6. Stainless steel:

a. As specified in Section 05120. b. In contact or within 36 inches of water: Type 316 or 316L. c. In sea air environment: Type 316 or 316L. d. Other locations: Type 304 or 304L. e. Source cleaning and passivation as specified in Section 05120.

C. Non-ferrous materials: 1. Bronze in contact with liquid: Composition of not more than 2 percent

aluminum nor more than 6 percent zinc; UNS Alloy C83600, C92200,or C93700 in accordance with ASTM B61, B62, B505, or B584, when not specified otherwise.

D. Dielectric materials for separation of dissimilar metals: 1. Neoprene, bituminous impregnated felt, heavy bituminous coatings,

nonmetallic separators or washers, or other materials as specified.

E. Non-shrink grout and epoxy non-shrink grout: As specified in Section 03600.

2.02 ANCHORS AND FASTENERS

A. Mechanical anchoring to concrete and masonry: 1. As specified in Section 05190:

a. Type 316 stainless steel. 2. Design as specified in Section 01612.

B. High-strength fasteners: 1. As specified in Section 05120.

C. Flange bolts: 1. As specified in Section 15052.

D. Mechanical assembly fasteners: 1. Stainless steel:

a. High Temperature Service or High Pressure Service: 1) Bolts: ASTM A193, Grade B8 (304 SST) or Grade B8M (316 SST),

Class 1, heavy hex. 2) Nuts: ASTM A194, Grade 8, heavy hex. 3) Washers: Alloy group matching bolts and nuts.

b. Low Temperature Service: 1) Bolts: ASTM A320, Grade B8 (304 SST) or Grade B8M (316 SST),

Class 1, heavy hex. 2) Nuts: ASTM A194, Grade 8 (304 SST) or Grade B8M (316 SST),

heavy hex. 3) Washers: Alloy group matching bolts and nuts.


c. General service: 1) Bolts: ASTM F593, Alloy group 1 (304 SST) or Alloy group 2 (316

SST). 2) Nuts: ASTM F594, Alloy group 1 (304 SST) or Alloy group 2 (316

SST). 3) Washers: Alloy group matching bolts and nuts.

2.03 SHAFT COUPLINGS

A. General: 1. Type and ratings: Provide non-lubricated type, designed for not less than

50,000 hours of operating life. 2. Sizes: Provide as recommended by manufacturer for specific application,

considering horsepower, speed of rotation, and type of service.

B. Shaft couplings for close coupled electric motor driven equipment: 1. Use for:

a. Equipment 1/2 horsepower or larger. b. Reversing equipment. c. Equipment subject to sudden torque reversals or shock loading: d. Examples:

1) Reciprocating pumps, blowers, and compressors. 2) Conveyor belts.

2. Manufacturers: One of the following or equal: a. Lovejoy. b. T.B. Woods.

3. Provide flexible couplings designed to accommodate angular misalignment, parallel misalignment, and end float.

4. Manufacture flexible component of coupling from synthetic rubber, or urethane.

5. Provide service factor of 2.5 for electric motor drives and 3.5 for engine drives. 6. Do not allow metal-to-metal contact between driver and driven equipment.

C. Shaft couplings for direct connected electric motor driven equipment: 1. Use for 1/2 horsepower or larger and subject to normal torque, non-reversing

applications. 2. Manufacturers: One of the following or equal:

a. Rexnord. b. T.B. Woods.

3. Provide flexible couplings designed to accommodate shock loading, vibration, and shaft misalignment or offset.

4. Provide flexible connecting element of rubber and reinforcement fibers. 5. Provide service factor of 2.0. 6. Connect stub shafts through collars or round flanges, firmly keyed to their

shafts with neoprene cylinders held to individual flanges by through pins.

D. Spacer couplings: Where cartridge type mechanical seals or non-split seals are specified, provide a spacer type coupling of sufficient length to remove the seal without disturbing the driver or driven equipment unless noted otherwise in the individual equipment specifications.


E. Specialized couplings: Where requirements of equipment dictate specialized features, supply coupling recommended for service by manufacturer: 1. Includes any engine driven equipment.

2.04 STUFFING BOX, SEAL CHAMBER, AND SHAFT SEALS

A. General: 1. Unless otherwise noted in the equipment section, provide cartridge type,

double mechanical shaft seals for pumps. 2. Provide a stuffing box large enough for a double mechanical seal. 3. Where packing is specified, provide stuffing box large enough to receive a

double mechanical seal. 4. Provide seal or packing flush connections, (3/4-inch size unless another size is

indicated on the Drawings). 5. Provide and route leakage drain line to nearest equipment floor drain. 6. For pumps with packing, design packing gland to allow adjustment and

repacking without dismantling pump except to open up packing box. 7. Seal or packing flush requirements shall be in accordance with API Standard

682 requirements. Unless otherwise indicated, specified or required by the equipment and seal manufacturers, the following API flushing Plan arrangements shall be utilized as appropriate for the application: a. Single seal, clean water applications: Plan 11 (Discharge bypass to seal). b. Single seal, vertical pump applications: Plan 13 (Seal bypass to suction). c. Single seal, clean hot water (greater than 180 degrees Fahrenheit)

applications: Plan 23 (Seal cooler and pumping ring). d. Single seal, solids, or contaminants containing water applications: Plan 32

(External seal water). e. Double seal applications: Plan 54 (External seal water)

B. Packing: When specified in the equipment section of the specifications, provide the following type of packing: 1. Wastewater, water, and sludge applications:

a. Asbestos free. b. PTFE (Teflon) free. c. Braided graphite. d. Manufacturers: One of the following or equal:

1) Chesterton, 1400. 2) John Crane Inc., equivalent product.

C. Mechanical seals: Provide seal types specified in the equipment sections and as specified. 1. Provide seal types meeting the following requirements:

a. Balanced hydraulically. b. Spring: Stationary, out of pumping fluid, Hastelloy C; Type Elgiloy or

17-7 PH stainless steel for split seals. c. O-ring: Viton 747. d. Gland: Type 316L stainless steel. e. Set screws: Type 316L stainless steel. f. Faces: Reaction bonded, Silicon Carbide.


g. Seal designed to withstand 300 pounds per square inch gauge minimum differential pressures in either direction; no requirement for seal buffer pressure to be maintained when pump is not operational even though process suction head may be present in pump.

2. Cartridge type single mechanical: Manufacturers: One of the following or equal: a. Chesterton, S10. b. John Crane, 5610 Series.

3. Cartridge type double mechanical: Manufacturers: One of the following or equal: a. Chesterton, S20. b. John Crane, 5620 Series.

4. Split face single mechanical: Manufacturers: One of the following or equal: a. Chesterton, 442. b. John Crane, 3740.

5. Cartridge type flushless mechanical: Manufacturers: One of the following or equal: a. Chesterton, 156. b. John Crane, 5870.

2.05 GEAR REDUCTION UNITS

A. Type: Helical or herringbone, unless otherwise specified.

B. Design: 1. Made of alloys treated for hardness and for severe service. 2. AGMA Class II service:

a. Use more severe service condition when such is recommended by unit's manufacturer.

3. Cast iron housing with gears running in oil. 4. Anti-friction bearings. 5. Thermal horsepower rating based on maximum horsepower rating of prime

mover not actual load. 6. Manufactured in accordance with applicable AGMA standards.

C. Planetary gear units are not to be used.

2.06 BELT DRIVES

A. Sheaves: 1. Separately mounted on bushings by means of at least 3 pull-up bolts or cap

tightening screws. 2. When 2 sheave sizes are specified, provide separate belts sized for each set

of sheaves. 3. Statically balanced for all; dynamically balanced for sheaves that operate at a

peripheral speed of more than 5,500 feet per minute. 4. Key bushings to drive shaft.

B. Belts: Anti-static type when explosion-proof equipment or environment is specified. 1. When spare belts are specified, furnish 1 spare belt for every different type

and size of belt-driven unit: a. Where 2 or more belts are involved, furnish matched sets.


b. Identify as to equipment, design, horsepower, speed, length, sheave size, and use.

c. Package in boxes labeled with identification of contents.

C. Manufacturers: One of the following or equal: 1. Dodge, Dyna-V belts with matching Dyna-V sheaves and Taper-Lock

bushings. 2. T.B. Wood's, Ultra-V belts with matching Sure-Grip sheaves and Sure-Grip

bushings.

2.07 BEARINGS

A. Type: Oil or grease lubricated, ball or roller antifriction type, of standard manufacture.

B. Oil lubricated bearings: Provide either pressure lubricating system or separate oil reservoir splash type system: 1. Size oil lubrication systems to safely absorb heat energy generated in bearings

when equipment is operating under normal conditions and with the temperature 15 degree Fahrenheit above the maximum design temperature as specified in Section 01610.

2. Provide an external oil cooler when required to satisfy the specified operating conditions: a. Provide air cooled system if a water-cooling source is not indicated on the

Drawings. b. Equip oil cooler with a filler pipe and external level gauge.

C. Grease lubricated bearings, except those specified to be factory sealed: Fit with easily accessible grease supply, flush, drain, and relief fittings. 1. Lubrication lines and fittings:

a. Lines: Minimum 1/4-inch diameter stainless steel tubing. b. Multiple fitting assemblies: Mount fittings together in easily accessible

location. c. Use standard hydraulic type grease supply fittings:

1) Manufacturers: One of the following or equal: a) Alenite. b) Zerk.

D. Ratings: Rated in accordance with ABMA 9 or ABMA 11 L10 life for bearings rating life of not less than 50,000 hours:

2.08 EQUIPMENT SUPPORT FRAMES

A. Bolt holes shall not exceed bolt diameter by more than 25 percent, up to a limiting maximum diameter oversize of 1/4 inch.

2.09 PIPING AND VALVES

A. Piping as specified in Section 15052.

B. Valves as specified in Section 15110.


2.10 SAFETY EQUIPMENT

A. Safety guards: 1. Provide guards that protect personnel from rotating shafts or components

within 7.5 feet of floors or operating platforms. 2. Requirements:

a. Allow visual inspection of moving parts without removal. b. Allow access to lubrication fittings. c. Prevent entrance of rain or dripping water for outdoor locations. d. Size belt and sheave guards to allow for installation of sheaves 15 percent

larger and addition of 1 belt. 3. Materials:

a. Sheet metal: Carbon steel, 12 gauge minimum thickness, hot-dip galvanized after fabrication.

b. Fasteners: Type 304 stainless steel.

B. Warning signs: 1. Provide warning signs in accordance with OSHA requirements for equipment

that starts automatically or remotely. 2. Material, sign size, and text: As specified in Section 10400. 3. Mount warning signs with stainless steel fasteners at equipment.

2.11 SPRING VIBRATION ISOLATORS

A. Design requirements: 1. Telescopic top and bottom housing with vertical stabilizers to resist lateral and

vertical forces. 2. Use steel coil springs. 3. Design vibration isolators in accordance with seismic design criteria as


B. Performance requirements: Minimum spring deflection of 1 inch under static load and capable of limiting transmissibility to 10 percent maximum at design operating load.

C. Manufacturers: One of the following or equal: 1. California Dynamics Corporation, Type RJSD. 2. Mason Industries, equivalent product.

D. Materials: 1. Fabricate isolators using welded steel or shatterproof ductile iron in

accordance with ASTM A536 Grade CS-45-12. 2. Spring steel: ASTM A125.

2.12 NAMEPLATES

A. Fastened to equipment at factory in an accessible and visible location.

B. Stainless steel sheet engraved or stamped with text, holes drilled or punched for fasteners.

C. Fasteners: Number 4 or larger oval head stainless steel screws or drive pins.


D. Text: 1. Manufacturer’s name, equipment model number and serial number, motor

horsepower when appropriate, identification tag number. 2. Indicate following additional information as applicable:

a. Maximum and Normal rotating speed. b. Service class per applicable standards.

3. Include for pumps: a. Rated total dynamic head in feet of fluid. b. Rated flow in gallons per minute. c. Impeller, gear, screw, diaphragm, or piston size.

4. Include for gear reduction units: a. AGMA Class of service. b. Service factor. c. Input and output speeds.

2.13 SHOP FINISHES 1. Provide appropriate factory coatings as specified in Section 09960.

a. Motors and gear reducers: Shop finish paint with manufacturer's standard coating, unless otherwise specified in the individual equipment specification.

2.14 SPECIAL TOOLS

A. Supply one set of special tools as specified in Section 01600.

2.15 SOURCE TESTING

A. Testing requirements unless specified otherwise in the individual equipment specifications: 1. Mechanical equipment: Level 1 General Equipment Performance Test as

specified in Section 15958. 2. Motors: As specified in Section 16222. 3. Vendor Control Panels: As specified in Section 17950.

2.16 SHIPPING


B. Prior to shipment of equipment: 1. Bearings (and similar items):

a. Pack separately or provide other protection during transport. b. Greased and lubricated.

2. Gear boxes: a. Oil filled or sprayed with rust preventive protective coating.

3. Fasteners: a. Inspect for proper torques and tightness.

PART 3 EXECUTION

3.01 DELIVERY, HANDLING, STORAGE, AND PROTECTION



B. Inspect fasteners for proper torques and tightness.

C. Storage: 1. Bearings:

a. Rotate units at least once per month or more often as recommended by the manufacturer to protect rotating elements and bearings.

2. Gear boxes: a. Inspect to verify integrity of protection from rust.

D. Protection: 1. Equipment Log shall include description of rotation performed as part of

maintenance activities.

3.02 INSTALLATION

A. Field measurements: 1. Prior to shop drawings preparation, take measurements and verify dimensions

indicated on the Drawings. 2. Ensure equipment and ancillary appurtenances fit within available space.

B. Sequencing and scheduling: 1. Equipment anchoring: Obtain anchoring material and templates or setting

drawings from equipment manufacturers in adequate time for anchors to be cast-in-place.

2. Coordinate details of equipment with other related parts of the Work, including verification that structures, piping, wiring, and equipment components are compatible.

C. Metal work embedded in concrete: 1. Accurately place and hold in correct position while concrete is being placed. 2. Clean surface of metal in contact with concrete immediately before concrete is

placed.

D. Concrete surfaces designated to receive non-shrink grout: 1. Heavy sandblast concrete surface in contact with non-shrink grout. 2. Clean concrete surfaces of sandblasting sand, grease, oil, dirt, and other

foreign material that may reduce bond to non-shrink grout. 3. Saturate concrete with water. Concrete shall be saturated surface damp at

time non-shrink grout is placed.

E. Install equipment in accordance with manufacturer's installation instructions and recommendations.

F. Lubrication lines and fittings: 1. Support and protect lines from source to point of use. 2. Fittings:

a. Bring fittings to outside of equipment in manner such that they are readily accessible from outside without necessity of removing covers, plates, housings, or guards.

b. Mount fittings together wherever possible using factory-mounted multiple fitting assemblies securely mounted, parallel with equipment lines, and protected from damage.


c. Fittings for underwater bearings: Bring fittings above water surface and mount on edge of structure above.

G. Alignment of drivers and equipment: 1. Where drive motors or other drivers are connected to driven equipment by

flexible coupling, disconnect coupling halves and align driver and equipment after complete unit has been leveled on its foundation.

2. Comply with procedures of appropriate HI, AGMA Standards, alignment tolerances of equipment manufacturers and the following requirements to bring components into angular and parallel alignment: a. Maximum total coupling offset (not the per plane offset): Not to exceed

0.5 mils per inch of coupling length for spacer couplings based on coupling length (not dial separation).

b. Utilize jacking screws, wedges, or shims as recommended by the equipment manufacturer and as specified in the equipment sections.

3. Use reverse-indicator arrangement dial type or laser type alignment indicators: Mount indicators on the driver/coupling flange and equipment/coupling flange. Alignment instrumentation accuracy shall be sufficient to read angular and radial misalignment at 10 percent or less of the manufacturer's recommended acceptable misalignment.

4. Alignment and calculations shall include measurement and allowance for thermal growth, spacer coupling length, indicator separation, and axial spacing tolerances of the coupling.

5. When alignment satisfies most stringent tolerance of system components, grout between base and foundation. a. Allow minimum 48 hours for grout to harden. b. After grout hardens, remove jacking screws, tighten anchor bolts and

other connections, and recheck alignment. c. Correct alignment as required.

6. After functional testing is complete, dowel motor or drivers and driven equipment: a. Comply with manufacturer's instructions.

H. Grouting under equipment bases, baseplates, soleplates, and skids: 1. Unless otherwise indicated on the Drawings, grout with non-shrink grout as

specified in Section 03600. a. Non-shrink epoxy grout required only when indicated on the Drawings.

2. Comply with equipment manufacturer's installation instructions for grouting spaces, and tolerances for level and vertical and horizontal alignment.

3. Install grout only after: a. Equipment is leveled and in proper alignment. b. Piping connections are complete and in alignment with no strain

transmitted to equipment. 4. Do not use leveling nuts on equipment anchors for supporting and leveling

equipment bases, baseplates, soleplates, and skids for grouting. 5. Use jack screws for supporting and leveling equipment bases, baseplates,

soleplates, and skids for grouting following the procedure defined below: a. Drill and tap equipment base plates, sole plates, and skids for jack

screws. b. Use suitable number and size of jack screws. c. End of jack screws shall bear on circular steel plates epoxy bonded to

equipment foundation.


d. Jack screw threads that will be in contact with grout: Wrap with multiple layers of tape or other material, acceptable to Engineer, to prevent grout from bonding to threads.

e. Place and cure grout as specified in Section 03600. f. After grout is cured, remove jack screws and material used to prevent

bonding to grout. 1) Provide jack screws to Owner for future use.

g. Tighten equipment anchors in accordance with equipment manufacturer requirements.

h. Fill holes where jack screws have been removed with grout. i. Cure as specified in Section 03600.

6. For equipment bases, baseplates, soleplates, and skids where it is not practical to use jack screws, use steel wedges and shims. a. Wrap wedges and shims that contact grout with multiple layers of tape or

other material, acceptable to Engineer, to prevent grout from bonding. b. Place and cure grout as specified in Section 03600. c. Remove wedges or shims. d. Tighten equipment anchors to in accordance with equipment

manufacturer requirements. e. Fill voids where wedges and shims have been removed with grout. f. Cure as specified in Section 03600.

7. Preparation of equipment bases, baseplates, soleplates, and skids for grouting: a. Metal in contact with grout: Grit blast to white metal finish. b. Clean surfaces of equipment bases, baseplates, soleplates, and skids in

contact with grout of dirt, dust, oil, grease, paint and other material that will reduce bond.

8. Preparation of concrete equipment foundation for grouting: a. Rough concrete surfaces in contact with grout. b. Concrete contact surface shall be free of dirt, dust, laitance, particles,

loose concrete, or other material or coatings that will reduce bond. c. Saturate concrete contact surface area with water for minimum of

24 hours prior to grouting. d. Remove standing water just prior to grout placement, using clean rags or

oil-free compressed air.

9. Forms and header boxes: a. Build forms for grouting of material with adequate strength to withstand

placement of grouts. b. Use forms that are rigid and liquid tight. Caulk cracks and joints with an

elastomeric sealant. c. Line forms with polyethylene film for easy grout release. Forms carefully

waxed with 2 coats of heavy-duty paste wax will also be acceptable. 10. Grout placement requirements:

a. Minimum ambient and substrate temperature: 45 degrees Fahrenheit and rising: 1) Conform to grout manufacturer’s temperature requirements.

b. Pour grout using header box. c. Keep level of grout in header box above bottom of equipment bases,

baseplates, soleplates, and skids at all times to prevent air entrapment. d. Grout shall flow continuously from header box to other side of forms

without trapping air or forming voids.


e. Vibrate, rod, or chain grout to facilitate grout flow, consolidate grout, and remove entrapped air.

f. After grout sets, remove forms and trim grout at 45 degree angle from bottom edge of equipment bases, baseplates, soleplates, and skids.

g. Cure as specified in Section 03600.

I. Special techniques: 1. Use applicable special tools and equipment, including precision machinist

levels, dial indicators, and gauges as required in equipment installations.

J. Tolerances: 1. Completed equipment installations: Comply with requirements for intended use

and specified vibration and noise tolerances.

K. Warning signs: 1. Mount securely with stainless fasteners at equipment that can be started

automatically or from remote locations.

3.03 FIELD PAINTING

A. Compatible with factory painting.

B. As specified in Section 09960.

3.04 COMMISSIONING


B. Functional testing requirements unless specified otherwise in the individual equipment specifications: 1. Mechanical equipment: Level 1 tests as specified in Section 15958. 2. Motors: As specified in Sections 16222 and 16950. 3. Vendor Control Panels: As specified in Section 17950.

END OF SECTION


SECTION 15052

COMMON WORK RESULTS FOR GENERAL PIPING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Basic piping materials and methods.

B. Related sections: 1. Section 01140 - Work Restrictions. 2. Section 01300 - Submittals. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 09960 - High-Performance Coatings. 5. Section 15061 - Pipe Supports. 6. Section 15062 - Preformed Channel Pipe Support System. 7. Section 15211 - Ductile Iron Pipe : AWWA C151. 8. Section 15230 - Plastic Piping and Tubing. 9. Section 15245 - Drain, Waste, and Vent Piping. 10. Section 15270 - Steel Pipe: Galvanized and Black, ASTM A 53 11. Section 15286 - Stainless Steel Pipe. 12. Section 15956 - Piping Systems Testing.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 Through 24. 2. B16.47 - Large Diameter Steel Flanges: NPS 26 Through NPS 60 Metric/Inch

Standard.

B. American Water Work Association (AWWA): 1. C105 – Standard for Polyethylene Encasement for Ductile-Iron Pipe Systems. 2. C207 - Standard for Steel Pipe Flanges for Waterworks Services-Size 4 In.

Through 144 In.

C. ASTM International (ASTM): 1. A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting

Materials for High Temperature or High Pressure Service and Other Special Purpose Applications.

2. A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both.

3. A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength.

4. A563 - Standard Specification for Carbon and Alloy Steel Nuts. 5. F37 - Standard Test Methods for Sealability of Gasket Materials.

D. California Health and Safety Code.

E. NSF International (NSF): 1. 61 - Drinking Water System Components - Health Effects.


2. 372 - Drinking Water System Components - Lead Content.

1.03 DEFINITIONS

A. Buried pipe: Pipe that is buried in the soil, or cast in a concrete pipe encasement that is buried in the soil.

B. Exposed pipe: Pipe that is located above ground, or pipe that is located inside a structure, supported by a structure, or cast into a concrete structure.

C. Underground piping: Piping actually buried in soil or cast in concrete that is buried in soil.

D. Underwater piping: Piping below tops of walls in basins or tanks containing water.

E. Wet wall: Wall with water on at least 1 side.

1.04 SUBMITTALS

A. Submit as specified in Section 01300

B. Product data: 1. For each piping product in this Section as applicable:

a. Design features. b. Load capacities. c. Material designations by UNS alloy number or ASTM Specification and

Grade. d. Data needed to verify compliance with the Specifications. e. Catalog data. f. Clearly mark submittal information to show specific items, materials, and

accessories or options being furnished.

C. Calculations: 1. Provide calculations in accordance with NSF 372 for materials in contact with

drinking water.

1.05 WARRANTY

A. Provide warranty as specified in Section 01783.

PART 2 PRODUCTS

2.01 GENERAL


B. Materials in contact with drinking waters: In accordance with NSF 61 and NSF 372.

2.02 ESCUTCHEONS

A. Material: Chrome-plated steel plate.


B. Manufacturers: One of the following or equal: 1. Dearborn Brass Company, Model Number 5358. 2. Keeney Manufacturing Company, Model Number 102 or Number 105.

2.03 LINK TYPE SEALS

A. Characteristics: 1. Modular mechanical type, consisting of interlocking neoprene or synthetic

rubber links shaped to continuously fill the annular space between the pipe and wall opening.

2. Assemble links solely with stainless steel bolts and nuts to form a continuous rubber belt around the pipe.

3. Provide a nylon polymer pressure plate with Type 316 stainless steel hardware. Isolate pressure plate from contact with wall sleeve.

B. Manufacturers: One of the following or equal: 1. Calpico, Incorporated. 2. Pipeline Seal and Insulator, Inc., Link-Seal.

2.04 FLANGE BOLTS

A. Lubricant for stainless steel bolts and nuts: 1. Chloride-free. 2. Manufacturers: One of the following or equal:

a. Huskey FG-1800.

PART 3 EXECUTION

3.01 INSTALLATION

A. General: 1. Piping drawings:

a. Except in details, piping is indicated diagrammatically. Not every offset and fitting, or structural difficulty that may be encountered has been indicated on the Drawings. Sizes and locations are indicated on the Drawings.

b. Perform minor modifications to piping alignment where necessary to avoid structural, mechanical, or other type of obstructions that cannot be removed or changed. 1) Modifications are intended to be of minor scope, not involving a

change to the design concept or a change to the Contract Price or Contract Times.

2. Piping alternatives: a. Provide piping as specified in this Section, unless indicated on the

Drawings or specified otherwise. b. Alternative pipe ratings:

1) Piping with greater pressure rating than specified may be substituted in lieu of specified piping without changes to the Contract Price.

2) Piping of different material may not be substituted in lieu of specified piping.

c. Valves in piping sections: Capable of withstanding specified test pressures for piping sections and fabricated with ends to fit piping.


d. For grooved joints, use couplings, flange adapters, and fittings of the same manufacturer. 1) The grooved joint manufacturer’s factory trained representative shall

provide on-site training for Contractor’s field personnel. 2) The representative shall periodically visit the jobsite and review

Contractor is following best recommended practices in grooved product installation.

3) A distributor’s representative is not considered qualified to conduct the training or jobsite visit(s).

e. For flanged joints, where 1 of the joining flanges is raised face type, provide a matching raised face type flange for the other joining flange.

3. Unless otherwise indicated on the Drawings, piping at pipe joints, fittings, couplings, and equipment shall be installed without rotation, angular deflection, vertical offset, or horizontal offset.

B. Wall and slab penetrations: 1. Provide sleeves for piping penetrations through aboveground masonry and

concrete walls, floors, ceilings, roofs, unless specified or otherwise indicated on the Drawings.

2. For piping 1 inch in nominal diameter and larger, provide sleeves with minimum inside diameters of 1 inch plus outside diameter of piping. For piping smaller than 1 inch in nominal diameter, provide sleeve of minimum twice the outside diameter of piping. a. Arrange sleeves and adjacent joints so piping can be pulled out of sleeves

and replaced without disturbing the structure. b. Cut ends of sleeves flush with surfaces of concrete, masonry, or plaster. c. Conceal ends of sleeves with escutcheons where piping runs through

floors, walls, or ceilings of finished spaces within buildings. d. Seal spaces between pipes and sleeves with link-type seals when not

otherwise specified or indicated on the Drawings. 3. Provide flexibility in piping connecting to structures to accommodate

movement due to soil settlement and earthquakes. Provide flexibility using details indicated on the Drawings.

4. Core drilled openings: a. Do not damage or cut existing reinforcing bars, electrical conduits, or

other items embedded in the existing concrete without acceptance by Engineer.

b. Determine location of reinforcing bars or other obstructions with a non-destructive indicator device.

c. Remove dust and debris from hole using compressed air.

C. Exposed piping: 1. Install exposed piping in straight runs parallel to the axes of structures, unless

otherwise indicated on the Drawings: a. Install piping runs plumb and level, unless otherwise indicated on the

Drawings. 1) Slope plumbing drain piping with a minimum of 1/4 inch per foot

downward in the direction of flow. 2) Slope digester gas piping to drip traps or low-point drains at a

minimum of 1/2 inch per foot where condensate flows against the gas, or at a minimum of 1/4 inch per foot where condensate flows with gas.


2. Install exposed piping after installing equipment and after piping and fitting locations have been determined.

3. Support piping: As specified in Sections 15061 and 15062: a. Do not transfer pipe loads and strain to equipment.

4. In addition to the joints indicated on the Drawings, provide unions, flexible couplings, flanged joints, flanged coupling adapters, and other types of joints or means which are compatible with and suitable for the piping system, and necessary to allow ready assembly and disassembly of the piping.

5. Assemble piping without distortion or stresses caused by misalignment: a. Match and properly orient flanges, unions, flexible couplings, and other

connections. b. Do not subject piping to bending or other undue stresses when fitting

piping. c. Do not correct defective orientation or alignment by distorting flanged

joints or subjecting flange bolts to bending or other undue stresses. d. Flange bolts, union halves, flexible connectors, and other connection

elements shall slip freely into place. e. Alter piping assembly to fit, when proper fit is not obtained. f. Install eccentric reducers or increasers with the top horizontal for pump

suction piping.

D. Buried piping: 1. Where 2 similar services run parallel to each other, piping for such services

may be laid in the same trench. a. Lay piping with sufficient room for assembly and disassembly of joints, for

thrust blocks, for other structures, and to meet separation requirements of public health authorities having jurisdiction.

2. Concrete encase all buried pipe installed under concrete slabs or structures.

E. Restraining piping: 1. Restrain piping at valves and at fittings where piping changes direction,

changes sizes, and at ends: a. When piping is underground, use concrete thrust blocks, mechanical

restraints, or push-on restraints. b. When piping is aboveground or underwater, use mechanical or structural

restraints. c. Determine thrust forces by multiplying the nominal cross sectional area of

the piping by design test pressure of the piping. 2. Provide restraints with ample size to withstand thrust forces resulting from test

pressures: a. During testing, provide suitable temporary restraints where piping does

not require permanent restraints. 3. Place concrete thrust blocks against undisturbed soil. 4. Place concrete so piping joints, fittings, and other appurtenances are

accessible for assembly and disassembly. 5. Provide underground mechanical restraints where specified in the Piping

Schedule or shown on the Drawings.

F. Connections to existing piping: 1. Expose existing piping to which connections are to be made with sufficient

time to permit, where necessary, field adjustments in line, grade, or fittings: a. Protect domestic water/potable water supplies from contamination:


1) Make connections between domestic water supply and other water systems in accordance with requirements of public health authorities.

2) Provide devices approved by Owner of domestic water supply system to prevent flow from other sources into the domestic supply system.

2. Make connections to existing piping and valves after sections of new piping to be connected have been tested and found satisfactory.

3. Provide sleeves, flanges, nipples, couplings, adapters, and other fittings needed to install or attach new fittings to existing piping and to make connections to existing piping.

4. For flanged connections, provide stainless steel bolts with isolation bushings and washers, and full-face flange gaskets.

G. Connections between ferrous and nonferrous metals: 1. Connect ferrous and nonferrous metal piping, tubing, and fittings with dielectric

couplings especially designed for the prevention of chemical reactions between dissimilar metals.

2. Nonferrous metals include aluminum, copper, and copper alloys.

H. Flanged connections between dissimilar metals such as ductile iron pipe and steel pipe: 1. Provide stainless steel bolts with isolation bushings and washers, and full-face

flange gaskets.

3.02 CLEANING

A. Piping cleaning: 1. Upon completion of installation, clean piping interior of foreign matter and

debris. 2. Perform special cleaning when required by the Contract Documents.

B. Cleaning air piping: 1. Perform special cleaning of filtered air piping from the intake clean air plenums

to the discharge points and high-pressure air piping. a. Protect surfaces from contamination.

2. Special cleaning shall include wire brushing, power tool cleaning, wiping down with lint-free cloths, brooming, and vacuuming to remove rust, scale, weld spatter, dust, dirt, oil, and other matter deleterious to operation of the air system: a. Do not sandblast installed piping.

3. To the greatest extent possible, clean piping immediately prior to final closure of piping systems: a. Enter piping, clean and wipe down surfaces, and vacuum out residue. b. Clean surfaces not accessible to this cleaning operation after installation

within 6 hours preceding installation. 4. Subsequent to cleaning, protect surfaces from contamination by dust, dirt,

construction debris, and moisture, including atmospheric moisture: a. Whether or not pipe upstream has been cleaned, temporarily seal

openings in partially completed work except when installation is actively in progress.

b. When installation is actively in progress, seal openings at the end of each day's construction or when construction is temporarily stopped.


5. Suspend cleaning and seal openings when inclement weather, including dust storms, is imminent.

6. Use clean, dry air for testing the piping and other elements of the system. 7. Prior to introduction of air to the system, blow piping clean.

a. Blow with maximum discharge rate possible for minimum 4 hours, using new blowers or compressors and filters.

8. Clean surfaces that become contaminated prior to acceptance.

3.03 COMMISSIONING


3.04 PIPING SCHEDULE


PIPING SCHEDULE

Process Abbrev. Service

Nominal Diameter (inches) Material

Pressure Class Special

Thickness Class

Schedule Wall Thickness

Pipe Spec.

Section Joints/ Fittings

Test Pressure/ Method Lining Coating Comments

AIR Aeration Air

Aboveground 4-16 Type 304L SST

SCH 10S 15286 WLD of FL, FL where shown

15 psig/AM

None None

DR Drain

Underground All PVC SCH 40 510 SOR 15 feet/GR

None None

Aboveground 0.5-6 GSP SCH 40 510 SCRD 15 feet/GR

None EPP

FE Final Effluent

Underground All PVC C900 DR 25

510 SOR 50 psig/HH

None None

Aboveground All DIP 150 510 FL 50AD2 psig /HH

CE EPP

ML Mixed Liquor

Underground 4-14 DIP 150 510 AD2Mech Rest. MJ

50 psig/HH

CE 2 Layers PEE

Aboveground 4-14 DIP 150 510 FL 50 psig/HH

CE EEP


PIPING SCHEDULE




Thickness Class


Pipe Spec.



NPW Non-Potable Water

Underground 1-3 PVC SCH 80 510 SW 125 psig /HH

None None

4-10 DIP 150 510 Mech Rest. MJ

125 psig/HH

CM 2 layers PEE

Aboveground 0.5-3 GSP SCH 80 510 SCRD 125 psig /HH

None EPP

PCE Primary Clarifier EffluentAD2

Underground All DIP 150 510 DIP Rest MJ

10 psig /LH

None None

Aboveground

All DIP UNO

150 510 FL 10 psig/LH

None None

RAS Return Activated Sludge


510 SOR 50 psig/HH

None None

Aboveground All DIP UNOAD2

CL 53 510 FL 50 psig /HH

CE EPP

SC Secondary Scum


510 SOR 50 psig/HH

None None

Aboveground All DIP

(UNO) 150 510 FL 50

psig/HH CE EPP

SD Stormwater Drain


PIPING SCHEDULE




Thickness Class


Pipe Spec.




510 SOR/DIP Rest. MJ

10 psig / LH

None None

Underground

AD2 All AD2 PVC AD2 SCH 40 AD2 510 AD2 SOR AD2 15 ft/GR

AD2 None AD2 None AD2

SL Primary Sludge/Scum


510 SOR 50 psig/HH

None None

Aboveground All DIP

(UNO) 150 510 FL 50

psig/HH CE EPP

SE Secondary Effluent

Underground All PVC C900/905 DR 25

510 SOR/DIP Rest. MJ

10 psig /LH

None None

SPD Sump Pump Discharge

Underground All Black Steel

SCH 40 510 B&SP 50 psig/HH

None None

Aboveground All GSP SCH 40 510 SCRD 50 psig/HH

None EPP

TF Thickener Filtrate

Underground All DIP 150 510 AD2Mech Rest. MJ

50 psig/HH

CE 2 Layers PEE

WAS Waste Activated Sludge

Underground All PVC C900 DR 25 510 SOR 125

psig/HH None None


PIPING SCHEDULE




Thickness Class


Pipe Spec.



Aboveground All DIP CL 53 510 FL 125 psig /HH CE EPP

Abbreviations: 1. The following abbreviations used in the column of test method refer to the respective methods as specified in Section 15956. AM Air method GR Gravity method HH High head method LH Low head method SC Special case 2. Abbreviations to designate piping include the following: B&SP Bell and spigot CE Ceramic Epoxy CI Cast iron CISP Cast iron soil pipe CL Class, followed by the designation CM Cement mortar CTP Coal tar pitch DIP Ductile iron piping EPP Epoxy polyurethane coating FLFlange GA Gauge, preceded by the designation

GE Grooved end joint GL Glass lined GSP Galvanized steel pipe MJ Mechanical joint NPS Nominal pipe size, followed by the number in inches psi pounds per square inch psig pounds per square inch gauge PE Polyethylene PEE Polyethylene encasement PTW Polyethylene tape wrap PVC Polyvinyl Chloride SCH Schedule, followed by the designation SCRD Screwed-On SOR Slip-on RestrainedAD2 SST Stainless steel SW Solvent welded VCP Vitrified clay piping WLD Weld

END OF SECTION

AD2 Addendum No. 2


SECTION 15061

PIPE SUPPORTS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Supports for pipe, fittings, valves, and appurtenances.

B. Related sections: 1. Section 01410 - Regulatory Requirements. 2. Section 01300 - Submittals. 3. Section 01600 - Product Requirements. 4. Section 01783 - Warranties and Bonds. 5. Section 05120 - Structural Steel. 6. Section 09960 - High-Performance Coatings. 7. Section 15050 - Common Work Results for Mechanical Equipment.

1.02 REFERENCES

A. ASTM International (ASTM): 1. A123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron

and Steel Products. 2. A380 - Standard Practice for Cleaning, Descaling, and Passivation of Stainless

Steel Parts, Equipment, and Systems. 3. A967 - Standard Specification for Chemical Passivation Treatments for

Stainless Steel Parts.

B. Manufacturer's Standardization Society (MSS): 1. SP-58 - Pipe Hangers and Supports - Materials, Design, and Manufacture.

1.03 SUBMITTALS

A. Shop drawings: Include schedule, indicating where supports will be installed, and drawings of pipe support system components.

B. Submit as specified in Section 01300

C. Product data. 1. Design features. 2. Load capacities. 3. Material designations by UNS alloy number or ASTM Specification and Grade. 4. Data needed to verify compliance with the Specifications. 5. Catalog data. 6. Clearly mark submittal information to show specific items, materials, and


1.04 WARRANTY



PART 2 PRODUCTS

2.01 GENERAL


2.02 MATERIALS

A. General: 1. Hot dip galvanized:

a. Fabricate as specified in Section 05120. b. Hot dip after fabrication of support in accordance with ASTM A123. c. Repair galvanized surface as specified in Section 05120.

2. Stainless steel. a. Fabricate as specified in Section 05120. b. Finish requirements: Remove free iron, heat tint oxides, weld scale, and

other impurities, and obtain a passive finished surface. c. At the shop, perform pickling and passivation on all surfaces inside and

out in accordance with ASTM A380 or A967. 1) Passivation treatments using citric acid are not allowed.

d. Field welding is prohibited unless specifically allowed by the Owner. All field welds shall be passivated.

B. Outdoor areas: Areas exposed to the natural outdoor environment: 1. Type 304 Stainless Steel.

C. Indoor areas: Areas exposed to an indoor environment including galleries and tunnels: 1. Hot Dip Galvanized.

D. Submerged, 3 feet or less above water level in a structure, or inside a water bearing structure: 1. Type 304 Stainless Steel.

E. Stainless steel piping system: 1. Type 304 Stainless Steel.

F. Chemical containment areas and chemical piping: 1. Type 304 Stainless Steel.

G. Fasteners: 1. As specified in Section 05120.

2.03 PIPE SUPPORTS

A. Hanger rods: Sized to match suspended pipe hanger, or as indicated on the Drawings: 1. Manufacturers: One of following or equal:

a. For stainless steel piping: 1) Bergen-Power, Figure 133. 2) Nibco-Tolco, Figure 103.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 140.


2) Bergen-Power, Figure 133. 3) Cooper B-Line Systems, Inc., Figure B3205.

B. Hanger rods, continuously threaded: Sized to match suspended pipe hanger, or as indicated on the Drawings: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Bergen-Power, Figure 94. 2) FM Stainless Fasteners.

b. For steel and ductile iron piping: 1) Anvil International, Figure 146. 2) Bergen-Power, Figure 94.

C. Eye bolts: 1. For stainless steel piping:

a. Type 316 stainless steel, welded and rated equal to full load capacity of rod.

2. For all other piping, unless indicated on the Drawings: a. Welded and rated equal to full load capacity of rod.

D. Welded eyebolt rod: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 101. 2) FM Stainless Fasteners.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 278. 2) Bergen-Power, Figure 93. 3) Cooper B-Line Systems, Inc., Figure B3210.

E. Adjustable ring hangers: MSS SP-58, Type 7 or Type 9 (system dependent): 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 1C.I. 2) Bergen-Power, Figure 100SS.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 97. 2) Cooper B-Line Systems, Inc., Figure B3172.

F. Adjustable clevis hangers: MSS SP-58, Type 1: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Cooper B-Line Systems, Inc, Figure B3100 or B3102. 2) FM Stainless Fasteners, Figure 60.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 260 or Figure 590. 2) Bergen-Power, Figure 100. 3) Cooper B-Line Systems, Inc., Figure B3100 or B3102.


G. Adjustable clevis hangers for insulated pipe: Oversize: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 1A.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 300. 2) Bergen-Power, Figure 100EL. 3) Cooper B-Line Systems, Inc. Figure B3108.

H. Single rod hangers for steam pipe: MSS SP-58, Type 43; malleable iron or steel yoke and roller hangers; swivel to allow rotation of yoke on rod: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 324. 2) Cooper B-Line Systems, Inc., Figure B3110. 3) FM Fasteners, Figure 81.


I. Double rod hangers for steam pipe: MSS SP-58, Type 41: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) FM Stainless Fasteners, Figure 71.


J. Brackets: MSS SP-58, Type 32 with back plate; rated for 1,500 pounds: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 30M. 2) Cooper B-Line Systems, Inc., Figure B3066. 3) FM Stainless Fasteners, Figure 98.


K. Standard U-bolt: MSS SP-58, Type 24: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 110. 2) Cooper B-Line Systems, Inc., Figure B3188. 3) FM Stainless Fasteners, Figure 37.



L. Riser clamps: MSS SP-58, Type 8: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Cooper B-Line Systems, Inc., Figure B3373. 2) FM Stainless Fasteners, Figure 61.


M. Pipe clamps: MSS SP-58, Type 4: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 4. 2) Cooper B-Line Systems, Inc., Figure 3140.


N. Adjustable offset pipe clamp: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 4. 2) Cooper B-Line Systems, Inc., Figure B3149. 3) FM Stainless Fasteners, Figure 63.


O. Offset pipe clamp: 1. Manufacturers: One of the following or equal:



P. Floor stand or stanchion saddles: MSS SP-58, Type 37. Provided with U-bolt hold down yokes: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 318. 2) FM Stainless Fasteners, Figure 59.


c. Threaded pipe stand support stanchion. Match pipe support material. 1) Anvil International, Figure 63T. 2) Bergen-Power, Figure 138.


3) Cooper B-Line Systems Inc., Figure B3088ST.

Q. Spring hangers: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Bergen-Power, Figure 920.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure B-268, Type G. 2) Bergen-Power, Figure 920.

R. One hole pipe clamps: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Not used.

b. For all other piping: 1) Anvil International, Figure 126. 2) Carpenter & Paterson, Figure 237S.

S. Welded beam attachment: MSS SP-58, Type 22: 1. Manufacturers: One of the following or equal:


b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 66. 2) Bergen-Power, Figure 113A or 113B. 3) Cooper B-Line Systems, Inc., Figure B3083.

T. Heavy pipe clamp: MSS SP-58, Type 4: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 4H.

b. For all other piping, unless called out otherwise on the Drawings: 1) Anvil International, Figure 216. 2) Bergen-Power, Figure 298.

U. PTFE pipe slide assembly: MSS SP-58, Type 35 with lateral and vertical restraint: 1. Manufacturers: One of the following or equal:

a. For stainless steel piping: 1) Nibco-Tolco, Figure 426.

b. For all other piping, unless indicated on the Drawings: 1) Anvil International, Figure 257, Type 3. 2) Cooper B-Line Systems, Inc., Figure B3893.

V. Anchor bolts, concrete anchors, concrete inserts, powder-actuated fasteners, and sleeve anchors: As specified in Section 05120.


PART 3 EXECUTION

3.01 INSTALLATION

A. Properly support, suspend, or anchor exposed pipe, fittings, valves, and appurtenances to prevent sagging, overstressing, or movement of piping; and to prevent thrusts or loads on or against connected pumps, blowers, and other equipment.

B. Field verify support location, orientation, and configuration to eliminate interferences prior to fabrication of supports.

C. Carefully determine locations of inserts. Anchor to formwork prior to placing concrete.

D. Use flush shells only where indicated on the Drawings.

E. Do not use anchors relying on deformation of lead alloy.

F. Do not use powder-actuated fasteners for securing metallic conduit or steel pipe larger than 1 inch to concrete, masonry, or wood.

G. Suspend pipe hangers from hanger rods and secure with double nuts.

H. Install continuously threaded hanger rods only where indicated on the Drawings.

I. Use adjustable ring hangers or adjustable clevis hangers, for 4 inch and smaller diameter pipe.

J. Use adjustable clevis hangers for pipe larger than 4 inches in diameter.

K. Secure pipes with double nutted U-bolts or suspend pipes from hanger rods and hangers. 1. For stainless steel piping, use stainless steel U-bolts. 2. For all other piping, use galvanized U-bolts.

L. Support spacing: 1. Support 2-inch and smaller piping on horizontal and vertical runs at maximum

5 feet on center, unless otherwise specified. 2. Support larger than 2-inch piping on horizontal and vertical runs at maximum

10 feet on center, unless otherwise specified. 3. Support exposed polyvinyl chloride and other plastic pipes at maximum 5 feet

on center, regardless of size. 4. Support tubing, PVC pipe 1-inch and smaller, copper pipe and tubing, fiber-

reinforced plastic pipe or duct, and rubber hose and tubing at intervals close enough to prevent sagging greater than 1/4 inch between supports.

5. Do not suspend or support valves, pipe and fittings from another pipe or conduit.

M. Install supports at: 1. Any change in direction. 2. Both sides of flexible pipe connections. 3. Base of risers.


4. Floor penetrations. 5. Connections to pumps, blowers, and other equipment. 6. Valves and appurtenances.

N. Securely anchor plastic pipe, valves, and headers to prevent movement during operation of valves.

O. Anchor plastic pipe between expansion loops and direction changes to prevent axial movement through anchors.

P. Provide elbows or tees supported from floors with base fittings where indicated on the Drawings.

Q. Support base fittings with metal supports or when indicated on the Drawings support on concrete piers.

R. Do not use chains, plumbers' straps, wire, or similar devices for permanently suspending, supporting, or restraining pipes.

S. Support plumbing drainage and vents in accordance with plumbing code as specified in Section 01410.

T. Supports, clamps, brackets, and portions of support system bearing against copper pipe: Copper plated, copper throughout, or isolated with neoprene or polyvinyl chloride tape.

U. Where pipe is insulated, install over-sized supports and hangers.

V. Install insulation shield in accordance with MSS SP-58, Type 40. Shield shall be galvanized steel unless otherwise specified or indicated on the Drawings.

W. Install riser clamps at floor penetrations and where indicated on the Drawings.

X. Coat support system components as specified in Section 09960.

END OF SECTION


SECTION 15062

PREFORMED CHANNEL PIPE SUPPORT SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Preformed channel pipe support system consisting of preformed channels, fittings, straps, and fasteners engineered to support piping.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01612 - Seismic Design Criteria.

1.02 REFERENCES

A. American Institute of Steel Construction (AISC).

B. American Iron and Steel Institute (AISI).

C. Manufacturer's Standardization Society (MSS): 1. SP-58 - Pipe Hangers and Supports - Materials, Design, and Manufacture. 2. SP-69 - Pipe Hangers and Supports - Selection and Application.


A. Design responsibility: 1. The manufacturer of the preformed channel pipe support system is

responsible for the design of the support system. 2. Prepare design calculations utilizing the design criteria included in these

Specifications. 3. Prepare detailed shop drawings illustrating the layout of the support system

and identifying the components of the support system.

B. Design criteria: 1. Include live, dead, and seismic loads associated with piping, valves, and

appurtenances. Consider the content of the pipes in load calculations. 2. Minimum gauge thickness: 12-gauge. 3. Allowable stress of channels:

a. Steel channels: The lesser of 25,000 pounds per square inch, or 0.66 times yield stress of steel.

b. Stainless steel channels: 0.66 times the yield stress of the stainless steel alloy.

4. Maximum deflection: 1/240 of span. 5. Allowable column loads: As recommended by manufacturer in published

instruction for column's unsupported height and "K" value for calculating effective column length of not less than 1.0.

6. Future loads: a. Support systems indicated on the Drawings may include spaces intended

to accommodate future pipes.


b. Assume such spaces are occupied by 6-inch diameter ductile iron pipes. Only the number of pipes that would physically fit into the space need be considered.

c. Include the weight of the pipe contents in determining future loads. Assume pipe contents are water.

7. Seismic design criteria: As specified in Section 01612 as specified for mechanical equipment.

8. Spacing of supports: As required to comply with design requirements but not more than 5 feet.

C. Supports below the top of walls of water bearing structures: Use Type 316 stainless steel for support system components. 1. Supports in other locations: Use hot-dipped galvanized components unless

other materials are specifically indicated on the Drawings.

1.04 SUBMITTALS


B. Shop drawings: Include layout of support system including pipe loads, selected channel size, fittings, and appurtenances.

C. Structural design calculations.


A. Design preformed channel pipe support system for loads in accordance with applicable provisions of: 1. AISC Manual of Steel Construction. 2. AISI Cold-Formed Steel Design Manual.

B. Product standards: 1. Pipe support components: In accordance with MSS SP-69. 2. Pipe support materials: In accordance with MSS SP-58.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Fabricate preformed channel pipe support system using, as a minimum, parts specified below and meeting the requirements specified under Design Criteria. 1. Manufacturers: One of the following or equal:

a. Unistrut, Series P1000 or P1001; P5500 or P5501. b. Allied Support Systems, Power Strut, Figure PS-200 or PS-200 2TS;

PS-150 or PS-150 2TS. c. Cooper Industries, B-Line, Channel Type B22 or B22A; B12 or B12A.

2.02 ACCESSORIES

A. Preformed channel concrete inserts: Minimum 12 inches long: 1. Manufacturers: One of the following or equal:

a. Unistrut, Series P-3200.


b. Allied Support Systems, Figure 282. c. Cooper Industries, B-Line Series B32I.

B. 90-degree angle fittings: 1. Manufacturers: One of the following or equal:

a. Unistrut, P1026. b. Allied Support Systems, Power Strut, P603.

C. Pipe straps: 1. For pipes 8 inches in diameter and smaller: Use 2-piece universal strap with

slotted hex head screw and nut. a. Manufacturers: One of the following or equal:

1) Unistrut, Series P1109 through P1126. 2) Allied Support Systems, PS1100. 3) Cooper Industries, B-Line Series B2000.

2. For pipes greater than 8 inches in diameter: Unless different material is otherwise indicated on the Drawings use 1-piece 1 inch wide by 1/8 inch thick steel strap, hot-dip galvanized after fabrication.

3. For stainless steel pipes: Use type of strap required for the pipe sizes specified above, but use Type 316 stainless steel materials.

D. Prefabricated double channel bracket: 1. Manufacturers: One of the following or equal:

a. Unistrut, P2542-P2546. b. Cooper Industries, B-Line Series B297.

E. Touch-up paint for galvanized surfaces: 1. Manufacturers: One of the following or equal:

a. Galvinox, Galvo-Weld.

F. Touch-up paint for painted surfaces: Same formulation as factory paint.

2.03 FABRICATION

A. Hot-dip galvanize support system components after fabrication to required length and shape.

B. Do not galvanize or paint stainless steel components.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install preformed channel concrete inserts for vertical support, quantity based on manufacturer's structural design calculations.

B. Fasten preformed channel pipe supports to existing walls using Z-fittings and concrete anchors as indicated on the Drawings.

C. Fasten preformed channel pipe supports to preformed channel concrete inserts embedded in ceiling using U-shaped fittings.


D. Suspend threaded rods from concrete inserts embedded in ceiling. Support preformed channel pipe supports with threaded rods.

E. Touchup cut or damaged galvanized surfaces.

F. Prevent contact between pipes and support components of dissimilar metals. Utilize rubber coated, plastic coated, or vinyl coated components, stainless steel components, or wrap pipe with PVC or polyethylene tape.

G. Install support as near as possible to concentrated loads.

H. Install support within 2 feet of horizontal and vertical changes in pipe alignment.

I. Adjust supports or install shims to obtain specified slope or elevation.

END OF SECTION


SECTION 15075

EQUIPMENT IDENTIFICATION

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Equipment nameplates. 2. Special items.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01770 - Closeout Procedures. 4. Section 09960 - High-Performance Coatings.

1.02 SUBMITTAL


B. Shop drawings: 1. Product data. 2. Installation instructions.

C. Samples.


A. Regulatory requirements: Comply with ANSI A13.1 latest edition,

PART 2 PRODUCTS

2.01 EQUIPMENT NAMEPLATES

A. Material and fabrication: 1. Stainless steel sheet engraved or stamped with text, holes drilled, or punch for

fasteners.

B. Fasteners: 1. Number 4 or larger oval head stainless steel screws or drive pins.

C. Text: 1. Manufacturer’s name, equipment model number and serial number,

identification tag number; and when appropriate, drive speed, motor horsepower with rated capacity, pump rated total dynamic head, and impeller size.


2.02 SPECIAL ITEMS

A. In addition, special coating of following items will be required:

Item Color Valve handwheels and levers Red Hoist hooks and blocks Yellow and black stripes

Steel guard posts In accordance with standard details

B. Paint minimum 2 inches high numbers on or adjacent to accessible valves, pumps, flowmeters, and other items of equipment which are indicated on the Drawings or in Specifications by number.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify satisfactory conditions of substrate for applying identification.

B. Verify that conditions are satisfactory for installation and application of products as specified in Section 01600.

3.02 PREPARATION

A. Prepare and coat surfaces of special items as specified in Section 09960.

B. Prepare surface in accordance with product manufacturer's instructions.

END OF SECTION


SECTION 15076

PIPE IDENTIFICATION

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Pipe identification including the following: 1. Pipe identification by color and legend. 2. Underground warning tape. 3. Valve identification.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01770 - Closeout Procedures. 4. Section 09960 - High-Performance Coatings.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. A13.1 - Scheme for the Identification of Piping Systems.

1.03 SUBMITTALS


B. Submit following: 1. Product data. 2. Samples. 3. Manufacturer's installation instructions. 4. Submit following as specified in Section 01770:

a. Operation and Maintenance Data. b. Warranty.

PART 2 PRODUCTS

2.01 ABOVE GROUND AND IN-CHASE PIPE IDENTIFICATION


a. Seton, Opti Code Pipe Markers. b. Lab Safety Supply. c. Marking Services, Inc.

B. Materials: 1. Pipe markers: Self-adhesive vinyl, suitable for outdoor application from

-40 degrees to 180 degrees Fahrenheit; in accordance with ASME A13.1 requirements.


a. Lettering:

Nominal Pipe Diameter Lettering Size

Less than 1.5 1/2 inch

1.5 inches to 2 inches 3/4 inch

2.5 inches to 6 inches 1-1/4 inches

8 inches to 10 inches 2-1/2 inches

Over 10 inches 3-1/2 inches

b. Marker colors:

Service Lettering Background Flammables, chemicals, toxics Black Yellow

Water, nontoxic solutions or low hazard liquids

White Green

Nonflammable or nontoxic gases White Blue

Fire quenching fluids (foam, fire water, CO2 Halon)

White Red

2. Coating: As specified in Section 09960. 3. Pipe identification tags: Aluminum or stainless steel with stamped-in 1/4 inch

high identifying lettering. 4. Pipe identification tag chains: Aluminum or stainless steel. 5. Snap-on markers: Markers with 3/4 inch high letters for 3/4 to 4 inch pipe or

covering, or 5 inch high letters for 5 inch or larger pipe or cover, as manufactured by one of following: a. Brady Bradysnap-On B-915. b. Seton Setmark.

2.02 BURIED PIPELINE IDENTIFICATION

A. Underground warning tape: 1. Manufacturer: One of the following or equal:

a. Seton Name Plate Company, Branford, CT. b. T. Christy Enterprises, Inc.

2. Material: a. Polyethylene tape for prolonged underground use. b. Minimum tape thickness: 4 mils. c. Overall tape width: 6 inches. d. Message: “CAUTION” with the name of the service followed by “LINE

BURIED BELOW.” in black lettering on colored background in accordance with approved APWA colors. 1) Water: Blue. 2) Sewer: Green. 3) Telephone: Orange. 4) Gas and other services: Yellow.

e. Aluminum backing or solid aluminum core.


2.03 VALVE IDENTIFICATION

A. The Contractor shall furnish and install tags for all valves and gates required for the Work. 1. Tags shall be 2-in diameter round, stainless steel or PVC for buried

applications. 2. Tags shall be furnished with a non-corrosive metal wire suitable for attaching

the tag to the operator base. 3. Tags shall be stamped in 1/4-inch high letter

a. Tags shall not be attached in such a way as to inhibit the operation of the valve or gate.

4. Buried valve tags shall be secured to concrete s with the specified valve or gate number.

5. Submit 2 samples of the type of tag proposed and the manufacturer’s standard color chart and letter styles to the Engineer for review.

6. Manufacturer: The following or equal: a. Seton Name Plate Company, Branford, CT.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify satisfactory conditions of substrate for applying identification.

B. Verify that conditions are satisfactory for installation and application of products as specified in Section 01600.

3.02 PREPARATION

A. Prepare and coat surfaces as specified in Section 09960.

B. Prepare surface in accordance with product manufacturer's instructions.

3.03 ABOVE GROUND AND IN-CHASE PIPING IDENTIFICATION

A. Identify exposed piping, valves, and accessories, and piping, valves, and accessories in accessible chases with lettering or tags designating service of each piping system with flow directional arrows and color code.

B. Color code: 1. Paint all piping with colors as scheduled in Piping Color Code and Marker

Schedule.

C. Lettering and flow direction arrows: 1. Stencil lettering on painted bands or use snap-on markers on pipe to identify

pipe. When stenciling, stencil 3/4 inch high letters on 3/4 through 4-inch pipe or coverings, or 5-inch high letters on 5-inch and larger pipe or coverings.

2. Provide lettering and flow direction arrows near equipment served, adjacent to valves, both sides of walls and floors where pipe passes through, at each branch or tee, and at intervals of not more than 50 feet in straight runs of pipe.


D. Where scheduled, space 6-inch wide bands along stainless steel pipe at 10-foot intervals and other pipe at 5-foot intervals.

E. Label chemical tank fill pipelines at locations which are visible from chemical fill stations.

F. Metal tags: 1. Where outside diameter of pipe or pipe covering is 5/8 inch or smaller, provide

metal pipe identification tags instead of lettering. 2. Fasten pipe identification tags to pipe with chain. 3. Where tags are used, color code pipe as scheduled.

3.04 BURIED PIPING IDENTIFICATION

A. Underground warning tape: 1. Place continuous run of warning tape in pipe trench, 12 inches above the pipe.

3.05 APPLICATION

A. Identify piping with legend markers, directional arrow markers, and number markers; use self-adhesive arrow roll tape to secure ends of piping markers and indicate flow direction.

B. Provide legend markers, directional arrow markers, and number markers where piping passes through walls or floors, at piping intersections and at maximum 15 foot spacing on piping runs.

C. Provide piping marker letters and colors as scheduled.

D. Place markers on piping so they are visible from operator's position in walkway or working platform near piping. Locate markers along horizontal centerline of pipe, unless better visibility is achieved elsewhere.

3.06 PIPING COLOR CODE AND MARKER SCHEDULE

Service Fluid Pipe Color Marker Legend Chemical Drain Charcoal CHEMICAL DRAIN

Cooling Water Blue COOLING WATER

Domestic Cold Water Light Blue DOMESTIC COLD WATER

Domestic Hot Water Light Blue DOMESTIC HOT WATER

Deionized Water Blue DEIONIZED WATER

Drain Charcoal DRAIN

Exhaust Gas Yellow EXHAUST GAS

Engine Jacket Water Dark Blue ENGINE JACKET WATER

Fuel Oil Orange FUEL OIL

Grit Black GRIT


Service Fluid Pipe Color Marker Legend Instrumental Air Purple INSTRUMENTATION AIR

Engine Lube Oil Red ENGINE LUBE OIL

Pumped Drain Charcoal PUMPED DRAIN

Process Water Dark Blue PROCESS WATER

Raw Wastewater Buff NONE USED

Return Water Silver/Grey RETURN WATER

Sample Green FLUID BEING SAMPLED

Sanitary Drain Charcoal SANITARY DRAIN

Service Air Green SERVICE AIR

Sodium Hypochlorite Yellow CHLORIDE SOLUTION

Sodium Bisulfite Yellow SODIUM BISULFITE SOLUTION

Tank Drain Charcoal TANK DRAIN

Vent Pipe Yellow VENT PIPE

Washdown Water (W3) Medium Blue WASHDOWN WATER

Letters Color of

Pipe Color of Bands

Color of Letters

Finished or Potable (cold) Light blue None Black

Potable (hot) Light blue Red Black

Nonpotable or Raw Light blue Dark Gray Black

Distilled or Demineralized Light Blue Black Black

Service Water (lines downstream from backflow prevention unit

Dark Blue White Red

Sample Dark Blue Black White

Fire Protection Red None Black

Hydrants Aluminum None Black

Filter-to-Waste Light Brown None Black

Wash Water Drain Light Gray None Black

Sewage Light Gray None Black

Solids Dark Brown None White

Scum Dark Brown None White

Drain Dark Gray None White

Sump Pump Pipe Line Dark Gray Red White


Letters Color of

Pipe Color of Bands

Color of Letters

Chlorine (gas, liquid, or vent) Yellow None Black

Chlorine (solution) Yellow Red Black

Ferric Chloride Orange Yellow Black

Alum Orange Yellow Black

Ammonia Yellow Dark Brown Black

Auxiliary Chemical Yellow Dark Blue Black

Sulfuric Acid Yellow Orange Black

Sodium Hydroxide Yellow Dark Green Black

Algaecide (Potassium Permanganate, Copper Sulfate)

Orange White Black

Polymer Orange Dark Green Black

Polyphosphate Orange Dark Gray Black

Carbon Black None White

Ozone None Red White

Stainless Steel Pipe White Red White

Ozone Off Gas

Stainless Steel Pipe None Orange White

Other Pipe White Orange White

Compressed Air Light Green None Black

Instrument Air Light Green Dark Green Black

Backwash Air (Low Pressure)

Stainless Steel Pipe None None Black

Other Pipe Light Green None Black

Process Air (Ozone-Low Pressure)

Stainless Steel Pipe None None Black

Other Pipe Light Green None Black

Laboratory Vacuum Dark Green Light Green Red

Natural Gas Red Yellow White

Refrigerant Yellow White Black

Heating Water (supply) Light Gray White Black

Heating Water (return) Light Gray Black Black

Condenser Water (supply) Light Gray Dark Brown Black


Letters Color of

Pipe Color of Bands

Color of Letters

Condenser Water (return) Light Gray Red Black

Chilled Water (supply) Light Brown Dark Gray White

Chilled Water (return) Light Brown Red White

END OF SECTION


SECTION 15082

PIPING INSULATION

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Insulation for piping and related systems.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01783 - Warranties and Bonds. 4. Section 15050 - Common Work Results for Mechanical Equipment. 5. Section 15052 - Common Work Results for General Piping. 6. Section 15076 - Pipe Identification. 7. Section 15282 - Copper Tube: Seamless, ASTM B280

1.02 REFERENCES

A. ASTM International (ASTM): 1. C177 - Standard Test Method for Steady-State Heat Flux Measurements and

Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus.

2. C518 - Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus.

3. C533 - Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation.

4. C547 - Standard Specification for Mineral Fiber Pipe Insulation. 5. C552 - Standard Specification for Cellular Glass Thermal Insulation. 6. C795 - Standard Specification for Thermal Insulation for Use in Contact with

Austenitic Stainless Steel. 7. C929 - Standard Practice for Handling, Transporting, Shipping, Storage,

Receiving, and Application of Thermal Insulation Materials for Use in Contact with Austenitic Stainless Steel.

8. C1136 - Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation.

9. E84 - Standard Test Method for Surface Burning Characteristics of Building Materials.

10. E96 - Standard Test Methods for Water Vapor Transmission of Materials.

1.03 DEFINITIONS

A. Buried: Piping that is installed below buildings, foundations, or finish grade, either in soil or encased in concrete in soil.

B. Concealed: Piping above suspended ceilings and within walls, partitions, shafts, or service spaces and spaces not normally exposed to view but not buried.


C. Exterior: Piping that is installed under canopies, outside a building, or within a pipe trench or tunnel.

D. Flame spread and smoke density: Burning characteristics determined in accordance with ASTM E84. No units apply to value.

E. Interior: Piping that is installed inside a building.

F. K factor: Thermal conductivity determined in accordance with ASTM C177 or C518 and expressed in units of BTU-inch/hour-square feet -degrees Fahrenheit.

G. Mineral fiber: Fibers manufactured of glass, rock, or slag processed from a molten state, with or without a binder.

H. Water vapor permeance: Water vapor transmission determined in accordance with ASTM E96 and expressed in units of perm-inch.

1.04 SUBMITTALS


B. Product data: As specified in Section15050. 1. Insulation properties: Include K factor, thickness, density, operating

temperature limits, tensile strength, compressive strength, moisture absorption, flame spread, and smoke developed in accordance with ASTM E84 and corrosivity to stainless steel piping in accordance with ASTM C795.

2. Jacket properties: Include covering material, cover thickness, tensile strength, tear strength, permeability in accordance with ASTM E96, flame spread, and smoke developed in accordance with ASTM E84, closure type or devices, and accessories.

3. Insulating blankets: Include materials, performance characteristics, method of attaching to equipment, listing of locations where insulating blankets will be installed.

4. Manufacturer's application instructions: Include assembly and application drawings and detailed instructions.

5. Laboratory report: Provide certified laboratory report stating that insulation is not manufactured using chlorinated polymers and does not contain chlorides, bromides, sulfates, or fire-rated materials.

C. Provide warranty as specified in Section 01783.

PART 2 PRODUCTS

2.01 PIPE INSULATION, GENERAL REQUIREMENTS


B. Insulation thicknesses: Provide insulation thickness in inches in accordance with the following table. Insulation thickness shown is nominal. Manufacturing tolerance of 15 percent variation is permissible.


Required Insulation Thicknesses (inches)

Service Temperature Range as Designated in Insulation

Schedule at End of this Section

Nominal Pipe Diameters 1 inch

and Less

1.25 to 2 inch

2.5 to 4 inch

5 to 10 inch

Over 10 inch

Above 200 degrees Fahrenheit 2.0 2.5 3.0 3.5 3.5 100 to 200 degrees Fahrenheit 1.5 1.5 1.5 2.0 2.5 40 to 100 degrees Fahrenheit 0.5 1.0 1.0 1.5 2.0 Below 40 degrees Fahrenheit 1.0 1.0 1.5 2.0 2.0 Heat Traced Pipes 1.0 1.0 1.0 1.5 2.0 Aeration Air Pipes 0.5 0.5 1.0 1.0 1.0

2.02 PIPE INSULATION

A. Insulation types: Provide in accordance with the insulation types listed and scheduled.

B. Insulation, Type 1: 1. Insulation material: Closed cell elastomeric insulation. 2. Manufacturers: One of the following or equal:

a. Armstrong World Industries, AP Armaflex. b. Apache Products Company, ISO-25.

3. Minimum temperature range: Minus 40 degrees Fahrenheit to plus 220 degrees Fahrenheit.

4. K factor at 75 degrees Fahrenheit: Not more than 0.27 BTU-inch/hour-square feet-degrees Fahrenheit.

5. Fire ratings: a. Flame spread: 25 or less. b. Smoke density: 50 or less for insulation thicknesses up to 1.5 inches.

6. Joints: Seal with manufacturer’s recommended contact adhesive to form continuous water barrier.

C. Insulation, Type 2: 1. Insulation material: Preformed mineral fiberglass insulation made from glass

fibers bonded with a thermosetting resin. a. In accordance with ASTM C547, Class 1. b. Provide with factory installed vapor barrier.

1) Material: White kraft paper bound to aluminum foil in accordance with ASTM C1136, Type I.

2) Longitudinal lap seals: Pressure-sensitive, self-sealing longitudinal lap strip with factory applied adhesive.

3) Circumferential butt seals: 4-inch wide tape or similar properties or 4-inch wide overlap with adhesive seal.

4) Vapor barrier permeability: 0.02 perms or lower. 5) Vapor barrier flame spread rating: 25 or less.

2. Minimum temperature range: Minus 0 degrees Fahrenheit to plus 850 degrees Fahrenheit.


3. K factor at 75 degrees Fahrenheit: Not more than 0.23 BTU-inch/hour-square feet degrees Fahrenheit.

4. Maximum moisture absorption, volume percent: 5. 5. Manufacturers: One of the following or equal:

a. Owens-Corning Fiberglas Corp. b. Johns Manville. c. Knauf Fiber Glass.

D. Insulation, Type 3: 1. Insulation material: Rigid cellular glass in accordance with ASTM C552,

Type II. 2. Temperature range: Minus 450 degrees Fahrenheit to plus 900 degrees

Fahrenheit. 3. K factor at 75 degrees Fahrenheit: Not more than 0.32 BTU-inch/hour-square

feet-degrees Fahrenheit. 4. Minimum average density: 7.5 pounds per cubic foot. 5. Maximum moisture absorption, volume percent: 5. 6. Minimum compressive strength: 87 pounds per square inch. 7. Moisture permeability: 0.00 perm-inch. 8. Manufacturers: One of the following or equal:

a. Pittsburgh Corning Corporation, Foamglas. b. Cell-U-Foam Corporation, Ultra-CUF.

E. Insulation, Type 4: 1. Insulation material: Asbestos-free, rigid calcium silicate in accordance with

ASTM C533; Type I for process temperatures up to 1,200 degrees Fahrenheit. 2. K factor at 500 degrees Fahrenheit: 0.55 for Type I. 3. Maximum average (dry) density: 14.5 pounds per cubic foot. 4. Compressive strength: 100 pounds per square inch, to produce a 5-percent

compression. 5. Manufacturers: One of the following or equal: In accordance with ASTM C533

Type I: a. Industrial Insulation Group, LLC, Thermo-12 Gold.

2.03 INSULATION JACKETS

A. Jacket, Type 1: 1. Material: 28 ounces per square yard polyvinyl chloride on polyester fabric; total

thickness 0.028 inches minimum. 2. Fire rating: 25 maximum flame spread, smoke developed 50 or less. 3. Color: As selected by the Engineer from manufacturer's standard colors. 4. Overlap: 1-inch minimum at joints and fittings. 5. Joint seal: Self-sealing lap tape. 6. Fittings: Factory made with full thickness insulation. 7. Manufacturers: One of the following or equal:

a. Accessible Products, Techlite Insulation, 379 SSL Series.

B. Jacket, Type 2: 1. Material: Ultraviolet-resistant polyvinyl chloride jacketing, 20 mil minimum

thickness. 2. Fire rating: 25 maximum flame spread, smoke developed 50 or less. 3. Color: White.


4. Overlap: 1-inch minimum at joints and fittings. 5. Joint seal: PVC solvent welded or adhesive as recommended by the

manufacturer. 6. Fittings: Factory made with full thickness insulation. 7. Manufacturers: One of the following or equal:

a. Johns Manville, Zeston 2000 PVC. b. Proto Corp., LoSMOKE PVC. c. Speedline Smoke Safe PVC Jacketing System. d. Knauf Covering System.

C. Jacket, Type 3: 1. Material: Aluminum, Alloy 5005; 0.016-inch (26 gauge) minimum thickness. 2. Overlap: Overlap circumferential joints 4 inches minimum; overlap longitudinal

joints 1-inch minimum; longitudinal joints oriented to minimize water entry. 3. Bands: 0.5 inch wide, 0.0508 inch (16 gauge) thick aluminum, same alloy as

jacket or 0.0179 inch thick Type 304 stainless steel; install on 18-inch centers, uniformly spaced and at all fitting joints.

4. Joint seal: Apply waterproof adhesive at joints and overlaps. 5. Fittings: Custom fit of same materials. 6. Manufacturers: One of the following or equal:

a. Childers Products. b. Premetco International.

2.04 VAPOR BARRIERS

A. Vapor barrier, Type 1: 1. Material: White kraft paper bound to aluminum foil in accordance with

ASTM C1136, Type 1. 2. Permeability: 0.02 perms or lower. 3. Maximum flame spread rating: 25. 4. Edge seal: Pressure-sensitive tape lap seal. 5. Circumferential joints: 4-inch wide tape or 4-inch overlap with adhesive seal.

B. Vapor barrier, Type 2: 1. Material: Mastic. 2. Manufacturers: One of the following or equal:

a. Benjamin Foster, No. 30-76. b. Insul-Coustic, No. I.C.-580. c. Foster Products, 36-10/46-10 Weatherite. d. Childers Products CP10/11 Vi-Acryl.


A. Cover adhesive: Premium adhesive as recommended by the insulation cover supplier for heavy-duty service in corrosive, wet environments. Standard-duty adhesives are not permitted.

2.06 REMOVABLE INSULATING BLANKETS

A. In piping systems specified to be insulated, use removable insulating blankets for valves, meters, strainers, filters, catalytic converters, engine exhaust silencers, and other in-line piping appurtenances and equipment requiring periodic servicing.


B. Size limits: Use removable insulating blankets for equipment and piping appurtenances 3-inch in nominal size and larger. Insulate equipment and piping appurtenances less than 3-inch with molded sections of insulation or by field cutting insulation to conform to the shape of the component and to fit tightly around the component.

C. Manufacturers: One of the following, or equal: 1. Pittsburgh Corning, Temp-Mat. 2. Accessible Products, Thermazip 2000 Jacket. 3. Thermal Energy Products, Inc., Energy Wrap.

D. Low temperature insulating blankets rated up to 800 degrees Fahrenheit: 1. Use: For service temperatures up to 800 degrees Fahrenheit. 2. Insulation: Fiberglass fiber, K factor 0.27 at 75 degrees Fahrenheit. 3. Cover: 17-ounce fabric with both sides covered with silicone-impregnated

glass cloth suitable for temperatures up to 800 degrees Fahrenheit. 4. Cover fasteners: Use one of the following systems:

a. Grommets in the blanket and stainless steel wire. b. 1-inch wide straps with stainless steel rectangular ring buckles and Velcro

on strap tail.

E. High temperature insulating blankets rated up to 1,400 degrees Fahrenheit: 1. Rated for sustained service temperatures up to 1,400 degrees Fahrenheit. 2. Insulation: Ceramic fiber, K factor 0.50 at 600 degrees Fahrenheit, insulation

material suitable for up to 2,300 degrees Fahrenheit, thickness to match adjacent piping insulation specified thickness.

3. Cover: 17-ounce silicone impregnated fiberglass cloth suitable for temperatures up to 1,400 degrees Fahrenheit.

4. Cover fasteners: Use one of the following systems: a. Grommets in the blanket and stainless steel wire. b. 1-inch wide straps with stainless steel rectangular ring buckles and Velcro

on strap tail.

2.07 SHIPPING


PART 3 EXECUTION



B. Store insulation materials and accessories under cover and protected from moisture.

C. Handle and store insulation for use on stainless steel in accordance with ASTM C929.


3.02 PREPARATION

A. Pressure test piping and complete application of coating system before applying insulation.

B. When piping is to be heat traced, install and functionally test heat tracing before installation of insulation.

C. Before beginning installation of piping insulation, verify that the Engineer has accepted piping tests, pipe coating applications, and heat tracing tests.

3.03 INSULATION SCHEDULEAD2

(1)

AD2 Addendum No. 2


Service

Designation(1) Location(2) Insulation

Type(3) Jacket Type(3) Service

Temp. °F(4) Vapor Barrier

Air Piping (AIR)(5) Interior or Exterior

1 or 2 Type 2 on Exterior

installations, Type 1 on

Interior installations

100-250 Install on Type 2

insulation

Non-Potable Water (NPW)(6)

Exterior 1 2 50-200 Required

Notes: (1) Refer to Piping Schedule in Section 15052 for service designations.

(2) Insulation jackets are not required for interior installations that are concealed. See definitions for description of concealed locations.

(3) Contractor may select from options listed. (4) Unless noted otherwise, use service temperature range provided in this table to establish

insulation thickness as required by Table in Article 2.01, Paragraph A. (5) Install insulation on all aeration air piping located within the Blower Building from the discharge of

blowers to 10 feet above floor slab. Insulation is not required for aeration air piping that is installed higher than 10 feet above the floor slab.

(6) Insulate all piping systems that are specified to be heat traced.

3.04 INSTALLATION

A. Install insulation and jacket materials in accordance with manufacturer's written instructions.

B. Apply insulation in smooth, clean manner with tight and finished smooth joints. Fit insulation tightly against surfaces. Insulate each continuous run of pipe with full-length sections of insulation with a single piece cut to length to complete the run of pipe. Do not use cut pieces or scraps to complete the installation.

C. Butt longitudinal and circumferential insulation joints firmly together.

D. Maintain the integrity of vapor barrier jacketing. Do not use staples to hold vapor barrier overlaps in place.

E. Apply sealant or cement when previous applications of adhesives and cement have thoroughly dried.

F. Apply insulation to permit expansion or contraction of pipelines without damage to insulation or jacketing.

G. Fittings: 1. Insulate fittings by covering with mitered sections of insulation or utilize

factory-made prefabricated fitting shapes. 2. Terminate preformed pipe jackets or covering at sufficient distance from

flanges to permit removal of bolts. 3. Overlap flange and flanged fitting insulation on adjacent pipe covering by at

least 2 inches.


H. Valves: 1. Insulate valves 3-inch in nominal size and larger with removable insulating

blankets. 2. Size blanket to extend up to packing gland only so that replacement of packing

does not require removal of insulating blanket.

I. Provide continuous insulation through and over pipe supports and provide protection saddles at supports.

J. Extend insulation against insulation end protection shields or covers so that insulation voids do not exist and provide watertight end seals and covers where insulation terminates.

K. Insulate pipeline strainers to permit removal of strainer basket without disturbing insulation on strainer body.

L. Provide continuous pipe insulation and covering through sleeves or openings in walls and floors. When buried pipe enters a building through a below grade wall or slab penetration, begin insulation system on interior side of penetration.

M. Apply premolded pipe insulation with extended legs when used on pipe traced with either tubing or electric cable type.

N. Thermally isolate all insulation closure locations (end caps, transitions, etc.) Type 1 or 2 jacket installation on piping with potential reach temperatures greater than 150 degrees Fahrenheit.

O. Apply piping identification on jackets as specified in Section 15076.

END OF SECTION


SECTION 15084

DUCTWORK INSULATION

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Internal acoustical insulation and external thermal insulation for metal air ductwork systems.

B. Related sections: 1. Section 01330 - Submittal Procedures. 2. Section 01410 - Regulatory Requirements. 3. Section 15052 - Common Work Results for General Process Piping.

1.02 REFERENCES

A. ASTM International (ASTM): 1. E84 - Standard Test Method for Surface Burning Characteristics of Building

Materials. 2. G21 - Standard Practice for Determining Resistance of Synthetic Polymeric

Materials to Fungi.

B. Sheet Metal and Air Conditioning Contractor's National Association (SMACNA).

1.03 SUBMITTALS


B. Product data: As specified in Section 15052.


A. Comply with SMACNA ducting construction standards and the specified requirement, whichever is more stringent.

PART 2 PRODUCTS

2.01 INTERNAL DUCTWORK INSULATION

A. Manufacturers: One of the following or equal: 1. Owens Corning, QuietR flexible duct liner or Fiberglass rigid duct liner. 2. Johns Manville, Linacoustic RC flexible duct liner.

B. Type: Flexible or board type duct liner with 1 coated surface meeting the following: 1. Thickness: As required to achieve the following R-values:

a. For interior ducting in ceiling plenums, attics or other unconditioned spaces provide 1-1/2 inches minimum thickness to meet an installed value of R4.2.


2. Temperature range: 40 to 250 degrees Fahrenheit. 3. Density: 1.5 pounds per cubic foot. 4. Thermal conductivity: 0.25 Btu-inch per hour per square foot per degree

Fahrenheit at 75 degrees Fahrenheit. 5. Fire hazard classification in accordance with ASTM E84:

a. Flame spread: 25. b. Smoke developed: 50.

6. Service conditions: Velocities to 2,500 feet per minute. 7. Acoustical performance: NRC of 0.55 minimum. 8. Bacterial growth: None in accordance with ASTM G21.

C. Edge treatment: Provide leading edges with galvanized metal nosing; seal other edges with manufacturer's recommended edge treatment.

PART 3 EXECUTION

3.01 INTERNAL DUCTWORK INSULATION

A. Provide rigid insulation on rectangular ducts carrying conditioned air that pass through outdoor or unconditioned spaces, or as indicated for the following systems: 1. HB-SST-AHU-001, supply. 2. HB-SST-AHU-002, supply. 3. HB-SST-AHU-003, supply.

B. Install with coated surface facing inside of duct; attach with adhesive to duct and provide fasteners spaced at not to exceed 12 inches transverse (perpendicular) to flow and 18 inches parallel (longitudinal) to flow; provide fasteners within 3 inches of transverse edges and 4 inches of longitudinal edges.

C. Follow manufacturer's published installation instructions.

D. Install metal nosing on leading edges and seal other exposed edges with manufacturer's edge treatment.

END OF SECTION


SECTION 15110

COMMON WORK RESULTS FOR VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Basic requirements for valves.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01730 - Operation and Maintenance Data. 3. Section 01650 - Facility Startup/Commissioning. 4. Section 09960 - High-Performance Coatings. 5. 511S - Water Valves.

1.02 REFERENCES

A. American Water Works Association (AWWA): 1. C111/A21.11 - Standard for Rubber-Gasket Joints for Ductile-Iron Pressure

Pipe Fittings.

B. ASTM International (ASTM): 1. A126 - Standard Specification for Gray Iron Casting for Valves, Flanges, and

Pipe Fittings. 2. A167 - Standard Specification for Stainless and Heat-Resisting Chromium-

Nickel Steel Plate, Sheet, and Strip. 3. A536 - Standard Specification for Ductile Iron Castings.

C. NSF International (NSF): 1. 61 - Drinking Water System Components - Health Effects.

D. Society for Protective Coatings (SSPC): 1. SP 7 - Brush-Off Blast Cleaning. 2. SP 10 - Near-White Blast Cleaning.


A. Pressure rating: 1. Suitable for service under minimum working pressures of 150 pounds per

square inch gauge. 2. When a piping system is specified in the Piping Schedule to be tested at a

pressure greater than 150 pounds per square inch gauge, provide valves for that piping system with design working pressure which is sufficient to withstand the test pressure.

B. Valve to piping connections: 1. Valves 3 inch nominal size and larger: Flanged ends. 2. Valves less than 3 inch nominal size: Screwed ends.


3. Plastic valves in plastic piping: a. Up to 2.5 inches: Provide solvent or heat welded unions. b. 3 inches and above: Provide solvent or heat welded flanges.

1.04 SUBMITTALS


B. Product data: 1. Submit the following information for each valve:

a. Valve type, size, pressure rating, Cv factor. b. Coatings. c. Power valve actuators:

1) Information on valve actuator including size, manufacturer, model number, limit switches, mounting; and motor enclosure, seating and unseating torque coefficient, dynamic torque, and bearing friction for calculation of maximum operating torque.

2) Complete wiring diagrams and control system schematics. d. Manual valve actuators:

1) Information on valve actuator including size, manufacturer, model number.

e. Certified drawings with description of component parts, dimensions, weights, and materials of construction.

f. Certifications of reference standard compliance: 1) Submit certification that the valves and coatings are suitable in

potable water applications in accordance with NSF 61. g. Clearly mark submittal information to show specific items, materials, and


C. Provide vendor operation and maintenance manual as specified in Section 01730. 1. Furnish bound sets of installation, operation, and maintenance instructions for

each type of manual valve 4 inch in nominal size and larger, and all non-manual valves. Include information on valve operators.

D. Provide Manufacturer’s Certificate of Source Testing as specified in Section 01650.

E. Provide Manufacturer’s Certificate of Installation and Functionality Compliance as specified in Section 01650.


A. Manufacturer qualifications: 1. Valves manufactured by manufacturers whose valves have had successful

operational experience in comparable service.

1.06 DELIVERY STORAGE AND HANDLING

A. Protect valves and protective coatings from damage during handling and installation; repair coating where damaged.


PART 2 PRODUCTS

2.01 MATERIALS

A. Stainless steel: In accordance with ASTM A167, Type 316, or Type 304, UNS Alloy S31600 or S30400.

B. Valve and operator bolts and nuts: 1. Fabricated of stainless steel for the following installation conditions:

a. Submerged in sewage or water. b. In an enclosed space above sewage or water. c. In structures containing sewage or water, below top of walls. d. At openings in concrete or metal decks.

2. Where dissimilar metals are being bolted, use stainless steel bolts with isolation bushings and washers.

3. Underground bolts: Low-alloy steel in accordance with AWWA C111/A21.11.

C. Bronze and brass alloys: Use bronze and brass alloys with not more than 6 percent zinc and not more than 2 percent aluminum in the manufacture of valve parts; UNS Alloy C83600 or C92200 unless specified otherwise.

D. Valve bodies: Cast iron in accordance with ASTM A126, Class 30 minimum or ductile iron in accordance with ASTM A536, Grade 65-45-12 minimum unless specified otherwise.

2.02 INTERIOR PROTECTIVE LINING

A. When specified in the particular valve specification, provide valves with type of protective lining specified in the particular valve Specification.

B. Apply protective lining to interior, non-working surfaces, except stainless steel surfaces.

C. Lining types: 1. Fusion bonded epoxy:

a. Manufacturers: One of the following or equal: 1) 3-M Company, ScotchKote 134; certified to NSF 61 for drinking water

use. b. Clean surfaces in accordance with SSPC SP 7 or SP 10, as

recommended by epoxy manufacturer. c. Apply in accordance with manufacturer's published instructions. d. Lining thickness: 0.010 to 0.012 inches except that:

1) Lining thickness in grooves for gaskets: 0.005 inches. 2) Do not coat seat grooves in valves with bonded seat.

e. Quality control: 1) Lining thickness: Measured with a non-destructive magnetic type

thickness gauge. 2) Verify lining integrity with a wet sponge-testing unit operating at

approximately 60 volts, or as recommended by the lining manufacturer.

3) Consider tests successful when lining thickness meets specified requirements and when no pinholes are found.


4) Correct defective lining disclosed by unsuccessful tests, and repeat test.

5) Repair pinholes with liquid epoxy recommended by manufacturer of the epoxy used for lining.

2. High solids epoxy: a. Product equivalent to high solids epoxy specified in Section 09960.

1) Certified in accordance with NSF 61 for drinking water use. 2) Interior: Coat valve interior with manufacturer's equivalent high

performance high solids epoxy coating system with a certifiable performance history for the service conditions and as approved by the Engineer. Manufacturer shall provide for approval, coating information sufficient to allow Engineer to assess equivalence to the specified high solids epoxy coating specified in Section 09960.

b. Clean surfaces to meet SP-7 or SP-10, or as recommended by coating manufacturer.

c. Quality control: After coating is cured, check coated surface for porosity with a holiday detector set at 1,800 volts, or as recommended by coating manufacturer. 1) Repair holidays and other irregularities and retest coating. 2) Repeat procedure until holidays and other irregularities are

corrected.

2.03 UNDERGROUND VALVES

A. Provide underground valves with flanged, mechanical, or other type of joint required for the type of pipe to which the valve is to be connected.

B. Coating and wrapping: 1. After installation, encase valves in 2 layers of polyethylene wrap as specified

for ductile iron piping in Section 15211. a. Ascertain that polyethylene wrapping does not affect operation of valve.

2.04 FIELD APPLIED COATING OF VALVE EXTERIOR

A. Match color and be compatible with manufacturer’s coating system and as specified in Section 09960. 1. When shop applied finish coating matches field applied coating on adjacent

piping, touch up shop coating in damaged areas in accordance with instructions recommended by the paint manufacturer.

2. When shop applied coating does not match field coating on adjacent piping, or when damage has occurred to the shop applied coating that requires more than touchup, blast clean valve surfaces or utilize other surface preparation recommended by the manufacturer of the coating material and apply the coating system used for coating adjacent piping.

2.05 VALVE BOXES

A. Provide cast-iron valve boxes at each buried valve to access valve and valve operators.

B. Do not support boxes on valve, valve operator, or pipe.


C. Boxes: 1. 2-piece, fabricated of cast iron; provide cover, with asphalt varnish or enamel

protective coating. 2. Adjustable to grade, install centered around the upper portions of the valve

and valve operator.

D. Manufacturers: One of the following or equal: 1. Tyler Pipe Industries, Inc. 2. Neenah Foundry Company.

2.06 VALVE OPERATORS

A. Valve operator "Open" direction: Open counterclockwise.

B. Provide valves located below operating level or deck with extensions for key operation or floor stands and handwheels.

C. Provide manually operated valves located not more than 6 feet above the operating level with tee handles, wrenches, or handwheels. 1. Make the valve operator more conveniently accessible by rolling valves,

located more than 5 feet but less than 6 feet above the operating level, toward the operating side.

2. Secure tee handles and wrenches to the valve head or stem, except where a handle or wrench so secured constitutes a hazard to personnel; in which case, stow handle or wrench immediately adjacent to the valve on or in a suitable hanger, bracket, or receptacle.

D. Fit valves located more than 6 feet above operating level with chain operated handles or valve wheels. 1. Chains: Sufficient length to reach approximately 4 feet above the operating

level. 2. Where chains constitute a nuisance or hazard to operating personnel, provide

holdbacks or other means for keeping the chains out of the way.

E. Provide an operator shaft extension from valve or valve operator to finished grade or deck level when buried valves, and other valves located below the operating deck or level, are specified or indicated on the Drawings to be key operated; provide 2 inch square AWWA operating nut, and box and cover as specified, or a cover where a box is not required.

PART 3 EXECUTION

3.01 EXAMINATION

A. Preparation prior to installation: 1. Install valves after the required submittal on installation has been accepted. 2. Determine after flanged valves and flanged check valves are selected, the

face-to-face dimensions of flanged valves and flanged check valves.

B. Fabricate piping to lengths taking into account the dimensions of flanged valves and flanged check valves.


3.02 INSTALLATION

A. Provide incidental work and materials necessary for installation of valves including flange gaskets, flange bolts and nuts, valve boxes and covers, concrete bases, blocking, and protective coating.

B. Where needed, furnish and install additional valves for proper operation and maintenance of equipment and plant facilities under the following circumstances: 1. Where such additional valves are required for operation and maintenance of

the particular equipment furnished by Contractor. 2. Where such additional valves are required as a result of a substitution or

change initiated by Contractor.

C. Install valves with their stems in vertical position above the pipe, except as follows: 1. Butterfly valves, gate valves aboveground, globe valves, ball valves, and angle

valves may be installed with their stems in the horizontal position. 2. Install buried plug valves with geared operators with their stems in a horizontal

position.

D. Install valves so that handles clear obstructions when the valves are operated from fully open to fully closed.

E. Place top of valve boxes flush with finished grade or as otherwise indicated on the Drawings.

F. Valves with threaded connections: 1. Install valves by applying wrench on end of valve nearest the joint to prevent

distortion of the valve body. 2. Apply pipe joint compound or Teflon tape on external (male) threads to prevent

forcing compound into valve seat area.

G. Valves with flanged connections: 1. Align flanges and gasket carefully before tightening flange bolts. 2. When flanges are aligned, install bolts and hand tighten. 3. Tighten nuts opposite each other with equal tension before moving to next pair

of nuts.

H. Valves with soldered connections: 1. Do not overheat connection to prevent damage to resilient seats and metal

seat rings. 2. Position valves in full open position before starting soldering procedure. 3. Apply heat to piping rather than to valve body.

3.03 COMMISSIONING


B. Manufacturer services from each manufacturer for all valves supplied: 1. Provide Manufacturer’s Certificate of Source Testing. 2. Provide Manufacturer’s Certificate of Installation and Functionality

Compliance.


C. As specified elsewhere for specific valve types, sizes or actuators. 1. Source testing. 2. Manufacturers on site services for Owner Training, Installation Testing,

Functional Testing, and during the Process Operational Period.

END OF SECTION


SECTION 15111

BALL VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Ball valves.


C. Related sections: 1. Section 01330 - Submittals. 2. Section 01650 – Facility Startup/Commissioning. 3. Section 01783 - Warranties and Bonds. 4. Section 09960 - High-Performance Coatings. 5. Section 13446 - Manual Actuators. 6. Section 13447 - Electric Motor Actuators. 7. Section 15052 - Common Work Results for General Piping. 8. Section 15110 - Common Work Results for Process Valves.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and

250. 2. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

B. American Water Works Association (AWWA): 1. C507 - Standard for Ball Valves 6 Inch Through 48 Inch.

C. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A216 - Standard Specification for Steel Castings, Carbon, Suitable for Fusion

Welding, for High-Temperature Service. 3. A351 - Standard Specification for Castings, Austenitic, for Pressure-Containing

Parts.


A. General: Unless otherwise indicated on the Drawings use: 1. Metal body ball valves on metallic pipelines. 2. Plastic body ball valves on plastic pipelines.

B. Do not use metal body ball valves in sodium hypochlorite or sodium bisulfite systems.

1.04 SUBMITTALS



B. Product data: As specified in Section 15110: 1. Metal body ball valves: 6 inches and larger only: Submit affidavit of compliance

in accordance with AWWA C507. 2. Operation and maintenance manual.

C. Commissioning submittals: 1. Provide Manufacturer’s Certificate of Installation and Functionality Compliance


1.05 WARRANTY


PART 2 PRODUCTS

2.01 METAL BODY BALL VALVES, LESS THAN 6 INCH SIZE

A. Manufacturers: One of the following, or equal: 1. Apollo Valves as manufactured by Conbraco Industries, Inc. 2. Metso Automation/Jamesbury. 3. NIBCO, Inc. 4. Flow-Tek, Inc.

B. General: 1. Type: Non-lubricated, full port and capable of sealing in either direction. 2. End connections:

a. Threaded or solder ends for sizes 3-inch and smaller. b. Class 150 flanged for sizes larger than 3 inch.

1) Flanges: In accordance with ASME B16.1 standards. 3. Stem packing: Manually adjustable while valve is under pressure. 4. Shafts:

a. Rigidly connected to the ball by a positive means. 1) Design connection to transmit torque equivalent to at least

75 percent of the torsional strength of the shaft. 5. Handles: Stainless steel latch lock handle with vinyl grip and stainless steel nut

designed to open and close the valve under operating conditions. 6. Temperature limits: Suitable for operation between minus 20 and 350 degrees

Fahrenheit.

C. Materials: 1. Valves in copper lines: Bronze body. 2. Valves in steel and ductile iron piping: Ductile iron or cast steel body. 3. Valves in stainless steel piping: Stainless steel body, material type to match

piping material as specified in Section 15052. 4. Ball: Type 304 or 316 stainless steel, Type 316 in digester gas applications. 5. Seats: PTFE. 6. Stem seals: PTFE or Viton. 7. Bearings: Self-lubricated, corrosion resistant material that will not contaminate

potable water. 8. Valves for combustible fluid applications (digester gas, natural gas, fuel oil,

etc.) must be of fire safe design.


2.02 PLASTIC BODY BALL VALVES

A. Manufacturers: One of the following or equal: 1. Asahi America. 2. Chemtrol Division, NIBCO, Inc. 3. Plast-O-Matic Valves, Inc. 4. Georg Fisher Piping Systems.

B. General: 1. Type: Non-lubricated and capable of sealing in either flow direction. 2. End connections: True union; solvent or heat welded to piping. 3. Operator handle: Lever.

C. Materials: 1. Body: Polyvinyl chloride (PVC). 2. Ball: Polyvinyl chloride (PVC). 3. Seats: PTFE (Teflon). 4. O-rings: EPDM.

PART 3 EXECUTION

3.01 INSTALLATION

A. General: Install each type of valve in accordance with manufacturers' printed instructions.

B. Special techniques: 1. PVC ball valves for hypochlorite service:

a. Provide valve with factory drilled 0.125-inch hole in the upstream side of the ball.

b. Provide an engraved plastic tag permanently attached to the valve stem stating "One side of ball drilled for hypochlorite service".

3.02 COMMISSIONING


B. Manufacturer services: 1. Provide certificates:

a. Manufacturer's Certificate of Installation and Functionality Compliance.

C. Functional testing: 1. Valves:

a. Test witnessing: Witnessed. b. Conduct pressure and leak test, as specified in Section 15110.

END OF SECTION

SECTION 15112

BUTTERFLY VALVES FOR AIR SERVICE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Metal body butterfly valves for air service.

B. Related sections: 1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the

Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work.

3. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents. a. Section 01300 – Submittals b. Section 01730 – Operations and Maintenance Data. c. Section 09960 – High-Performance Coatings. d. Section 13446 – Manual Actuators. e. Section 15110 – Common Work Results for Valves.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.1 – Cast Iron Pipe Flanges and Flanged Fittings, Classes 25, 125 and

250. 2. B16.5 – Pipe Flanges and Flanged Fittings, NPS 1/2 through NPS 24.

B. American Water Works Association (AWWA): 1. C110 – Standard for Ductile-Iron and Gray-Iron Fittings. 2. C504 – Rubber-Seated Butterfly Valves. 3. C540 – Standard for Power-Actuating Devices for Valves and Sluice Gates. 4. C550 – Protective Interior Coatings for Valves & Hydrants. 5. C606 – Standard for Grooved and Shouldered Joints.

C. ASTM International (ASTM): 1. A 126 – Standard Specification for Gray Iron Castings for Valves, Flanges, and

Pipe Fittings. 2. A 216 – Standard Specification for Steel Castings, Carbon, Suitable for Fusion

Welding, for Higher-Temperature Service. 3. A 276 – Standard Specification for Stainless Steel Bars and Shapes. 4. A 351 – Standard Specification for Castings, Austenitic, for

Pressure-Containing Parts. 5. A 395 – Standard Specification for Ferritic Ductile Iron Pressure-Retaining

Castings for Use at Elevated Temperatures.

6. A 479 – Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels.

7. A 515 – Standard Specification for Pressure Vessel Plates, Carbon Steel, for Intermediate – and Higher-Temperature Service.

8. A 516 – Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate – and Lower-Temperature Service.

9. A 536 – Standard Specification for Ductile Iron Castings. 10. A 564 – Standard Specification for Hot-Rolled and Cold-Finished Age-

Hardening Stainless Steel Bars and Shapes. 11. A 582 – Standard Specification for Free-Machining Stainless Steel Bars 12. A 743 – Standard Specification for Castings, Iron-Chromium, Iron-Chromium-

Nickel, Corrosion Resistant, for General Application. 13. B 584 – Standard Specification for Copper Alloy Sand Castings for General

Applications. 14. D 429 – Standard Test Methods for Rubber Property-Adhesion to Rigid

Substrate.

D. Compressed Gas Association (CGA): 1. Standard G-4.1 – Cleaning Equipment for Oxygen Service.

E. NSF International (NSF): 1. Standard 61 – Drinking Water System Components – Health Effects.


A. Design requirements: 1. General purpose AWWA butterfly valves:

a. Design standard: Provide valves designed and manufactured in accordance with AWWA C504.

b. Class: 1) Provide butterfly valves in accordance with AWWA Class 150B,

unless otherwise specified. 2) Provide butterfly valves in accordance with AWWA Class 250B in

piping systems with test pressure greater than 150 pounds per square inch and less than 250 pounds per square inch.

2. Industrial class butterfly valves: a. Industrial class butterfly valves capable of 150 pounds per square inch

leak tight shut off. 3. Stainless steel butterfly valves:

a. Stainless steel butterfly valves capable of a minimum of 100 pounds per square inch leak tight shut off and with special cleaning, packaging, and handling.

B. Usage: 1. Provide and install butterfly valve types as outlined in the Butterfly Valve

Application Schedule at the end of this Section.

C. Design requirements for all butterfly valves with power actuating devices: 1. Design valves and actuators for maximum operating torque, in accordance

with and using safety factors required in AWWA C540, using the following values: a. Maximum water velocity: 16 feet per second with valve fully open.

b. Maximum pressure differential across the closed valve equal to the pressure class designation.

c. Coefficient for seating and unseating torque, dynamic torque, and bearing friction in accordance with valve manufacturer's published recommendations.

2. Valve disc: Seat in an angular position of 90 degrees to the pipe axis and rotate an angle of 90 degrees between fully open and fully closed positions: a. Do not supply valves with stops or lugs cast with or mechanically secured

to the body of the valve for limiting the disc travel. 3. Unacceptable thrust bearings: Do not provide valves with thrust bearings

exposed to the fluid in the line and consisting of a metal bearing surface in rubbing contact with an opposing metal bearing surface.

D. Performance requirements: 1. Tight shutoff at the pressure rating of the valve with pressure applied in either

direction. 2. Suitable for the following service conditions:

a. Throttling. b. Frequent operation. c. Operation after long periods of inactivity. d. Installation in any position and flow in either direction.

1.04 SUBMITTALS

A. Shop drawings: Submit the following information as specified in Section 01300 and Section 15110: 1. Product data:

a. For valves greater than or equal to 36 inches, include manufacturer's published recommendations for seating and unseating torque coefficient, dynamic torque, and bearing friction for calculation of maximum operating torque.

2. Certificates: a. General purpose AWWA butterfly valves:

1) Proof-of-design tests: Certified statement that proof-of-design tests were performed and all requirements were successfully met.

2) Affidavit of compliance attesting valves provided comply with all provisions in accordance with AWWA C504.

b. Interior epoxy coatings: Affidavit of compliance attesting that epoxy coatings applied to interior surfaces of butterfly valves comply with all provisions in accordance with AWWA C550.

c. Certification, for all valves and coatings in contact with potable water, that the products used are suitable for contact with drinking water in accordance with NSF Standard 61.

3. Operation and Maintenance Manual as specified in Section 01730.

1.05 WARRANTY



A. Protect valves and protective coatings and linings from damage during handling and installation; repair coating or lining where damaged.

B. Deliver, store, and handle products in accordance with Section 01600.

PART 2 PRODUCTS

2.01 GENERAL PURPOSE AWWA BUTTERFLY VALVES

A. Manufacturers: One of the following or equal: 1. DeZurik/Sartell Model BAW. 2. Henry Pratt Company. 3. Bray Controls.

B. Valve body: 1. Material: Cast iron, ASTM A 126, Grade B, or ductile iron, ASTM A 536, Grade

65-45-12. 2. Body design:

a. Flanged body valves: 1) Usage: Comply with limitations specified in the Butterfly Valve

Application Schedule. 2) Flanges: In accordance with ASME B16.1 Class 125 flanges for

Class 150B valves, in accordance with ASME B16.1 Class 250 flanges for Class 250B valves.

C. Disc: 1. Material: Cast iron or ductile iron with Type 316 stainless steel edge that

matches seat in valve body. 2. Secure valve disc to shaft by means of smooth-sided, taper or dowel pins,

Type 316 stainless steel, or Monel. 3. Extend pins through shaft and mechanically secure in place.

D. Shaft and bearings: 1. Shaft design:

a. Valves 20-inch and less: 1 piece, through disc design. b. Valves greater than 20-inch size: 2 piece, stub shaft design.

2. Shaft seal: Vee type, chevron design. 3. Shaft material for Class 150B valves: Type 316 stainless steel, ASTM A 276. 4. Shaft material for Class 250B valves: Type 17-4 pH stainless steel,

ASTM A 564. 5. Shaft bearings: Self-lubricating sleeve type:

a. Valves 20-inch and less: Nylatron. b. Valves greater than 20-inch size: Teflon with stainless steel or fiberglass

backing.

E. Seats: 1. Seat materials:

a. In low-pressure air applications: EPDM. b. In all other applications: NBR or natural rubber.

2. For valves 20 inches in nominal size and smaller, bond or vulcanize seat into the valve body.

3. For valves 24 inches in nominal size and larger, retain seats mechanically or by adhesive: a. Mechanical retainage: Retain seat by a clamping ring with segmented

clamping ring locks with adjusting locking screws.

1) Clamping ring, ring locks, and adjusting locking screws: Type 316 stainless steel.

2) Provide means to prevent ring locks and screws used to retain seats from loosening due to vibration or cavitation.

b. Adhesive retainage: Inset the seat within a groove in the valve body and retain in place with epoxy injected behind the seat so that the seat expands into the body.

c. Do not provide valves with seats retained by snap rings or spring-loaded retainer rings.

4. Resilient seat: Withstand 75 pound per inch pull when tested in accordance with ASTM D 429, Method B.

F. Valve packing: 1. Valves 4 inch to 48 inch nominal size: Self-adjusting V-type packing or

chevron-type packing. NBR or EPDM to match seat material.

2.02 INDUSTRIAL CLASS BUTTERFLY VALVES

A. Manufacturers: One of the following or equal: 1. SPX/DeZurik Style BOS. 2. Tyco-Keystone Figure AR2. 3. Bray Series 31 Resilient Seated Butterfly Valve. 4. Henry Pratt, BF Series.

B. Valve body: 1. Pressure rating: 125 pounds per square inch, minimum. 2. Material: Cast iron, ASTM A126, Class B, or Ductile Iron, ASTM A 395,

Grade 60-40-18 or ASTM A536 Grade 65-45-12. 3. Body design: Lugged style body with drilled and tapped bolt holes in

accordance with ASME B16.1, Class 125 and Class 150 flange drilling dimensions.

C. Disc: 1. Materials:

a. For valves 20 inches in nominal size and smaller: Type 316 stainless steel, ASTM A 351, Grade CF8M.

b. For valves 24 inches in nominal size and larger: Cast iron, ASTM A 126, Class B or Ductile Iron, ASTM A 536, Grade 65/45/12

2. Disc edge: Nickel-plated or Type 316 stainless steel when cast iron or ductile iron disc is used.

D. Shaft and bearings: 1. Shaft: Type 316 stainless steel, ASTM A 276. 2. Shaft bearings: Self-lubricating sleeve type, either Teflon with stainless steel or

fiberglass backing, or Rulon®. a. Bearings must be rated up to at least 250 deg F operating temperature.

E. Disc pins (if applicable): Secure valve disc to shaft by means of solid, smooth-sided, taper or dowel pins. No pins are required if disc design utilizes positive engagement. 1. Material: Type 316 stainless steel 2. Extend pins through shaft and mechanically secure in place.

F. Seats: 1. Material:

a. All applications: EPDM. 2. Seat retention ring, if used on larger sizes: Type 316 stainless steel or bronze,

ASTM B 584, with stainless steel fasteners. For all such valves, bond the seat to the retention ring.

G. Valve shaft packing: 1. All applications: EPDM or Teflon.

2.03 BUTTERFLY VALVE ACTUATORS

A. Provide four-key mounting position for valve actuators, where available.

B. Cylinder actuators, motorized actuators, and portable actuators are specified in Section 13447. Additional requirements for manual actuators are specified in Section 13446.

C. Manual actuators for aboveground valves, 4 inches in nominal size and smaller for liquid service, and 10 inches in nominal size and smaller for aeration air service. 1. For valves operating at pressures up to and including 250 pounds per square

inch, provide hand lever type with locking device so that the valve can be locked in any position with a wing nut. a. Locking device: Rigid, allowing no vibration or chattering of the valve. b. Hand lever: 12 inches long, with handgrip.

2. For valves operating at pressures above 250 pounds per square inch, provide totally enclosed worm gear actuator mounted on the valve.

3. If hand levers are unavailable, handwheel type actuators are an acceptable alternative.

D. Manual actuators for aboveground valves in nominal sizes and in service applications other than specified above, except for valves 30 inches and larger. 1. For valves operating at pressures up to and including 250 pounds per square

inch, provide either a totally enclosed worm gear actuator or a totally enclosed traveling nut actuator mounted on the valve.

2. For valves operating at pressures above 250 pounds per square inch, provide totally enclosed worm gear actuator mounted on the valve.

E. Manual actuators for aboveground valves 30 inches in nominal size and larger, all pressures. 1. Provide totally enclosed worm gear actuator mounted on the valve.

F. Link Arm Chainwheel actuators for valves higher than 6 feet from the ground

G. Manual actuators for buried or submerged valves, all sizes, and pressures. 1. Provide totally enclosed worm gear actuator mounted on the valve. 2. Actuators for buried or submerged valves: Hermetically sealed and grease

packed. 3. For buried valves, provide 2-inch square AWWA nut on enclosed actuator. 4. For buried valves, provide extension stem, valve box, and valve box cover as

specified in Section 15110. 5. For submerged valves, provide extension stem as indicated on the Drawings.

H. Position indication: 1. For all aboveground worm gear or traveling nut manual actuators, provide

position indication on the actuator enclosure.

I. Limit switches: Provide limit switches on manually actuated valves where indicated on the Drawings: 1. Limit switches: Heavy-duty, industrial grade, oiltight, with not less than

2 auxiliary contacts. 2. Rating: Rated for 10 amps, 120 volts alternating current. 3. Enclosure: NEMA 4X enclosure and with stainless steel levers and arms.

Provide switch with NEMA 7 enclosure when switch is located within areas with NEC Class 1, Division 1 or Class 1, Division 2 designations as indicated on the Drawings.

2.04 COATING

A. Shop coat interior and exterior metal surfaces of valves, except as follows: 1. Interior machined surfaces. 2. Surfaces of gaskets and elastomeric seats and stem seals. 3. Bearing surfaces. 4. Stainless steel surfaces and components.

B. Coating material for potable water applications: 1. Formulate coating material from materials in accordance with the Food and

Drug Administration, Title 21 of the Code of Federal Regulations on Food Additives.

C. Field applied coatings: 1. Additional coating of the valve exterior will be required to match the epoxy or

epoxy/polyurethane paint system. a. When shop applied finish coating matches field applied coating on

adjacent piping, touch up shop coating in damaged areas in accordance with instructions recommended by the paint manufacturer.

b. When shop applied coating does not match field coating on adjacent piping, or when damage has occurred to the shop applied coating that requires more than touchup, blast clean valve surfaces or utilize other surface preparation recommended by the manufacturer of the coating material and apply the coating system used for coating adjacent piping.

D. Surface coatings: 1. Interior surfaces, except for valves used in low-pressure air service: High

solids epoxy. 2. Interior surfaces of valves used in low-pressure air service: High temperature

coating for range of 150 to 350 degrees Fahrenheit. 3. Exterior surfaces of valves, actuators, and accessories:

a. Submerged valves: High solids epoxy. b. Buried valves: Coal tar epoxy. c. Other valves: High solids epoxy with polyurethane topcoat.

4. Polished and machined surfaces: Apply rust-preventive compound.

E. Coating materials: 1. High solids epoxy:

a. Products: Ameron Amerlock 2: 1) Coating product in contact with potable water must be in accordance

with AWWA C550 and NSF 61. 2. High temperature coating 150 to 350 degrees fahrenheit: Ameron Amerlock

2/400 and in accordance with AWWA C550. 3. Rust-preventive compound: One of the following or equal:

a. Houghton, Rust Veto 344. b. Rust-Oleum, R-9.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install valves with valve shafts horizontal, unless a vertical shaft is required to suit a particular installation, and unless a vertical shaft is indicated on the Drawings.

B. Install pipe spools or valve spacers in locations where butterfly valve disc travel may be impaired by adjacent pipe lining, pipefittings, valves, or other equipment.

3.02 TESTING

A. The tests shall include performance tests, leakage test and hydrostatic tests per AWWA C504.

3.03 BUTTERFLY VALVE APPLICATION SCHEDULE

A. Acceptable butterfly valve types and body styles are listed in the Butterfly Valve Application Schedule provided at the end of this Section. Furnish and install butterfly valves in accordance with this Schedule.

BUTTERFLY VALVE APPLICATION SCHEDULE Valve Type and Style Acceptable Applications

General Purpose AWWA Butterfly Valves – Flanged Body Design

Aboveground or submerged in the following service applications only: - Acceptable in all service applications except oxygen

and ozone service and high-pressure service - Aeration air piping inside Blower Room and aeration

air flow control valves - May be used in buried applications when required by

the specified piping system Industrial Class Butterfly Valves – Lugged Body Design

Aboveground in the following service applications only: - Aeration Air Systems - Natural Gas Systems - Digester Gas Systems - Chilled and Hot Water Systems

Industrial Class Butterfly Valves – Wafer (not lugged) Body Design

Not allowed.

END OF SECTION


SECTION 15114

CHECK VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Swing.

B. Related sections: 1. Section 01650 – Facility Startup/Commissioning. 2. Section 09960 - High-Performance Coatings. 3. Section 15110 - Common Work Results for Valves.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and

250. 2. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Inch

Standard.

B. American Water Works Association (AWWA): 1. C508 - Standard for Swing-Check Valves for Waterworks Service 2 Inch

Through 24 Inch (50-mm Through 600-mm) NPS.

C. ASTM International (ASTM): 1. A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and

Pipe Fittings. 2. A313 - Standard Specification for Stainless Steel Spring Wire. 3. A536 - Standard Specification for Ductile Iron Castings. 4. B582 - Standard Specification for Nickel-Chromium-Iron-Molybdenum-Copper

Alloy Plate, Sheet, and Strip. 5. B584 - Standard Specification for Copper Alloy Sand Castings for General

Applications.


A. Design requirements: 1. Check valves: When not otherwise specified as indicated on the Drawings,

provide check valves suitable for service as follows: a. In either horizontal or vertical position. b. Suitable for service working pressures up to 150 pounds per square inch

gauge.

1.04 SUBMITTALS



PART 2 PRODUCTS

2.01 SWING CHECK VALVES

A. Valves 1/4 inch through 3 inch: 1. Manufacturers: One of the following or equal:

a. Crane Valve Company, Number 36. b. Lunkenheimer Company, Figure 554Y.

2. Valve design: a. Threaded joints. b. Y-pattern body with integral seat. c. Hinged disc. d. Access to valve seat for regrinding without disassembly of piping.

3. Materials: a. Body, cap, hinge, and disc: Bronze.

B. Valves 4 inch through 24 inch: 1. Manufacturers: One of the following or equal:

a. Kennedy, Figure 106LW or M&H, Model 159. b. Mueller Company, Model A-2600. c. APCO Model 250. d. Crispin SWL Series.

2. Valve design: a. In accordance with AWWA C508. b. Constructed to permit top entry and removal of internal components

without removing the valve. c. Equipped with outside lever and weight.

3. Materials: a. Body: Cast iron, ASTM A126 Class B or ASTM A536 Grade 65-45-12

Ductile Iron. b. Disc:

1) Valve disc shall be ASTM A126 cast iron, ASTM A536 ductile iron, or ASTM B584 bronze.

2) 4-inch valves: Bronze or stainless steel rings and seats. 3) 6 inches and larger valves: Bronze-faced or stainless steel rings and

seats. 4) Rubber seat Buna-N or EPDM.

c. Hinge pins: Stainless steel.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install valves as specified in Section 15110 and the manufacturer’s instructions.

B. Flapper-type check valves: 1. Install with proper orientation of flow direction arrow on valve body. 2. When installed in horizontal pipelines, mount with shaft on vertical locations. 3. When mounted in a vertical pipeline, directly downstream of an elbow, mount

with the shaft perpendicular to the outermost portion of the elbow. 4. Mount on downstream side of discharge silencer when used on positive

displacement and centrifugal blowers.


3.02 COMMISSIONING


B. Manufacturer services from each manufacturer for all valves supplied: 1. As specified in Section 15110. 2. On-site services.




Functional Testing

Process Operational Period

Maintenance (hrs per session)




Days (each trip)

X X X X X X X

3. Source testing.

3.03 ADJUSTING

A. Adjust cushioned swing check valves in the field by means of external adjustment devices to minimize pressure surges.

B. Adjust weight on swing check valves to affect proper closing action on equipment shutdown.

END OF SECTION


FACILUT SECTION 15115

GATE, GLOBE, AND ANGLE VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Gate, globe, angle, plug disc and plain hose valves, and yard hydrants.


C. Related sections: 1. Section 01330 - Submittal Procedures. 2. Section 01650 – Facility Startup/Commissioning. 3. Section 01783 - Warranties and Bonds. 4. Section 09960 - High-Performance Coatings. 5. Section 15110 - Common Work Results for Valves.

1.02 REFERENCES

A. American Water Works Association (AWWA): 1. C515 - Standard for Reduced-Wall, Resilient-Seated Gate Valves for Water

Supply Services. 2. C 550 - Protective Interior Coatings for Valves and Hydrants.

B. ASTM International (ASTM): 1. B98 - Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes.

1.03 SUBMITTALS



C. Commissioning submittals: For valves larger than 16-inch: 1. Provide Manufacturer’s Certificate of Installation and Functionality

Compliance as specified in Section 01650.

1.04 WARRANTY


B. Interior epoxy coatings: Affidavit of compliance attesting that epoxy coatings applied to interior surfaces of valves comply in accordance with all provisions of AWWA C550.


PART 2 PRODUCTS





2.02 HOSE VALVES AND YARD HYDRANTS

A. Hose valves: 1. Manufacturers:

a. Globe threaded valve: One of the following or equal: 1) Crane, No. 7TF. 2) Stockham, Figure No. B22T.

b. Angle threaded valve: One of the following or equal: 1) Crane, No. 17TF. 2) Stockham, Figure No. B222T.

2. Design: a. Size and configuration: Indicated on the Drawings. b. Valve: Globe or angle valve with threaded ends. c. Disc: Renewable, made of Teflon or Buna-N. d. Threaded ends rated for a pressure of 200 pounds per square inch.

B. Freezeless yard hydrant: 1. Manufacturers: One of the following or equal:

a. Kupferle Foundry Company. 1) #1 Total Eclipse Yard Hydrant - 3/4 inch and 1 inch.

b. Murdock Company: 1) #M-75 – 3/4 inch or #M100 - 1 inch.

c. Zurn Company: 1) #1385 - 3/4 inch or 1 inch.

2. Design: a. Self-draining, non-freezing, compression type.

1) Inlet connection size: Indicated on the Drawings. 2) Outlet connection size: Indicated on the Drawings. 3) Materials:

a) Exterior casing pipe material: Indicated on the Drawings. b) Interior operating rod material: Indicated on the Drawings. c) Casing guard material: Indicated on the Drawings. d) Principal interior operating parts material: brass and/or bronze

and removable from yard hydrant for servicing without excavation.

4) Provide 4 Spoke, Ball Wheel Handle operated.


C. Freezeless post hydrants: 1. Manufacturers: The following or equal:

a. Kupferle Foundry Company: 1) #2 Eclipse Post Hydrant.

b. Mueller Company: 1) #A-411 Post Hydrant.

c. Murdock Company: 1) #M-200 Post Hydrant.

2. Design: a. Self-draining, non-freezing, compression type with a 2-3/16 inch valve

opening. b. Inlet connection size: Indicated on the Drawings. c. Outlet connection size: Indicated on the Drawings. d. Materials:

1) Exterior casing pipe material: Indicated on the Drawings. 2) Interior operating rod material: Indicated on the Drawings. 3) Top stock material: Indicated on the Drawings. 4) Principal interior operating parts material: Brass and/or bronze and

removable from hydrant for servicing without excavation. e. Provide 1-1/2 inch pentagon operating nut operated by a hydrant wrench

or 10 inch hand wheel: 1) Manufacturers: The following or equal:

a) Kupferle Foundry Company.

PART 3 EXECUTION

3.01 INSTALLATION

A. Mount yard hydrants on minimum 1 inch supply pipe or size indicated on the Drawings.

B. Mount Post hydrants on minimum 2 inch supply pipe or size indicated on the Drawings.

C. Set yard and post hydrants in 4 cubic feet of 3/4 inch minimum crushed stone surrounding valve body to allow for proper drainage. 1. Install in accordance with AWWA recommendations for hydrants.

3.02 COMMISSIONING


B. Manufacturer services: For valves larger than 16-inch. 1. Provide certificates:

a. Manufacturer’s Certificate of Installation and Functionality Compliance.


a. Test witnessing: Witnessed. b. Conduct pressure and leak test as specified in Section 15110.

END OF SECTION


SECTION 15116

PLUG VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Non-lubricated plug valves.

B. Related sections: 1. Section 01650 – Facility Startup/Commissioning. 2. Section 09960 - High-Performance Coatings. 3. Section 15110 - Common Work Results for Valves.

1.02 REFERENCES

A. American Water Works Association (AWWA): 1. C606 - Grooved and Shouldered Joints. 2. C517 - Resilient-Seated Cast Iron Eccentric Plug Valves.

B. ASTM International (ASTM): 1. A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and

Pipe Fittings. 2. A536 - Standard Specification for Ductile Iron Castings.

1.03 SUBMITTALS


PART 2 PRODUCTS

2.01 NON-LUBRICATED PLUG VALVES

A. Manufacturers: One of the following or equal: 1. DeZurik, "PEC". 2. Clow Valve.

B. Design: 1. Type: Non-lubricated eccentric type, in accordance with AWWA C517. 2. Plug face: Resilient material that operates satisfactorily at a temperature of

180 degrees Fahrenheit continuous and 215 degrees Fahrenheit intermittent, except for valves in compressed air or digester gas service. a. Valves in compressed air service: Resilient material suitable for

continuous duty at 250 degrees Fahrenheit. b. Valves in digester gas service: Resilient material suitable for petroleum or

digester gas at continuous duty at 180 degrees Fahrenheit.


3. Compression washer: Provide flat compression washer made of Teflon, or of a material having equal physical characteristics on valve stem between plug and bonnet.

4. Stem seals: Provide stem seals serviceable without unbolting the valve bonnet assembly.

5. Grit excluders: Provide PTFE grit excluders at upper plug journals to prevent entry of foreign solids in bearing area.

6. Clearly mark valves to indicate their open and closed positions. 7. Provide valves with ends as required by piping details indicated on the

Drawings. 8. Grooved end body valves:

a. Usage: Plug valves with grooved ends may be used in piping systems specified in the Piping Schedule to have grooved end joints and as indicated on the Drawings.

b. Grooved end joint design: In accordance with AWWA C606.

C. Materials: 1. Body and plug: ASTM A126, Class B, cast-iron, with plug face of neopreneor

EPDM material suitable for the intended service as specified under paragraph "Design" above.

2. Body seats in valves 3 inch size and larger: Provide with overlay of not less than 90-percent nickel and minimum thickness of 1/8 inch on surfaces contacting the plug face.

3. Stem bearing and bottom bearing: Type 316 stainless steel. 4. Internal parts, except the body and plug: Type 316 stainless steel,Monel, or

Nickel. 5. Exposed nuts, bolts, and washers: Zinc plated. Exception: Exposed nuts,

bolts, and washers for buried service: Stainless steel.

2.02 VALVE OPERATORS

A. Furnish valves with an operating wrench or worm gear operator: 1. Equip valves 4 inch nominal size and smaller with a lever operator. 2. Equip valves 6 inch nominal size and larger with a worm gear operator.

2.03 COATING

A. Coat interior metal surfaces as specified in Section 15110.

B. Coat exterior metal surfaces as specified in Section 09960.

C. Field applied coating of valve exterior: 1. Match color and be compatible with manufacturer’s coating system and as

specified in Section 09960. a. When shop applied finish coating matches field applied coating on

adjacent piping, touch up shop coating in damaged areas in accordance with instructions recommended by the paint manufacturer.

b. When shop applied coating does not match field coating on adjacent piping, or when damage has occurred to the shop applied coating that requires more than touchup, blast clean valve surfaces or utilize other surface preparation recommended by the manufacturer of the coating material and apply the coating system used for coating adjacent piping.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install valves as specified in Section 15110 and the manufacturer’s instructions.

B. Install valves so that in the closed position the pressure in the pipeline applies a seating head on the valves.

C. Lubrication: Lubricate plug valves and fill extended lubricant pipes with lubricant suitable for service intended.

D. Install valves so that in the open position the plug is located in the top half of the valve body.

3.02 COMMISSIONING AND PROCESS START-UP REQUIREMENTS


B. Manufacturer services from each manufacturer for all valves supplied, 1. As specified in Section 15110. 2. On site services.

Manufacturer Rep Onsite Training

Requirements Installation

Testing Functional

Testing Process

Operational Period Maintenance

(hrs per session)




Days (each trip)

X X X X X X X

3. Source testing.

END OF SECTION


SECTION 15117

SPECIALTY VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Solenoid valves.

B. Related sections: 1. Section 01650 - Facility Startup/Commissioning. 2. Section 15082 - Piping Insulation. 3. Section 15110 - Common Work Results for Valves.

1.02 REFERENCES

A. American Society of Civil Engineers (ASCE): 1. 25 - Earthquake-Actuated Automatic Gas Shutoff Devices.

B. American Society of Mechanical Engineers (ASME): 1. B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300.

C. American Water Works Association (AWWA): 1. C511 - Standard for Reduced Pressure-Principle Backflow-Prevention

Assembly. 2. C800 - Underground Service Line Valves & Fittings (Also Included: Collected

Standards For Service Line Materials).

D. ASTM International (ASTM): 1. A48 - Standard Specification for Gray Iron Castings. 2. A126 - Standard Specification for Gray Iron Casting for Valves, Flanges, and

Pipe Fittings. 3. A276 - Standard Specification for Stainless Steel Bars and Shapes. 4. A536 - Standard Specification for Ductile Iron Castings. 5. B584 - Standard Specification for Copper Alloy Sand Castings for General

Application.

E. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

1.03 DEFINITIONS

A. NEMA Type 4 enclosure in accordance with NEMA 250.

1.04 SUBMITTALS




A. Manufacturer qualifications: Manufactured by manufacturers whose valves have had successful operational experience in comparable service.


A. Protect valves from damage during handling and installation.

PART 2 PRODUCTS





2.02 SOLENOID VALVES

A. 2-way solenoid valves: 1. Manufacturers: One of the following or equal:

a. Automatic Switch Company, Series 8210. b. Skinner Electric Valve Division, Series C.

B. 3-way solenoid valves: 1. Manufacturers: One of the following or equal:

a. Automatic Switch Company, Series 8320. b. Skinner Electric Valve Division, Type A4.

C. 4-way solenoid valves: 1. Manufacturers: One of the following or equal:

a. Automatic Switch Company, Bulletin 8344. b. Skinner Electric Valve Division, Series V9.

D. Design: 1. Valves: Suitable for service under the following conditions:

a. Fluid: Water. b. Temperature of fluid: 60-80 degrees Fahrenheit. c. Piping test pressure: <100 pounds per square inch gauge.

2. Unless otherwise indicated on the Drawings, provide valves that: a. Minimum NEMA Type 4 enclosure. b. 120 VAC operation. c. Suitable for use as indicated on the Drawings. d. Minimum Class F coil insulation.


3. 2-way valves: Furnish with openings of size equal to or larger than the nominal size designation of the valve.

4. Furnish with manual/bypass operators.

E. Materials: 1. Body: Brass or bronze. 2. Seats: Resilient material.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install as specified in Section 15110 in accordance with manufacturer's published instructions.

B. Install sensing line insulation as specified in Section 15082.

C. Backflow preventers: 1. Install with a minimum clearance of 12 inches and with maximum clearance of

30 inches between the relief port and the floor or finished grade. 2. Install with sufficient side clearance for access for testing and maintenance.

D. Plastic body diaphragm valves for sodium hypochlorite service: 1. When valves are installed horizontally, install valves with valve stem position

rotated as necessary such that no internal valve obstruction prevents the passage of vapors traveling along the top of adjacent piping from traveling through the valve.

E. Flow control valves: 1. Install orifice in accordance with manufacturer’s requirements.

3.02 COMMISSIONING


B. Manufacturer services from each manufacturer for all valves supplied, 1. As specified in Section 15110. 2. On site services.

Manufacturer Rep Onsite Training

Requirements Installation

Testing Functional

Testing Process

Operational Period Maintenance

(hrs per session)




Days (each trip)

X X X X X X X

3. Source testing.

END OF SECTION


SECTION 15119

AIR AND VACUUM RELIEF VALVES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Air release valves, air and vacuum valves, and air vents.


C. Related sections: 1. Section 01300 - Submittals. 2. Section 01650 – Facility Startup/Commissioning. 3. Section 01783 - Warranties and Bonds. 4. Section 09960 - High-Performance Coatings. 5. Section 15110 - Common Work Results for Valves.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME). 1. B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and

250. 2. B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through 24.

B. American Water Works Association (AWWA).

C. ASTM International (ASTM): 1. A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and

Pipe Fittings. 2. A240 - Standard Specification for Chromium and Chromium-Nickel Stainless

Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications.

3. A270 - Standard Specification for Seamless and Welded Austenitic Stainless Steel Sanitary Tubing.

4. B584 - Standard Specification for Copper Alloy Sand Castings for General Applications.

1.03 SUBMITTALS



C. Commissioning submittals: 1. Provide Manufacturer’s Certificate of Installation and Functionality Compliance



1.04 WARRANTY


PART 2 PRODUCTS

2.01 AIR RELEASE VALVES, WATER SERVICE

A. Manufacturers: One of the following or equal: 1. Valve and Primer Corporation, DeZurik/APCO Series 200. 2. Multiplex Manufacturing Company, Crispin PL Series.

B. Design: 1. Pressure rating: 150 pounds per square inch gauge. 2. Inlet: Screwed, 2-inch. 3. Orifice size: 1/4 inch diameter.

C. Materials: 1. Valve body: Cast iron. 2. Float and internal trim: Type 316 stainless steel. 3. Seat or valve plunger: Buna-N.

2.02 COMBINATION AIR VALVES - SEWAGE SERVICE

A. The air-vacuum release valves for use in sanitary sewer service shall be manufactured by ARI Flow Control, Model D-025 or equal.

B. Valve shall release air and gases at a flow equal to or greater than the pumping capacity during filling of the system and admit air under vacuum conditions. Valve shall maintain an air pocket separation between the pumped liquid and the working mechanism.

C. The operating mechanism shall be non-metallic and corrosion resistant. The valve body, floats, float guide, and stem shall be of stainless steel Type 316. The resilient seat shall be of Buna N.

D. The valve shall be suitable for 230 PSIG working pressure. Valve shall have standard NPT inlets and outlet ports. Provisions shall be made for back-flushing the valve with clean water via cam lock attachment.

E. Provide valve with corrosion-proof ball valve of equal size to the air valve inlet to permit removal of the valve while maintaining the pumping system in service.

F. Provide poppet valve for attachment on air discharge elbow to enable operation without vacuum release function.

G. The air release valve for sanitary sewer service shall come with a five year warranty.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install as specified in Section 15110 and manufacturer’s instructions.

B. Install air release valves and air and vacuum valves with suitable discharge lines to nearest drainage system.



piping, touch up shop coating in damaged areas in accordance with instructions recommended by the manufacturer.

2. When shop applied coating does not match field coating on adjacent piping, or when damage has occurred to the shop applied coating that requires more than touchup, remove existing coating by abrasive blast cleaning and apply the coating system used for coating adjacent piping in accordance with Section 09960. a. Submerged valves: SP-5 White Metal Blast cleaning. b. Other valves: SP-10 Near-white blast cleaning.

3.03 COMMISSIONING



a. Manufacturer's Certificate of Installation and Functionality Compliance.


a. Test witnessing: Witnessed. b. Conduct pressure and leak test as specified in Section 15110.

END OF SECTION


SECTION 15120

PIPING SPECIALTIES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Piping specialties including: 1. Rubber expansion joints.AD2 2. Spray nozzles.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 01783 - Warranties and Bonds. 5. Section 15052 - Common Work Results for General Piping.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24.

B. American Water Works Association (AWWA): 1. C110 - Standard for Ductile-Iron and Gray-Iron Fittings. 2. C151 - Standard for Ductile-Iron Pipe, Centrifugally Cast.

C. ASTM International (ASTM): 1. A148 - Standard Specification for Steel Castings, High-Strength, for Structural

Purposes. 2. A536 - Standard Specification for Ductile Iron Castings.

D. NSF International (NSF): 1. 61 - Drinking Water System Components - Health Effects, Includes Errata. 2. 372 - Drinking Water System Components - Lead Content.

1.03 SUBMITTALS


B. Product data: 1. For each piping product in this Section as applicable:





C. Manufacturer’s Certificate of Installation and Functionality Compliance as specified in Section 01650: 1. Provide as specified in this Section.

1.04 WARRANTY


PART 2 PRODUCTS

2.01 GENERAL


B. Materials in contact with drinking waters: In accordance with NSF 61 and NSF 372.

2.02 RUBBER EXPANSION JOINTSAD2

A. A.Manufacturers: One of the following or equal: 1. Mercer Rubber Co., Style 500 or 700. 2. Red Valve Co., Inc., Type J 1. 3. Proco Products, Inc., Series 230 or 240.

B. Provide rubber expansion joints complete with control units and split retaining rings.

C. Design: 1. Material: EPDM rubber, reinforced with embedded steel rings, and a strong

synthetic fabric. 2. Expansion rings, suitable for pressures of at least 125 pounds per square inch

gauge, except as follows: a. Expansion joints in pump suction piping and where indicated on the

Drawings suitable for minimum 90 pounds per square inch gauge pressure, and minimum 30 inches mercury vacuum.

b. Ends of expansion joints, 150 pound ASME flanges with drilling to match that of the piping.

3. Bolts, nuts, control rods/plates, and retaining rings shall be galvanized steel unless otherwise specified.

4. Bolts, nuts, control rods/plates, and retaining rings for low pressure air systems provide materials matching the piping system.

5. Bolts, nuts, control rods/plates, and retaining rings submerged in water or wastewater, buried, in wet vaults or structures, adjacent to wet walls, or above open water-containing structures shall be Type 316 stainless steel in accordance with ASTM A193, Grade B8M for bolts and in accordance with ASTM A194, Grade 8M for nuts.

D. Rubber expansion joints for blowers: Butyl type rubber formulated for service application and for maximum temperature of 250 degrees Fahrenheit, suitable for minimum 40 pounds per square inch gauge pressure, and minimum 15 inches mercury vacuum.”


2.03 SPRAY NOZZLES

A. Location: 1. Primary Scum Sump 2. Secondary Scum Vault 3. Secondary ClarifiersAD2

B. Design: 1. Operating pressure 10 pounds per square inch gauge, at which pressure each

nozzle discharges not less than 3.5 gallons per minute, nor more than 5.0 gallons per minute. a. Spray: Flat, heavy sheet, fan with uniform distribution. b. Fan width at the water surface not less than 6.5 feet at 10 pounds per

square inch gauge. c. Spray deflection with a replaceable deflector insert free to rotate away

from the orifice opening and mechanically locked in place and counterweighted.

2. Spray nozzles structurally suitable for pressure up to 200 pounds per square inch gauge.

3. Nozzles, easy flush type.

C. Materials: 1. Spray nozzles: Leaded bronze. 2. Nozzles provided with 1/4 inch national pipe thread, and the orifice diameter

not less than 1/4 inch. 3. Replaceable spray deflector: Neoprene rubber.

2.04 SHIPPING


PART 3 EXECUTION

3.01 GENERAL A. As specified in Section 01600.

B. Drawings supersede conflicts with this Section.

C. Bellows type expansion joints and vibration control joints: 1. Protect joints against damage during pressure test.

3.02 COMMISSIONING


B. Field testing: 1. As specified in Section 15052. 2. Protect bellows type expansion joints and vibration control joints.

END OF SECTION

AD2 Addendum No. 2


SECTION 15121

PIPE COUPLINGS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Pipe couplings for ductile iron piping. 2. Pipe couplings for carbon steel piping. 3. Pipe couplings for stainless steel piping. 4. Pipe couplings for connecting stainless steel to PVC piping.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01600 - Product Requirements. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 01783 - Warranties and Bonds. 5. Section 09960 - High-Performance Coatings. 6. Section 15052 - Common Work Results for General Piping.

1.02 REFERENCES

A. American National Standards Institute (ANSI).

B. American Society of Mechanical Engineers (ASME): 1. B31.1 - Power Piping. 2. B31.9 - Building Services Piping.

C. American Water Works Association (AWWA): 1. C111 - Standard for Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and

Fittings. 2. C207 - Standard for Steel Pipe Flanges for Waterworks Service - Sizes 4 In.

Through 144 In. 3. C606 – Standard for Grooved and Shouldered Joints.

D. ASTM International (ASTM): 1. A36 - Standard Specification for Carbon Structural Steel. 2. A53 - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless. 3. A193 - Standard Specification for Alloy Steel and Stainless Steel Bolting

Materials for High Temperature or High Pressure Service and Other Special Purpose Applications.

4. A325 - Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength.

5. A351 - Standard Specification for Castings, Austenitic, for Pressure-Containing Parts.

6. A449 - Standard Specification for Hex Cap Screws, Bolts and Studs, Steel, Heat Treated, 120/105/9 ksi Minimum Tensile Strength, General Use.

7. A536 - Standard Specification for Ductile Iron Castings.


8. A563 - Standard Specification for Carbon and Alloy Steel Nuts. 9. A576 - Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special

Quality. 10. D2000 - Standard Classification System for Rubber Products in Automotive



E. NSF International (NSF). 1. 61 - Drinking Water System Components - Health Effects. 2. 372 - Drinking Water System Components - Lead Content.

1.03 SUBMITTALS


B. Product data: 1. For each product in this Section as applicable:




C. Calculations. 1. Provide calculations in accordance with NSF 372 for materials in contact with

drinking water.

1.04 WARRANTY


PART 2 PRODUCTS

2.01 GENERAL

A. As specified in Section 01600: 1. Materials in contact with drinking waters: In accordance with NSF 61 and

NSF 372.

B. Known acceptable manufacturers are listed by specific products.

C. Provide references as specified in this Section by specific product.

D. Manufacturer’s representatives requirements as specified in Section 01650 and this Section by specific product.

E. Gaskets for flexible couplings and flanged coupling adapters:


1. Provide gasket materials for piping applications as follows: a. Low-pressure and high-pressure air, steam, hot water: EPDM. b. All other piping applications: Neoprene rubber or Buna-N.

F. Exterior coatings for underground and submerged applications: 1. Manufacturers: One of the following or equal:

a. Tapecoat Company, Inc., T.C. Mastic. b. Kop-Coat Company, Inc., Bitumastic Number 50.

2. Thickness: Minimum 0.040 inch.

2.02 PIPE COUPLINGS FOR DUCTILE IRON PIPING

A. Dismantling joints: 1. Manufacturers: One of the following or equal:

a. Romac Industries, Inc., Style DJ400. b. Smith-Blair, Inc., Series 975.

2. Materials: a. Flanged spool: AWWA C207 steel pipe:

1) ASTM A53 for sizes 3 inches to 12 inches. 2) ASTM A36 for sizes 14 inches to 72 inches.

b. End ring and body: 1) For sizes 3 inches to 12 inches, ductile iron in accordance with

ASTM A536. 2) For sizes 14 inches to 72 inches, steel in accordance with ASTM A36

or A53. c. Follower ring: Ductile iron in accordance with ASTM A536. d. Bolts and hex nuts:

1) Aboveground: High strength, low alloy steel in accordance with AWWA C111.

2) Buried and underwater: Type 316 stainless steel bolts in accordance with ASTM F593.

e. Tie rods: High tensile steel in accordance with ASTM A193 Grade B7. 3. Flange design: Class D steel ring flange in accordance with AWWA C207,

compatible with ANSI Class 125 and 150 bolt circles. 4. Coating and lining: Manufacturer’s standard fusion bonded epoxy, NSF 61

certified.

B. Flanged coupling adapters: 12-inch size and smaller: 1. Manufacturers: One of the following or equal:

a. Dresser, Inc., Style 227. b. Romac Industries, Inc., Style FCA501. c. Smith-Blair, Inc., Series 912.

2. Materials: a. Flanged body: Ductile iron in accordance with ASTM A536. b. Follower ring: Ductile iron in accordance with ASTM A536. c. Bolts and hex nuts:



3. Flange design: Class D steel ring flange in accordance with AWWA C207 compatible with ANSI Class 125 and 150 bolt circles.


4. Coating and lining: Manufacturer’s standard fusion bonded epoxy, NSF 61 certified.

C. Flanged coupling adapters: Greater than 12-inch size: 1. Manufacturers: One of the following or equal:

a. Dresser, Inc., Style 128-W. b. Romac Industries, Inc., Style FC400. c. Smith-Blair, Inc., Series 913.

2. Materials: a. Flange and flanged body: Ductile iron or low carbon steel having a

minimum yield strength of 30,000 pounds per square inch. b. Follower ring: Low carbon steel having a minimum yield strength of

30,000 pounds per square inch. c. Bolts and hex nuts:





D. Flexible couplings: 1. Manufacturers: One of the following or equal:

a. Dresser, Inc., Style 253. b. Romac Industries, Inc., Style 501. c. Smith-Blair, Inc., Series 441.

2. Materials: a. Center rings: Ductile iron in accordance with ASTM A536. b. Follower rings: Ductile iron in accordance with ASTM A536. c. Bolts and hex nuts:


2) Buried and underwater: Type 316 stainless steel in accordance with ASTM F593.


4. Center sleeve dimensions: Provide center sleeves with lengths in accordance with following table:

Nominal Pipe Size Sleeve Length 3 inch and smaller Manufacturer’s standard

4 inch through 8 inch 7 inches

10 inch through 14 inch 12 inches

Greater than 16 inch Use steel flexible coupling per Pipe Couplings for Steel Piping


E. Restrained flange coupling adapter: 1. Manufacturers: One of the following or equal:

a. Romac Industries, Inc., Style RFCA. b. Star Pipe Products, 3200 StarFlange.

2. Materials: a. Flange and flanged body: Ductile iron in accordance with ASTM A536. b. Follower ring: Lug type restraint system.

1) Follower ring: Ductile iron in accordance with ASTM A536. 2) Restraining lugs: Ductile iron in accordance with ASTM A536.

a) Designed to contact the pipe and apply forces evenly. 3) Restraining bolts:

a) Ductile iron in accordance with ASTM A536. b) Bolt heads shall be designed to twist off when the proper torque

has been applied. c. Bolts and hex nuts:





5. Angular deflection: Restrained flange coupling adapter must allow angular deflection after assembly.

F. Grooved joint couplings: 1. Manufacturers:

a. Victaulic Company, Series 31 or equal. 2. Materials:

a. Housings: Ductile iron in accordance with ASTM A536. b. Gasket:

1) FlushSeal® type, or equal. Elastomer in accordance with ASTM D2000.

2) Neoprene or BUNA-N. c. Bolts and nuts: Electroplated steel in accordance with ASTM A449. d. Coating: As specified in Section 09960.

3. For use with rigid or flexible radius grooved components in accordance with AWWA C606.

4. For connection to IPS steel pipe sizes, Victaulic Style 307.

2.03 PIPE COUPLINGS FOR STAINLESS STEEL PIPING

A. Flexible couplings: 1. Manufacturers: One of the following or equal:

a. Dresser, Inc., Style 38 2. Materials:

a. Casing: 1) Stainless steel in accordance with ASTM A 240.

b. Sealing Sleeve: 1) EPDM elastomer capable of withstanding temperatures up to 250

deg F.


3. Expansion: a. Coupling must provide a minimum of 1 inch of expansion/contraction.

4. Angular Deflection: a. Coupling must allow a minimum of 2 degrees of angular deflection.

B. Grooved joint couplings: 1. Manufacturers: One of the following or equal:

a. Victaulic Company. 2. Materials:

a. Housings: 1) Ductile iron in accordance with ASTM A536. 2) Stainless steel in accordance with ASTM A351.

b. Gasket: Elastomer in accordance with ASTM D2000. c. Bolts and nuts:

1) Electroplated steel in accordance with ASTM A449. 2) Stainless steel in accordance with ASTM F593.

3. Rigid type: a. Victaulic Style 89 and W89 (ductile iron housings). b. Victaulic Style 489 (stainless steel housings).

4. Flexible type: Victaulic Style 77S.

C. Bolted, split-sleeve couplings: 1. Split-sleeve type pipe coupling with a fully stainless steel double arch cross

section. Coupling shall be designed to close around the pipe ends, confining the gaskets beneath the arches of the sleeve. A watertight, axial seal is created by tightening the bolts to pull the coupling against the outside wall of the pipe.

2. Manufacturers: One of the following or equal: a. “Expansion x expansion” configuration:

1) Victaulic, Depend-O-Lok, E x E, Type 2 Coupling. 2) Straub, Air Flex

b. “Fixed x expansion” configuration: 1) Victaulic, Depend-O-Lok, F x E, Type 2 Coupling.

c. “Fixed x fixed” configuration: 1) Victaulic, Depend-O-Lok, F x F, Type 2 Coupling. 2) Straub, Grip-L

d. “Fixed x fixed modified” configuration: 1) Victaulic, Depend-O-Lok, F x F, Type 2 Modified Restrained

Coupling. 3. Materials:

a. Couplings: Stainless steel in accordance with ASTM A240. b. Bolts and nuts: In accordance with ASTM F593 and ASTM F594. c. Sealing Sleeve: EPDM elastomer capable of withstanding temperatures

up to 250 deg F. 4. Pipe preparation:

a. Pipe ends shall be smooth for expansion or contraction requirements. b. Where thrust restraint is required or is indicated on the Drawings, pipe

ends shall include restraint rings affixed for pipe end restraint requirements.

c. The coupling manufacturer shall provide restraint rings that shall be shop welded to the pipe in accordance with the manufacturer’s requirements.


d. Follow coupling manufacturer’s recommendation for size and amount of welding required to attach the restraint rings to the pipe.

2.05 PIPE COUPLINGS FOR CONNECTING STAINLESS STEEL TO PVC PIPING

A. Manufacturers: One of the following or equal: 1. JCM 131 All Stainless Universal Clamp Coupling.

B. Materials: 1. Band:

a. 18-8 Type 304 Stainless Steel 2. Lugs:

a. CF-8M Cast Stainless Steel (equivalent to 316 Stainless Steel) 3. Bolts:

a. 18-8 Type 304 Stainless Steel 4. Gasket:

a. EPDM

C. Pipe preparation: The pipes must be aligned vertically prior to installing the coupling clamp or the clamp may leak. The clamp has limited ability to seal misaligned piping. Coupling clamp must be installed a minimum of 2 feet below low water level. Also, the gap between the drop pipe and drop stub shall be less than 0.25” (6.5 mm) to ensure proper sealing of the coupling clamp.

PART 3 EXECUTION

3.01 INSTALLATION

A. In underground and underwater installations, coat the exterior of coupling with a protective coating in accordance with manufacturer's instructions.

B. Joints and flexible connections shall be installed centered with no angular deflection unless otherwise indicated on the Drawings.

C. Flexible couplings and flange coupling adapters: Install with gap between pipe ends in accordance with the following table unless a greater gap is indicated on the Drawings. Maximum gap tolerance shall be within 1/8 inch. 1. Install flexible coupling with pipe gap located in middle of center sleeve. 2. Install flanged coupling adapter with end of plain end pipe in middle of flanged

coupling body.

Center Ring Length Gap Dimension and Tolerance 4 inch through 6 inch 3/8 inch

7 inch 5/8 inch

10 inch and greater 7/8 inch

D. Provide harnesses (tie-downs) for flexible couplings unless otherwise indicated on the Drawings with a written note. 1. Design harnesses (tie-downs) for the test pressures as specified in the Piping

Schedule in Section 15052.


E. Grooved joint couplings: 1. Grooved ends: Clean and free from indentations, projections, and roll marks in

the area from pipe end to groove. 2. Gaskets: Elastomer grade suitable for the intended service, and molded and

produced by the coupling manufacturer.

F. Bolted, split-sleeve couplings: 1. Inspect each coupling to insure that there are no damaged portions of the

coupling. a. Pay particular attention to the sealing pad/sealing plate area. b. Before installation, thoroughly clean each coupling of any foreign

substance which may have collected thereon and shall be kept clean at all time.

2. Wrenches: a. Conform to manufacturer instructions. b. Bolts and studs shall be tightened so as to secure a uniform gasket

compression between the coupling and the body of the pipe with all bolts or studs tightened approximately the same amount.

c. Final tightening shall be done by hand (no air impact wrenches) and is complete when the coupling is in uniform contact with the outside surface of the pipe all around the circumference of the pipe.

3. No joint shall be misfit in any plane. 4. On the fixed ends of bolted, split-sleeve couplings, the shoulders shall bear on

the restraint rings all around with no visible gap. 5. Ends of piping where coupler are installed shall be smooth and free of defects.

a. Remove weld splatter and grind smooth. b. Grind pipe seam welds flush with pipe wall and smooth.

END OF SECTION


SECTION 15170

ELECTRICAL MOTOR, INDUCTION, 600 VOLTS AND BELOW

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install mill and chemical duty high efficiency, squirrel cage induction motor as hereinafter specified. Furnish and install as integral part of rotating driven equipment unit.

1.02 RELATED REQUIREMENTS

A. Driven equipment specifications, PLANS, and equipment manufacturer requirements define voltage, speed, special features, driven equipment requirements, and special submittal data.

B. Related work as called for on PLANS or specified in this or other Sections of the Specifications.

C. Refer, furnish and adhere to additional requirements specified in Section 11376E “Multi-Stage Centrifugal Blower Systems”.

1.03 REFERENCES

A. The publications listed below form a part of this Specification to the extent referenced. The publications are referred to in the text by basic designation only. 1. American Bearing Manufacturers Association (ABMA)

a. ABMA 9 Load Ratings and Fatigue Lift for Ball Bearings. 2. Institute of Electrical and Electronic Engineers (IEEE)

a. IEEE 112 Standard Test Procedures for Polyphase Induction Motors and Generators

b. IEEE 841 Standard for Petroleum and Chemical Industry-Severe Duty Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors-Up to and Including 500 Hp

3. National Electrical Manufacturers Association (NEMA) a. NEMA MG 1 Motors and Generators.

1.04 SUBMITTALS

A. Furnish the following in accordance with Specifications Section 01330, “Submittals” and Section 01730, “Operation and Maintenance Data”. 1. Shop drawings. In addition to the items specified in Section 01330,

“Submittals”, furnish the following information with the driven equipment submittal: a. Full nameplate information in accordance with NEMA Standard MG 1-

10.37; full load and locked rotor torque, efficiency and power factor data at full load, 3/4 load, and 1/2 load, space heater wattage and voltage, safe


stall time, inertia, number of allowable starts (cold/hot) per day and associated time between successive starts

b. When power factor correction capacitor is provided in motor circuit, all nameplate information affected by addition of capacitor to be corrected and submitted in addition to information described herein.

c. Thermal damage curves and speed-torque characteristic d. Full load, no load, and locked rotor ampere at rated voltage e. Wiring diagrams f. Dimensioned drawings, weights, bearing calculations and data. g. Platinum resistance temperature detector (RTD) literature and wiring

diagram. h. Submit RTD alarm and shutdown setpoints. i. For motors to be started using a reduced voltage auto-transformer type

starter, submit acceleration time characteristics, composite speed torque characteristics, and inertia data of the motor and pump for reduced voltage auto-transformer tap settings of fifty (50), sixty-five (65), eighty (80), and one hundred (100) percent of the across-the-line voltage. Submit composite characteristics of the voltage-speed characteristics for reduced voltage auto-transformer tap settings of fifty (50), sixty-five (65), eighty (80), and one hundred (100) percent of the across-the-line voltage.

j. For motors to be started using a reduced voltage auto-transformer type starter, submit the suggested time to transition from the reduced voltage (Start) operation to the full voltage (Run) operation.

2. Operation and Maintenance Manuals: Furnish as part of driven equipment O&M manual.


A. Design and construction of motors to be in accordance with NEMA Standard MG 1 and applicable provisions of IEEE, ANSI, NEC, OSHA, and UL.

B. Furnish identical motors and accessories from a single motor manufacturer for multiple units of the same equipment.

C. Sole Source Responsibility: Utilize a single supplier to provide the drive motor, the driven equipment and any accessories.


A. Protect from weather and insects with polyethylene wrapper, energize space heaters to preclude moisture.

PART 2 PRODUCTS

2.01 MANUFACTURER(S)

A. Teco-Westinghouse

B. U.S. Motor

C. Reliance/Baldor


D. General Electric

2.02 MATERIALS AND/OR EQUIPMENT

A. General: Unless otherwise noted in the driven equipment specification sections, the following items apply as a default standard: 1. Enclosure: TEFC. 2. Service Factor: 1.15. 3. Mounting: As required by the driven equipment. 4. Duty Rating: Continuous. 5. 120-volt space heaters. Wire to the motor terminal box unless specified

otherwise. 6. Starting: Across the line, full voltage starting except motors larger than 75 HP

to be suitable for reduced voltage starting with 65% voltage tap settings on reduced voltage starters.

7. Frequency: 60 Hz. 8. Lifting Lug.

B. Performance: Unless otherwise noted in the driven equipment specification sections, the following items apply as a default standard: 1. Brake Horsepower: As designated in driven equipment specification. Brake

horsepower of the driven equipment is not to exceed motor nameplate horsepower rating, excluding any service factor.

2. Power Factor: a. Minimum full load power factor (uncorrected) shall be 85%. b. When shown on the PLANS, corrected minimum full load power factor

shall be 95% 3. Efficiency: Motors shall be of a premium energy-efficient design per NEMA

MG 1, Tables 12-12 and 12-13. 4. Locked Rotor kVA Code G or lower for motors sized 15 horsepower and

larger.

C. Construction and Materials: 1. Frame: Cast iron, size per NEMA designations. 2. End Shields: Cast iron. 3. Drain/Breather: Stainless Steel “T” drains in end brackets. 4. Fan Shroud: Cast iron. 5. Motor Terminal Box:

a. General: Oversized, cast iron, diagonally split, rotatable, threaded hubs for conduit attachment. Sized per NEMA MG 1, section 1, paragraph 4.19. Terminal box shall be gasketed to frame and furnished with grounding lug.

b. Multi-Stage Centrifugal Blower Motors: 1) High Voltage Termination Box: Fabricated of 316 stainless steel

NEMA 4X watertight and corrosion resistant construction, complete with hinged front doors with locking handle. Sized large enough to permit termination of size and quantity of power and space heater conductors shown on the PLANS and to permit the installation of current transformer to monitor motor amperage. Refer to the PLANS and to Specification Section 11376E “Multi-Stage Centrifugal Blower


Systems”. Motor leads into and out of the termination box shall be sealed watertight.

2) Resistance Temperature Detector (RTD) Termination Box: Fabricated of 316 stainless steel NEMA 4X watertight and corrosion resistant construction. Extend RTD wiring into termination box and terminate to labeled terminal blocks located inside the RTD termination box. Refer to Specification Section 11376E “Multi-Stage Centrifugal Blower Systems”. Submit RTD wiring diagram which identifies each RTD, its associated stator winding phase, and corresponding terminal blocks and terminal block labels for review.

6. Cooling Fan: Aluminum or polypropylene. 7. Wiring and Insulation: Copper with non-hygroscopic Class F insulation, Class

B temperature rise not to exceed insulation temperature rating when operating at service factor rating in 40 degrees Celsius ambient according to NEMA MG 1-12.42. Include extra dips and bakes for high humidity.

8. Rotor: a. General: Precision cast aluminum rotor conductor bars, statically and

dynamically balanced. b. Multi-Stage Centrifugal Blower Motors: Copper/copper alloy rotor,

statically and dynamically balanced 9. Bearings: Ball bearings, B10 life of 75,000-hours per ABMA 9, grease

lubricated with cast iron bearing caps. Labyrinth sealed with removable grease relief plugs. Extended lubrication lines with Alemite fittings in both end shields. Provide for adding new and draining old grease without major motor disassembly. Provide grease catch pan and chute below each bearing to capture excess grease.

10. Hardware: Stainless Steel. 11. Shaft: High strength carbon steel, precision turned and ground. Non-metallic

V-ring shaft slinger to prevent moisture seepage along shaft into motor. 12. Nameplate: Stainless Steel securely attached to motor with stainless steel

screws. All data to be permanently stamped into nameplate. Data shall include: a. Horsepower. b. RPM. c. NEMA design. d. Phase e. Hertz. f. Service factor. g. NEMA nominal efficiency. h. Power factor. i. Frame size. j. Duty. k. Class of insulation. l. Ambient temperature. m. Locked rotor KVA code. n. Full load amps. o. Locked rotor amps. p. Bearing identification by ABMA number. q. Model and catalog number.


2.03 FABRICATION (NOT USED)


A. Factory Tests: 1. Perform routine (production) tests on all motors in accordance with NEMA MG

1 and IEEE 112. 2. For motors 100 Hp and smaller, testing can be conducted on an identical

motor. 3. Testing:

a. No load power at rated voltage. b. Locked rotor current. c. Efficiency at 50, 75 and 100 percent of rated horsepower in accordance

with IEEE 112, Test Method B, and NEMA MG 1, paragraphs 12.59 and 12.60.

d. Power factor. e. Speed. f. Current at rated horsepower. g. kW input at rated horsepower.

B. Test Report Forms: 1. Routine Tests: IEEE 112, Form A-1. 2. Efficiency and power factor by Test Method B, IEEE 112, Form A-2, and

NEMA MG 1, Table 12-11.

PART 3 EXECUTION

3.01 ERECTION/INSTALLATION/APPLICATION AND/OR CONSTRUCTION

A. Follow manufacturer’s published instructions and alignment requirements for driven unit. Measure and record amperes at maximum load and verify proper overload heater selection.

3.02 MEASUREMENT AND PAYMENT

A. No separate measurement or payment for work performed under this Section. Include cost of same in Contract price bid for work of which this is a component part.

END OF SECTION


SECTION 15245

DRAIN, WASTE, AND VENT PIPING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Plastic drain, waste, and vent pipe and fittings.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 15052 - Common Work Results for General Piping.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.12 - Cast Iron Threaded Drainage Fittings.

B. International (ASTM): 1. B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus. 2. D635 - Standard Test Method for Rate of Burning and/or Extent and Time of

Burning of Plastics in a Horizontal Position. 3. D1248 - Standard Specification for Polyethylene Plastics Extrusion Materials

for Wire and Cable. 4. D1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC)

Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. 5. D1785 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe,

Schedules 40, 80, and 120. 6. D2235 - Specification for Solvent Cement for Acrylonitrile-Butadiene-Styrene

(ABS) Plastic Pipe and Fittings. 7. D2321 - Standard Practice for Underground Installation of Thermoplastic Pipe

for Sewers and Other Gravity-Flow Applications. 8. D2412 - Standard Test Method for Determination of External Loading

Characteristics of Plastic Pipe by Parallel-Plate Loading. 9. D2466 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe

Fittings, Schedule 40. 10. D2467 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe

Fittings, Schedule 80. 11. D2564 - Standard Specification for Solvent Cements for Poly(Vinyl Chloride)

(PVC) Plastic Piping Systems. 12. D2657 - Standard Practice for Heat Fusion Joining of Polyolefin Pipe and

Fittings. 13. D2661 - Standard Specification for Acrylonitrile-Butadiene-Styrene (ABS)

Schedule 40 Plastic Drain, Waste, and Vent Pipe and Fittings. 14. D2665 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Drain,

Waste, and Vent Pipe and Fittings. 15. D2683 -Standard Specification for Socket-Type Polyethylene Fittings for

Outside Diameter-Controlled Polyethylene Pipe and Tubing. 16. D2843 - Standard Test Method for Density of Smoke from the Burning of

Decomposition of Plastics.


17. D2863 - Standard Test Method for Measuring the Miniman Oxygen Concentration to Support Candle-Like Combustion of Plastics (Oxygen Index).

18. D2855 - Standard Practice for Making Solvent-Cemented Joints with Poly (Vinyl Chloride)(PVC) Pipe and Fittings.

19. D3035 - Standard Specification for Polyethylene (PE) Plastic Pipe (DR-Project Representative) Based on Controlled Outside Diameter.

20. D3138 - Standard Specification for Solvent Cements for Transition Joints Between Acrylonitrile-Butadiene-Styrene (ABS) and Poly(Vinyl Chloride) (PVC) Non-Pressure Piping Components.

21. D3222-Standard Specification for Unmodified Poly(Vinylidene Fluoride)(PVDF) Molding Extrusion and Coating Materials.

22. D3261 -Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing.

23. D3350 - Standard Specification for Polyethylene Plastic Pipes and Fittings Materials.

24. D3965 - Specification for Rigid Acrylonitrile-Butadiene-Styrene (ABS) Materials for Pipe and Fittings.

25. D4101 – Standard Specification for Polypropylene Injection and Extrusion Materials.

26. D6713 - Standard Specification for Extruded and Compression Molded Shapes Made from Poly(Vinylidene Fluoride) (PVDF).

27. E84 - Standard Test Method for Surface Burning Characteristics of Building. 28. F402 - 05 Standard Practice for Safe Handling of Solvent Cements, Primers,

and Cleaners Used for Joining Thermoplastic Pipe and Fittings. 29. F628 - Standard Specification for Acrylonitrile-Butadiene-Styrene (ABS)

Schedule 40 Plastic Drain, Waste, and Vent Pipe With a Cellular Core. 30. F645 - Standard Guide for Selection, Design, and Installation of Thermoplastic

Water-Pressure Piping Systems. 31. F714 - Standard Specification for Polyethylene (PE) Plastic Pipe (SDR-PR)

Based on Outside Diameter. 32. F1055 - Standard Specification for Electrofusion Type Polyethylene Fittings for

Outside Diameter Controlled Polyethylene Pipe and Tubing. 33. F1056 - Standard Specification for Socket Fusion Tools for Use in Socket

Fusion Joining Polyethylene Pipe or Tubing and Fittings. 34. F1290 - Standard Practice for Electrofusion Joining Polyolefin Pipe and

Fittings. 35. F1412 - Standard Specification for Polyolefin Pipe and Fittings for Corrosive

Waste Drainage Systems. 36. F1673 - Standard Specification for Polyvinylidene Fluoride (PVDF) Corrosive

Waste Drainage Systems. 37. F1668 - Standard Guide for Construction Procedures for Buried Plastic Pipe. 38. F2620 - Standard Practice for Heat Fusion Joining of Polyethylene Pipe and

Fittings.

C. CSA International (CSA).

D. NSF International (NSF): 1. 61 - Drinking Water System Components - Health Effects.

E. Underwriters Laboratories, Inc. (UL): 1. 94 - Standard for Tests for Flammability of Plastic Materials for Parts in

Devices and Appliances.


1.03 ABBREVIATIONS

A. ABS: Acrylonitrile-butadiene-styrene.

B. DWV: Drain, waste, and vent.

C. PE: Polyethylene.

D. PP: Polypropylene.

E. PVC: Polyvinyl chloride.

F. PVDF: Unmodified Poly(Vinylidene Fluoride).

1.04 SUBMITTALS



C. Shop drawings:As specified in Section 15052. 1. Describe materials, pipe, fittings, gaskets, and solvent cement. 2. Installation instructions.


A. Install drain system in accordance with all local and national plumbing codes.

B. Fusion machine technician qualifications: 1-year experience in the installation of similar PE piping systems from the same manufacturer.

C. Plastic pipe in potable water applications: Provide pipe and tubing bearing NSF 61 seal: 1. Mark plastic pipe with nominal size, type, class, schedule, or pressure rating,

manufacturer and all markings required in accordance with AS™ standards.


A. PVC piping, Schedule Type: 1. Mark pipe and fittings in accordance with ASTM D1785.

B. PP piping: 1. Test samples and testing: Cut test samples of pipe, 6 inches long, from full

length sections and test by the method outlined in accordance with ASTM D2412: a. Deflect pipe at least 35 percent without failure. Stiffness at 5 percent

deflection equals or exceeds 55 pounds per square inch after the test samples have been immersed in a 5 percent solution by weight of sulfuric acid and n-Heptain for a period of 24 hours prior to testing.

b. Failure is defined as rupture of the pipe wall. c. Stiffness factor may be computed by the method outlined in accordance

with ASTM D2412 or by dividing the load in pounds per linear inch by the deflection in inches and 5 percent deflection.



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

B. Do not allow surface temperatures on pipe and fittings to exceed 120 degrees Fahrenheit.

C. Store and handle PE pipe and fittings as recommended by manufacturer in published instructions.

PART 2 PRODUCTS

2.01 MATERIALS

A. Extruding and molding material: Virgin material containing no scrap, regrind, or rework material except where permitted in the referenced standards.

B. Fittings: Same material as the pipe.

C. Unions 2-1/2 inches and smaller: Socket end screwed unions. Make unions 3 inches and larger of socket flanges with 1/8-inch full-face soft EPDM gasket.

2.02 PVC PIPING

A. Materials: 1. PVC Pipe: Designation PVC 1120 in accordance with ASTM D1785 and

appendices: a. Pipe and fittings: Extruded from Type I, Grade 1, Class 12454-B material

in accordance with ASTM D1784. b. PVC Pipe: Schedule 80 unless otherwise indicated on the Drawings.

2. Fittings: a. Supplied by pipe manufacturer. b. Pressure fittings: In accordance with ASTM D2466 or ASTM D2467. c. DWV fittings: In accordance with ASTM D2665.

3. Solvent cement: In accordance with ASTM D2564: a. Chemical service: For CPVC or PVC pipe in chemical service, provide the

following primer and cement, or equal: 1) Primer: IPS Corp Type P-70™. 2) Cement: IPS Corp Type 724™ cement or cement certified by the

manufacturer for chemical service.

PART 3 EXECUTION

3.01 INSTALLATION

A. General: 1. Where not otherwise specified, install piping in accordance with ASTM F645,

or manufacturer's published instructions for installation of piping, as applicable to the particular type of piping.

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


3. Locate unions where indicated on the Drawings, and elsewhere where required for adequate access and assembly of the piping system.

4. Provide serrated nipples for transition from plastic pipe to rubber hose. 5. Heat fusion joining shall be in accordance with ASTM D2657. 6. Underground installation shall be installed in accordance with ASTM D2321

and ASTM F1668. 7. Solvent cements shall be handled in accordance with ASTM F402.

B. Installation of PVC piping, Schedule Type: 1. Solvent weld joints in accordance with ASTM D2855:

a. For PVC pipe in chemical service use IPS Corp. Type 724™ cement in accordance with manufacturer's instructions.

2. Install piping in accordance with manufacturer's published instructions.


A. Test piping as specified in Section 15052.

END OF SECTION


SECTION 15282

COPPER TUBE: SEAMLESS, ASTM B280

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Copper tube-seamless, ASTM B 280.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 15052 - Common Work Results for General Piping. 3. Section 15061 - Pipe Supports. 4. Section 15062 - Preformed Channel Pipe Support System.

1.02 REFERENCES

A. ASTM International (ASTM): 1. B32 - Standard Specification for Solder Metal. 2. B280 - Standard Specification for Seamless Copper Tube for Air Conditioning

and Refrigeration Field Service. 3. B828 - Standard Practice for Making Capillary Joints by Soldering of Copper

and Copper Alloy Tube and Fitting.

B. International Association of Plumbing and Mechanical Officials (IAPMO): 1. IS 3 - Installation Standard for Copper Plumbing Tube, Pipe, and Fittings.

1.03 SUBMITTALS


A. Product data: As specified in Section 15052.

PART 2 PRODUCTS

2.01 MATERIALS

A. Seamless copper tubing for air conditioning and refrigeration field service: 1. Type: ASTM B280, USN Alloy C12200, outside diameter sized, minimum wall

thickness in accordance with ASTM B280. 2. Fittings: Solder fittings or brass flared fittings. 3. ASTM B280 copper tubing may be bundled into groups of parallel or spirally

cabled tubes with a plastic sheath. 4. Solder: In accordance with ASTM B32, Alloy Grade Sb5.


PART 3 EXECUTION

3.01 INSTALLATION

A. General: 1. Support copper tubing as specified in Sections 15061 and 15062. 2. Clean copper lines with high-pressure air after first disconnecting piping at

instruments, filters, pressure reducers, valve operators, and other special devices.

3. Install copper pipe in accordance with IAPMO IS 3.

B. Installation of copper tubing: 1. Install copper tubing in accordance with ASTM B828 and IAPMO IS 3. 2. Install copper tubing in straight runs, supported at intervals close enough to

avoid sagging. 3. Make cuts square with a tubing cutter or with a 32-tooth hacksaw.

a. Provide a sizing tool to correct distortions. 4. Ream the inside of the tubing and remove burrs from the outside, holding the

end of the tubing downward and preventing chips and fillings from entering the tubing.

5. Perform flaring with a flare block and yoke type screw feed flaring tool: a. After removing the tubing from the flare block, inspect both surfaces of the

flare for splits, cracks, or other imperfections. b. Where there are imperfections, cut off the imperfect flare and prepare a

new flare.


A. Testing: Test copper lines in the same manner as the piping system to which they connect.

END OF SECTION


SECTION 15286

STAINLESS STEEL PIPE AND TUBING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Stainless steel piping and tubing.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01650 - Facility Startup/Commissioning. 3. Section 09960 - High-Performance Coatings. 4. Section 15052 - Common Work Results for General Piping. 5. Section 15121 - Pipe Couplings and External Joint Restraints.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME): 1. B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through 24. 2. B16.11 - Forged Fittings, Socket-Welded and Threaded. 3. B31.3 - Process Piping. 4. B36.19 - Stainless Steel Pipe.

B. American Welding Society (AWS): 1. D1.6 - Structural Welding Code - Stainless Steel.

C. ASTM International (ASTM): 1. A182 - Standard Specification for Forged or Rolled Alloy and Stainless Steel

Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service.

2. A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications.

3. A194 - Standard Specification for Carbon and Alloy Steel Nuts and Bolts for High Pressure or High Temperature Service, or Both.

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

5. A269 - Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service.

6. A276 - Standard Specification for Stainless Steel Bars and Shapes. 7. A312 - Standard Specification for Seamless, Welded, and Heavily Cold

Worked Austenitic Stainless Steel Pipes. 8. A351 - Standard Specification for Castings, Austenitic, for Pressure-Containing

Parts. 9. A380 - Standard Practice for Cleaning, Descaling, and Passivation of Stainless

Steel Parts, Equipment, and Systems. 10. A403 - Standard Specification for Wrought Austenitic Stainless Steel Piping

Fittings.


11. A743 - Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application.

12. A744 - Standard Specification for Castings, Iron-Chromium-Nickel, Corrosion Resistant, for Severe Service.

13. A774 - Standard Specification for As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Services at Low and Moderate Temperatures.

14. A778 - Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products.

15. A789 - Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for General Service.

16. A790 - Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Pipe.

17. A928 - Standard Specification for Ferritic/Austenitic (Duplex) Stainless Steel Pipe Electric Fusion Welded with Addition of Filler Metal.

18. A967 - Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts.

19. B912 - Standard Specification for Passivation of Stainless Steels Using Electropolishing.

20. F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.

D. NSF International (NSF): 1. Standard 61 - Drinking Water System Components - Health Effects.


A. Piping layout: Lay out and fabricate piping systems with piping sections as long as possible, while still allowing shipment, so that joints are minimized. 1. Piping design indicated on the Drawings illustrates piping layout and

configuration and does not indicate the location of every joint and flexible coupling that may be needed to connect piping sections fabricated in the shop.

2. Add joints and flexible couplings in a manner that achieves intent of maximizing size of individual piping sections.

B. Shop fabrication: Fabricate piping sections in the shop and pickle and passivate at point of manufacture.

C. Field assembly: 1. Field welding is prohibited. 2. Assemble shop-fabricated piping in the field using the joints designed into the

piping layout or by using flexible couplings. 3. Field welding is prohibited except where expressly shown on the drawings.

1.04 SUBMITTALS


B. Shop drawings: 1. Detailed layout drawings:

a. Dimensions and alignment of pipes. b. Location of valves, fittings, and appurtenances. c. Location of field joints.


d. Location of pipe hangars and supports. e. Connections to equipment and structures. f. Location and details of shop welds.

2. Thickness and dimensions of fittings and gaskets. 3. Photographs, drawings, and descriptions of pipe, fittings, welding procedures,

and pickling and passivating procedures. 4. Material specifications for pipe, gaskets, fittings, and couplings. 5. Data on joint types and components used in the system including stub ends,

backing flanges, flanged joints, grooved joint couplings and screwed joints.

C. Field welding references: 1. Welder and weld operator qualification certificates and welding procedures.



PART 2 PRODUCTS

2.01 STAINLESS STEEL PIPE

A. General: 1. Pipe sizes specified in the Specifications and indicated on the Drawings are

nominal.

B. Wall thickness: 1. As specified in Section 15052.

a. Piping with Vic-Press joints:

1) Minimum wall thickness corresponding to Schedule 10S. 2. Piping with threaded or grooved joints:

a. For general service applications with pressures less than 250 pounds per square inch gauge, minimum wall thickness corresponding to Schedule 40S.

C. Piping material and manufacturing: 1. Comply with the requirements outlined in the following table:

Service Stainless Steel Grade Pipe Manufacturing

Process For low chloride water service with chloride concentrates below 200 parts per million and/or free chlorine less than 2 parts per million at ambient temperatures.

Piping 3 inches in nominal diameter and larger

Type 304L stainless steel in accordance with

ASTM A240

In accordance with ASTM A778


Service Stainless Steel Grade Pipe Manufacturing

Process Piping less than 3 inches in

nominal diameter Type 304L stainless steel in

accordance with ASTM A240

In accordance with ASTM A312

PREN: Pitting Resistance Equivalency Number PREN = Cr% + (3.3 x Mo%) + (16 x N%)

2. Location of material fabrication

D. Fittings for piping 3 inches in nominal diameter and greater: 1. Material: In accordance with ASTM A240 stainless steel, grade to match the

pipe. 2. Manufacturing standard: In accordance with ASTM A774. 3. Wall thickness of fitting: In accordance with ASME B36.19 for the schedule of

pipe specified. 4. End configuration: As needed to comply with specified type of joint. 5. Dimensional standards:

a. Fittings with weld ends: In accordance with ASME B16.11. b. Fittings with flanged ends: In accordance with ASME B16.5, Class 150.

E. Fittings for piping less than 3 inches in diameter: 1. Material: In accordance with ASTM A240 stainless steel, grade to match the

pipe. 2. Manufacturing standard: In accordance with ASTM A403, Class WP. 3. Wall thickness and dimensions of fitting: In accordance with ASME B16.11 and

as required for the schedule of pipe specified. 4. End configuration: As needed to comply with specified type of joint. 5. Forgings in accordance with ASTM A182, or barstock in accordance with

ASTM A276. Match forging or barstock material to the piping materials.

F. Piping joints: 1. Joint types, piping greater than 2 inches in diameter, general:

a. Where type of joint is specifically indicated on the Drawings or specified, design and shop-fabricate piping sections utilizing type of joint illustrated or scheduled.

b. Where type of joint is not specifically indicated on the Drawings or as specified in Section 15052 Piping Schedule, design and shop-fabricate piping sections utilizing any of the following joint types: 1) Piping stub ends with backing flanges. 2) Welded joints. 3) Flanged joints. 4) Grooved joints.

c. Joints at valves and pipe appurtenances: 1) Provide flanged valves and flanged pipe appurtenances in stainless

steel piping systems with flanged ends. 2) Design and fabricate piping sections to make connections with

flanged valves and pipe appurtenances using piping stub ends with backing flanges, flanged coupling adapters or flanged joints.


a) Flexible couplings and flanged coupling adapters: Provide stainless steel construction with materials matching the piping system, and conforming to requirements as specified in Section 15121.

3) Buried piping: Welded or mechanically restrained. 2. Joints in piping 2 inches in diameter and smaller: Flanged, grooved, or

screwed with Teflon tape thread lubricant, as specified in Section 15052. 3. Welded joints:

a. Pipe 12 inches and larger in diameter: Automatically weld joints using gas tungsten-arc procedures.

b. Piping 4 inches through 12 inches in diameter: Double butt welded joints. c. Piping less than 4 inches in diameter: Single butt-welded joints. d. Mark each weld with a symbol that identifies the welder.

4. Flanged joints: Conforming to the requirements in accordance with ASME B16.5, Class 150.

5. Piping stub ends and backing flanges for pipe 3 inches and larger: a. Piping stub ends: Cast stainless steel to match the pipe material with

machined gasket and wetted surfaces of stub ends free of crevices, pits, cracks and protrusions. 1) Manufacturers: The following or equal:

a) Alaskan Copper Works, Figure SK-38. b. Backing flanges: Forged or plate stainless steel (type to match pipe

material) with drilled bolt patterns in accordance with ASME B16.1, Class 125 or ASME B16.5, Class 150[, 300 or 600, as scheduled]. 1) Manufacturers: The following or equal:

a) Alaskan Copper Works, Figure SK-39 (tube) or SK-39P (pipe). c. Stub ends and backing flanges are not allowed for use with wafer style or

lugged style valves. 6. Flanges for Schedule 40S and Schedule 80S pipe:

a. Provide forged stainless steel (type matching piping system) welding neck flanges or slip-on flanges in accordance with ASME B16.5 Class 150.

b. Material: In accordance with ASTM A182. 7. Grooved joints:

a. Pressure less than 500 pounds per square inch: 1) Cut grooves from Schedule 40 or higher.

b. Heavier schedule pipe sections used for cut groove ends: 1) Tapered inside diameter to transition from the inside diameter of the

lighter schedule pipe. c. Butt welds connecting pipes of different schedules that leave an abrupt

change in inside diameter are not allowed. d. Couplings:

1) Rigid type, cast from ductile iron, Victaulic Style 07 or equal.

G. Gaskets: 1. Ozone and oxygen service: TFE sheet. 2. Aeration air service: As specified in Section 15052. 3. All other service applications: EPDM, nitrile, or other materials compatible with

the process fluid.


H. Bolts for flanges and stub end/backing flanges: 1. Bolts and nuts: Type 316 stainless steel in accordance with ASTM A193 heavy

hex head. a. Bolt length such that after installation, end of bolt projects 1/8-inch to

3/8-inch beyond outer face of nut. b. Nuts: In accordance with ASTM A194 heavy hex pattern.

I. Fabrication of pipe sections: 1. Welding: Weld in accordance with ASME B31.3. 2. Weld seams:

a. Full penetration welds, free of oxidation, crevices, pits and cracks, and without undercuts.

b. Provide weld crowns of 1/16 inch with tolerance of plus 1/16 inch and minus 1/32 inch.

c. Where internal weld seams are not accessible, use gas tungsten-arc procedures with internal gas purge.

d. Where internal weld seams are accessible, weld seams inside and outside using manual shielded metal-arc procedures.

e. Field welded joints must be passivated inside and out.

J. Cleaning (pickling) and passivation: 1. Following shop fabrication of pipe sections, straight spools, fittings, and other

piping components, clean (pickle) and passivate fabricated pieces. 2. Clean (pickle) and passivate in shop fabricated pieces in accordance with

ASTM A 380 or A 967, and field welded joints in accordance with ASTM A 380 Table A1.1 Code B. a. If degreasing is required before cleaning to remove scale or iron oxide,

cleaning (pickling) treatments with citric acid are permissible. 1) However, these treatments must be followed by inorganic cleaners

such as nitric acid/hydrofluoric acid. b. Passivation treatments with citric acid are not allowed.

3. Finish requirements: Remove free iron, heat tint oxides, weld scale, and other impurities, and obtain a passive finished surface. a. Owner has the option to test finish of any stainless steel per wet cloth

method described in ASTM A380. If there is a failed test, the Contractor shall re-pickle stainless steel until the area passes testing. The re-pickling shall be done at no cost to the Owner.

2.02 SPARE PARTS

A. If Victaulic couplings are used, provide 1 new and unused Victaulic PFT-510 series tool to Owner upon project completion. Tool shall be provided as a complete set which includes the following (at a minimum): 1. 18 volt battery and charge: 1. 2. Wire brush: 1. 3. Paint stick: 1. 4. Pipe marking gauges: 1 set. 5. Standard Vic-Press™ Jaw: 1. 6. Vic-Press™ ring with adaptor jaws to fit each size of pipe installed using this

system: 1. 7. Hard plastic tool case: 1. 8. Hard plastic accessory case: 1.



A. Visually inspect pipe for welding defects such as crevices, pits, cracks, protrusions, and oxidation deposits.

B. Provide written certification that the pipe as supplied are in accordance with ASTM A778. Supplemental testing is not required.

C. Provide written certification that the fittings as supplied are in accordance with ASTM A774. 1. Supplementary testing is not required.

D. Thoroughly clean any equipment before use in cleaning or fabrication of stainless steel.

E. Storage: Segregate location of stainless steel piping from fabrication of any other piping materials.

F. Shipment to site: 1. Protect all flanges and pipe ends by encapsulating in dense foam. 2. Securely strap all elements to pallets with nylon straps. Use of metallic straps

is prohibited. 3. Cap ends of tube, piping, pipe spools, fittings, and valves with non-metallic

plugs. 4. Load pallets so no tube, piping, pipe spools, fittings, or valves bear the weight

of pallets above. 5. Notify Engineer when deliveries arrive so Engineer may inspect the shipping

conditions. 6. Engineer may reject material due to improper shipping methods or damage

during shipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install piping in such a manner as not to impart strain to connected equipment.

B. Slope horizontal lines so that they can be drained completely.

C. Provide valve drains at low points in piping systems.

D. Install eccentric reducers where necessary to facilitate draining of piping system.

E. Provide access for inspection and flushing of piping systems to remove sediment, deposits, and debris.

3.02 FIELD ASSEMBLY OF SHOP-FABRICATED PIPING SECTIONS

A. Join shop-fabricated piping sections together using backing flanges, flexible couplings, flanged coupling adapters, grooved couplings, or flanges.



A. Test piping to pressure and by method as specified in Section 15052. 1. If pressure testing is accomplished with water:

a. Use only potable quality water. b. Piping: Thoroughly drained and dried or place immediately into service.

B. Visually inspect pipe for welding defects such as crevices, pits, cracks, protrusions, and oxidation deposits.

3.04 PROTECTION

A. Preserve appearance and finish of stainless steel piping by providing suitable protection during handling and installation and until final acceptance of the Work. 1. Use handling methods and equipment to prevent damage to the coating,

include the use of wide canvas slings and wide padded skids. 2. Do not use bare cables, chains, hooks, metal bars, or narrow skids. 3. Store stainless steel piping and fittings away from any other piping or metals.

Storage in contact with ground or outside without projection from bad weather is prohibited.

4. Protect stainless steel piping and fittings from carbon steel projections (when grinding carbon steel assemblies in proximity) and carbon steel contamination (do not contact stainless steel with carbon steel wire brush or other carbon steel tool).

3.05 COMMISSIONING


B. Manufacturer services: 1. Provide Manufacturer’s Certificate of Source Testing. 2. Provide Manufacturer’s Certificate of Installation and Functionality

Compliance.



Non-witnessed)



Functional Testing

Process Operational

Period Maintenance

(hrs per session)




Days (each trip)

Non-witnessed Not required Not required Not required Not required

END OF SECTION


SECTION 15294

RUBBER HOSE

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Hose.

1.02 SUBMITTALS

A. Product data: Manufacturer's data indicating service type, sizes, materials, and required accessories.

PART 2 PRODUCTS

2.01 HOSE

A. Hose material: Neoprene or acceptable oil resistant material suitable for a working pressure of minimum 100 pounds per square inch, gauge.

B. Size as indicated on the Drawings fit ends with appropriate combination clamped nipples and threaded ends as indicated on the Drawings.

C. Hose larger than 1-1/2 inches in size: Industrial fire hose. Provide one 50 foot long hose for each utility station (hose bib and hose rack) provided. 1. Manufacturers: One of the following or equal:

a. Goodyear Rubber Products Corp. b. Uniroyal, Inc. c. Goodall Rubber Company.

D. Hose 1/2 inch through 1-1/2 inch nominal diameter: General purpose hose. Provide one 75 foot long hose for each utility station (hose bib and hose rack) provided. 1. Manufacturers: One of the following or equal:

a. Goodyear Rubber Products Corp. b. Uniroyal. c. Goodall Rubber Company.

E. Equip and fit hose ends with appropriate combination clamped nipples and threaded ends to make up the assembly indicated on the Drawings.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install hose in accordance with manufacturer's published instructions.

B. Provide a hose for every hose bib with a hose rack.

END OF SECTION


SECTION 15400

PLUMBING FIXTURES AND EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Materials and installation of plumbing system.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01410 - Regulatory Requirements. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 15052 - Common Work Results for General Piping.

1.02 REFERENCES

A. American Society of Mechanical Engineers (ASME).

B. ASTM International (ASTM).

C. National Electrical Manufacturers Association (NEMA): 1. 250- Enclosures for Electrical Equipment (1000 V Maximum).

D. Plumbing and Drainage Institute (PDI): 1. PDI-WH 201 - Water Hammer Arresters Standard.

1.03 DEFINITIONS

A. NEMA Type 3 enclosure in accordance with NEMA 250.


A. System requirements: 1. Include in plumbing system fixtures; soil, drain, vent, and water piping;

connections; cleanouts, fittings, accessories, and testing for complete and functional system.

2. Except in details, piping is indicated on the Drawings in diagrammatic form. Sizes and locations are indicated on the Drawings; however, not every offset and fitting, nor every structural difficulty that will be encountered in the Work has been indicated.

3. As part of the Work, modify piping alignment indicated on the Drawings as necessary to avoid structural or mechanical obstructions and to clear the work of other trades.

4. Furnish such parts and pieces necessary to provide a complete and operational system.

1.05 SUBMITTALS





A. Regulatory requirements: Perform work under this Section in accordance with the plumbing code specified in Section 01410, and in accordance with applicable laws and regulations, including requirements for accessibility, energy, water conservation, and health including related requirements for water fountains and coolers. 1. Where provisions specified in these Specifications or the design indicated on

the Drawings are in conflict with the plumbing code specified in Section 01410 or laws or regulations, the Code and the laws or regulations take precedence over the specified provisions and design.

PART 2 PRODUCTS

2.01 MATERIALS

A. General: 1. Manufactured units: Fixture fittings and piping which are exposed shall be

heavy-duty chrome. 2. Accessories:

a. Stops: 1) Fixtures, except showers, shall have stops at the fixtures' service. 2) Stops for laboratory equipment, and for other equipment or fixtures

for which stops have not been otherwise specified in this Section, shall be chrome-plated straight pattern compression stops or chrome-plated angle pattern compression stops.

B. Drain, waste, and vent piping: 1. Piping:

a. Piping for drain, waste and vent: As specified in Section 15052. 2. Joints:

a. Threaded joints: American standard taper screw threads, clean cut, and made up with graphite and oil or other suitable pipe compounds.

b. Slip joints permitted only in trap seals or on the inlet side of the traps. 1) Do not use long screws or bushings.

c. Other types of joints: As specified in the piping sections. 3. Fittings:

a. Fittings for screwed waste and vent piping: Cast iron drainage pattern fittings.

b. Additional provisions for fittings specified within piping section. 4. Flashing:

a. Roof vent, roof drain, and pipe flashing: Minimum 4-pound lead sheet.

C. Plumbing piping accessories: 1. Cleanouts:

a. Wall-mounted cleanouts (WCO) for concealed piping: Provide complete including cast-iron tapped tee, round smooth stainless steel access cover, and securing screw.


1) Manufacturers: One of the following or equal: a) Josam Company, 58910-19 (Tee & Plug) and 58600 (Access

Cover). b) Zurn Industries, Z1446-BP.

b. Floor cleanouts (FCO) in finished floor areas: Provide complete including cast-iron ferrule, countersunk plug, gastight and watertight seal, adjustable cleanout head extension, scoriated nickel-bronze top, and securing screw. 1) Manufacturers: One of the following or equal:

a) Josam Company, 56070. b) Zurn Industries, Inc., ZN-1400.

c. Floor cleanouts (FCO) in unfinished floor areas: Same as floor cleanouts specified for finished floor areas, except heavy-duty scoriated bronze top suitable for heavy traffic conditions. 1) Manufacturers: One of the following or equal:

a) Josam Company, 55000. b) Zurn Industries, Inc., Z-1400-HD.

d. Yard cleanouts (YCO) in asphalt or ground areas: Floor cleanouts in unfinished floor areas specified before, for encasement in a concrete pad as indicated on the Drawings and flush with grade.

2. Traps: a. Furnish traps with the fixtures.

1) Do not provide double trapped fixtures. b. Traps installed on bell-and-spigot pipe: Cast iron. c. Traps installed on threaded pipe: Recessed drainage pattern or as

specified with the fixture. 3. Floor drainage:

a. Floor drainage piping: PVC SCH 40 pipe and fittings.AD2 b. Equipment and floor drains.

1) Provide with adjustable strainer head, floor level grate, 4-inch diameter funnel extension and provided with no-hub outlet and nickel bronze top.

2) Manufacturers: One of the following or equal: a) Floor drain:

(1) Josam Company, 30000-A, combination drip drain, less clamping collar.

(2) Zurn Industries, Inc., ZN-415 strainer. b) Funnel extension:

(1) Josam Company, E-2. (2) Zurn Industries, Inc., ZN-328.

4. Kitchen sinks: a. Single compartment stainless steel sinks: Provide furnish complete with

18-gauge stainless steel single bowl, self-rimming, soft satin finish with mirror polished bowl edges, flush fittings deck, sound dampening, 7-1/2 inches deep, 14 inch by 15 3/4 inch bowl size; 1 hole punching size, stainless steel crumb strainer cup, 1-1/2 inch by 4 inch 20-gauge stainless steel tail piece; adjustable cast brass "P" trap with tubing drain to wall, 1-1/2-inch inlet, 1-1/2 inch outlet, ground swivel joint, cleanout plug, slip inlet; faucet supply assembly with 3/8-inch angle valve, wheel handle flexible tube riser, chrome finish.


b. Kitchen faucet: Center mount post type, single lever faucet with 9-1/2-inch tubular swing spout with aerator and 2.2 gallons per minute maximum flow, brass construction, finished in chrome plate.

PART 3 EXECUTION

3.01 PREPARATION

A. Rough-in fixtures and accessories in accordance with the dimensions supplied by the manufacturers of the fixtures.

3.02 INSTALLATION

A. General: 1. Mount fixtures and accessories without cutting of finish surface. 2. Conceal plumbing piping unless otherwise indicated on the Drawings or

specified in the specifications. 3. Furnish and install vents required in drainage piping as part of the plumbing

system, in accordance with Laws and Regulations.

B. Drain, waste, and vent piping: 1. Where not specified otherwise, install horizontal piping with a grade of 1/4 inch

per foot. 2. Provide vents, roof drains, and pipes flashed and made watertight at the roof

with lead sheet flashings. 3. Extend flashing not less than 6 inches up the pipes, and counterflash with

standard cast iron or malleable iron recessed roof couplings. 4. Extend flashing for vents up to the top of the vent and turn down into the pipe. 5. Extend flashing shields not less than 8 inches from vent and pipe in all

directions.

C. Plumbing piping accessories: 1. Provide cleanouts of the same size as the size of the waste and drain piping

on which cleanouts are installed, up to 4 inches in diameter. Provide cleanouts 4 inches in diameter on waste and drain piping larger than 4 inches diameter.

2. Provide traps at all fixture and equipment connections to the sanitary drainage system. Install traps as near to the fixtures as possible.

3. Sizes of equipment drains and of floor drains shall be as indicated on the Drawings.


A. Testing: 1. Test soil, waste, drain, and vent lines as specified and in accordance with

plumbing code as specified in Section 01410. 2. Test water piping with water under a pressure of 100 pounds per square inch. 3. Repair and correct defective work disclosed by testing. Repeat testing until

defective work is corrected.

B. As specified in Section 01650 and this Section.


C. Functional testing: 1. Pipe:

a. Test witnessing: Witnessed. b. Conduct pressure and leak test, as specified.

3.04 CLEANING

A. Flush piping and leave clean.

END OF SECTION

AD2 Addendum No. 2


SECTION 15732

AIR CONDITIONING UNITS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Packaged, split system air conditioning units. 2. Outside air chemical filtration package.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01410 - Regulatory Requirements. 3. Section 01610 - Project Design Criteria. 4. Section 01612 - Seismic Design Criteria. 5. Section 01614 - Wind Design Criteria. 6. Section 01650 – Facility Startup/Commissioning. 7. Section 01730 - Operations and Maintenance Data. 8. Section 15050 - Common Work Results for Mechanical Equipment. 9. Section 15082 - Piping Insulation. 10. Section 15820 - Ductwork Accessories. 11. Section 15936 - Instrumentation and Control Devices for HVAC. 12. Section 15954 - Testing, Adjusting, and Balancing for HVAC. 13. Section 15170 - Electrical Motor, Induction, 600 Volts and Below. 14. Section 16300 - Wiring Devices.

1.02 REFERENCES

A. Air-Conditioning, Heating, and Refrigeration Institute (AHRI): 1. 210-240 - Performance Rating of Unitary Air-Conditioning and Air-Source Heat

Pump Equipment. 2. 270 - Sound Rating of Outdoor Unitary Equipment. 3. 340/360 - Performance Rating of Commercial and Industrial Unitary

Air-Conditioning and Heat Pump Equipment.

B. American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE): 1. Standard 15 - Safety Standard for Refrigeration System. 2. Standard 52.2 - Methods of Testing General Ventilation Air-Cleaning Devices

for Removal Efficiency by Particle Size. 3. Standard 62.1 - Ventilation for Acceptable Indoor Air Quality.

C. American National Standards Institute (ANSI): 1. Z21.47 - Gas Fired Central Furnaces (except Direct Vent Central Furnaces)

with Addenda.

D. Air Movement and Control Association International, Inc. (AMCA): 1. 210 - Laboratory Methods for Testing Fans for Certified Aerodynamic

Performance Rating.


E. Federal Specification (FS): 1. Standard 141 - Paint, Varnish, Lacquer and Related Materials: Methods of

Inspection, Sampling and Testing.

F. National Electrical Code (NEC).

G. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

H. National Fire Protection Association (NFPA): 1. 90A - Standard for the Installation of Air Conditioning and Ventilating Systems.

I. Underwriters’ Laboratories, Inc. (UL).

1.03 DEFINITIONS

A. NEMA Type 3R enclosure in accordance with NEMA 250.


A. Design requirements: 1. Seismic supports: Design support to meet criteria as specified in

Section 01612. 2. Wind supports: For exterior units, design support that meet the criteria as

specified in Section 01614. 3. Electrical components: UL listed and met the design and installation

requirements of the NEC. 4. Gas, water piping, drains, and venting: In accordance with building code,

mechanical code, and plumbing code a specified in Section 01410 and in accordance with NFPA 90A.

5. Motors: As specified in Section 15170. 6. Fans: Rated in accordance with AMCA 210. 7. Unit air conditioners: Rated in accordance with AHRI Standards 210-240 or

340/360 and AHRI 270. Conform to the latest version of ASHRAE 15. 8. Unit air conditioners with heating options: Certified in accordance with ANSI

Z21.47. 9. Refrigerant: HFC R-410A.

B. Performance requirements: 1. As specified and as listed on the Air Conditioning Unit Schedule at the end of

this Section. 2. Outdoor noise levels: Outdoor noise levels in the 8 octave band range as

measured in accordance with AHRI Standard 270 for unit air conditioners and split system condensers shall not exceed the following:

Unit Nominal Capacity (Tons)

OCTAVE BANDS, hertz 63 125 250 500 1,000 2,000 4,000 8,000

3 to 5 64 70 71 74 74 71 67 61

6 79 85 78 74 71 73 66 59


Unit Nominal Capacity (Tons)

OCTAVE BANDS, hertz 63 125 250 500 1,000 2,000 4,000 8,000

7-1/2 to 10 64 70 73 79 82 78 74 67

12-1/2 and larger 84 88 84 83 84 78 72 68

3. Units shall be capable of starting and running at 125 degrees Fahrenheit ambient outdoor air temperature and exceeding the maximum load criteria of AHRI Standard 210-240 or 340/360.

4. Cooling capacities and energy efficiency ratios: Provide units with the following cooling capacities and energy efficiency ratios (EER) as rated in accordance with AHRI 210-240 or 340/360 and 270, unless scheduled otherwise.

Equipment Type Net Cooling Cap (Btuh) EER(1)

Air Cooled >65,000 and <135,000 11.2

Air Cooled >135,000 and < 240,000 11.0

Air Cooled >240,000 and < 760,000 10.0

Air Cooled > 760,000 9.7

Water Cooled >65,000 and <135,000 12.1

Water Cooled >135,000 and < 240,000 12.5

Water Cooled >240,000 and < 760,000 12.4

Water Cooled > 760,000 12.2 Note: (1) Deduct 0.2 from the required EERs for units with a heating section other than electric resistance

heat.

5. Units with heating capabilities: Meet or exceed the following efficiencies: a. Annual fuel utilization efficiency: 80 percent. b. Steady state efficiency: 80 percent. c. For projects located in California, California seasonal efficiency:

76.9 percent. 6. Unit air flows for cooling: A minimum of 300 cubic feet per minute per ton but

not exceeding 500 cubic feet per minute per ton of cooling unless scheduled otherwise.

7. Air filters: 25 to 30 percent efficiency when rated in accordance with ASHRAE Standard 52.2.

C. Electrical and control system design: 1. Design and supply necessary electrical power and control systems,

thermostats, components, and wiring to make a complete functioning system.

1.05 SUBMITTALS



B. Product data: 1. Shop drawings:

a. System layout, mechanical, electrical power, and control diagrams. b. Materials. c. Supports and seismic bracing calculations and details. d. Cut sheets on all primary and ancillary equipment. e. Proposed cutting and patching. f. Noise levels in 8 octave bands showing compliance with specified levels.

C. Installation instructions.

D. Provide vendor operation and maintenance manual as specified in Section 01730. 1. Furnish bound sets of installation, operation, and maintenance instructions for

each type of unit.

E. Provide Manufacturer’s Certificate of Source Testing as specified in Section 01650.

F. Provide Manufacturer’s Certificate of Installation and Functionality Compliance as specified in Section 01650.

G. Manufacturer's warranties.

H. Operation and Maintenance Manual.


A. Regulatory requirements: 1. Comply with and be installed in accordance with all applicable 2012

International Codes and local amendments of city of Austin.


A. Deliver units in 1 piece, factory assembled, piped, internally wired, charged with refrigerant and compressor oil, and tested.

B. Protect equipment from dust and atmospheric exposure: 1. Provide temporary closures for equipment openings designed for airflow.

C. Protect equipment from dust and atmospheric exposure as recommended by the unit manufacturer. 1. Provide temporary closures for equipment openings designed for airflow.



B. Units shall be capable of starting and operating in ambient temperatures as specified in this Section.


1.09 WARRANTY

A. Special warranties: From the date of acceptance of the project or date of beneficial use. 1. 1-year warranty: All components. 2. 5 years: For refrigerant compressors and closed or sealed refrigerant systems. 3. 10 years: For gas fired heat exchangers. 4. 10 years: For evaporator and condensing coils.

1.10 MAINTENANCE

A. Extra materials: 1. Provide 2 extra sets of filters per unit installed. 2. Provide 1 extra set of drive belts for each size belt system provided.

PART 2 PRODUCTS

2.01 SPLIT SYSTEM PACKAGED ELECTRIC-COOL AIR CONDITIONING UNITS

A. Manufacturers: One of the following or equal: 1. Carrier, Condenser Series38AUZ; when indoor handling unit scheduled,

Series40RUA. 2. Johnson Controls, Approved Similar. 3. Trane, Approved Similar.

B. Refrigerant components: Refrigerant circuit including: 1. Accumulator and filter/drier. 2. Compressor. 3. Thermostatic expansion valve. 4. Gauge ports. 5. Flow control valves. 6. Circuit feed system. 7. Service gauge connections with gauges on suction, discharge, and liquid lines

to charge, evacuate, and contain refrigerant. 8. Insulate refrigerant piping as specified in Section 15082.

C. Compressors: 1. Fully hermetically sealed, high efficiency, reciprocating or scroll type, with

internal and external vibration isolation. 2. Equipped with high-pressure relief. 3. Equipped with crankcase heater.

D. Condenser fan: 1. Propeller type, direct drive, aluminum blades, dynamically balanced, and

vertical discharge. 2. Permanently sealed ball bearings and permanently lubricated.

E. Condenser coil: Seamless copper tubes with mechanically bonded aluminum plate fins.


F. Condenser unit casing: 1. Manufactured of minimum 22-gauge galvanized steel, bonderized, corrosion

protected, and exterior coated with a baked enamel finish interior primer coated. Coating shall withstand Federal Test Method Standard 141 (Method 6061) 500-hour salt spray test.

2. Weatherproof design, reinforced, and braced for maximum rigidity. 3. Provide gasketed removable panels or access doors to service equipment

components and connections. 4. Provide with:

a. Non-corrosive drain pan in accordance with ASHRAE Standard 62.1. b. Minimum 3/4-inch horizontal drain connection. c. Knockouts for utility and control connections. d. Minimum 14 gauge steel roll formed base rail with lifting holes; provide

support feet for roof mounting on units under 6 tons size.

G. Controls and equipment safety features: 1. Provide unit controls for a complete and properly functioning system. Provide,

as a minimum, the following: a. Condenser fan controls. b. Evaporator fan controls with time delay after compressor shutdown. c. Motor contactors. d. 24-volt or 120-volt control circuit as scheduled; if 24-volt scheduled,

provide control power transformer. e. Manually reset circuit breakers. f. 5-minute compressor cycle delay. g. Check filter switch suitable for field connection remote alarm.

2. Equipment safety features, include: a. High-pressure switch. b. Compressor overtemperature and overcurrent. c. Loss of charge/low pressure switch. d. Freeze thermostat on evaporator. e. Lock out protection.

3. Interface to building HVAC control system: a. Provide contacts and signals to operate unit with the building control

system as specified in Section 15936. b. If no building control system specified in Section 15936, provide unit

interface devices and programmable electronic thermostat: 1) Setpoint range of 60 to 90 degrees Fahrenheit with digital

temperature and setpoint indication. 2) Provide 2-stage heating and 2-stage cooling when specified unit has

2 stages. 3) ON-OFF-AUTO air handler fan selector switch. 4) HEAT-OFF-COOL unit selector switch or automatic switch over. 5) 7-day programming schedule with at least 1 set back period per day. 6) Indicator lights for unit operating mode and unit failure. 7) Wall mounted with insulated backing plate. 8) Time delay for compressor restarts and for automatic switch over. 9) Provide with differential enthalpy economizer control when

economizer scheduled.


H. Electrical: 1. Unit power and control wiring entering unit cabinet at 1 location. 2. Provide 15 amp, 120 volt, single phase, ground fault interrupter convenience

outlet at condenser unit; provide factory installed transformer, and independent fuse or breaker protection for outlet.

3. Provide power disconnect switch at each piece of unit; mount disconnect in NEMA Type 3R enclosure if exterior to unit.

I. Indoor air handling unit, when scheduled, provide: 1. Indoor air section compartment: Insulated with minimum 1/2 inch thick,

permanent, fireproof, odorless glass fiber material, and coated on the air side. 2. Evaporator fan:

a. Belt driven, forward curved, double inlet, centrifugal type, steel with corrosion resistant finish, statically and dynamically balanced.

b. Permanently sealed ball bearings and permanently lubricated. c. Adjustable pitch motor pulley. d. Where the condenser fan is 7.5 horsepower or larger, provide a variable

speed or 2 speed fan. 3. Provide with ducted discharge; orientation as scheduled or as indicated on the

Drawings. Provide flexible duct connector where ducts connect to units. 4. Provide with direct expansion coil aluminum drip pan and polyvinyl chloride

drainpipe. 5. Filter section:

a. Provide filter with at least a MERV 8 rating. b. Provide with 2-inch filters accessible through front of unit. c. Provide with expanded metal return air grill to cover filter section. d. Low velocity 2-inch thick pleated filters of commercially available sizes. e. Filter face velocity: Not to exceed 350 feet per minute nominal flow. f. All filters for any 1 unit shall be the same size. g. Filter: Manufacturers: The following or equal:

1) American Air Filter. 6. Provide sub-base for floor mounting with room for condensate drain; when

scheduled provide outside air connection and economizer. 7. Evaporator coil: Seamless copper tubes with mechanically bonded aluminum

plate fins. 8. All components factory painted with optional coating suitable for corrosive

environments.

J. Indoor air terminal unit, when scheduled provide: 1. Fan coil unit: Fan coil air terminal unit; airflow rates and conditions as

scheduled on the Air Conditioning Unit Schedule. 2. Evaporator coil: Seamless copper tubes with mechanically bonded aluminum

plate fins.

K. Motors: 1. As specified in Section 15170, except as modified:

a. Compressor motors: Cooled by refrigerant gas passing through windings and with line break thermal and current overload protection.

b. Evaporator fan motor, condenser fan motor, and supply air fan motor: Permanently lubricated ball bearings and inherent automatic reset thermal overload protection.


L. Accessories. 1. Roof support for condenser; for roof mounted units provide:

a. Factory fabricated 16 gauge galvanized steel support with wood nailer strip.

b. Capable of supporting entire unit weight. c. Suitable for installing and connecting refrigerant piping to evaporator unit. d. In accordance with NRCA Standards. e. Shall extend a minimum of 8 inches above top of built up roofing, but shall

be no less than 14 inches high. Flashing in accordance with NRCA Standards.

2. Economizer, when scheduled provide: a. Integrated type capable of modulating to utilize up to 100 percent outdoor

air for cooling when outdoor air and humidity are at set acceptable levels. b. Including:

1) Differential bulb enthalpy control. 2) Damper drive motor. 3) Gravity relief damper. 4) Low leakage dampers, not to exceed 3 percent leakage at 1-inch

static pressure. c. Differential enthalpy sensor for economizer control.

3. Hail guard over condenser to protect against damage from hail and other flying debris.

4. Coil guard grill to protect condenser coil from penetration by large objects. 5. Provide condensate drainpipe in accordance with mechanical code as

specified in Section 01410. 6. Provide flexible duct connector on supply and return ducts where connected to

air handler or terminal units.

2.02 OUTSIDE AIR CHEMICAL FILTRATION PACKAGE

A. Manufacturers: One of the following or equal: 1. Sparks Technology, Inc. 2. Camfil Farr.

B. Filters: 1. Provide a 2-inch pre-filter equal to Farr 30/30.

a. Size pre-filter for a maximum velocity of 250 feet per minute. 2. Provide an activated carbon filter section in a ‘V’ configuration.

a. Select chemical filter for H2S adsorption and wastewater treatment plant odors.

b. Chemical filter shall supply air of 3 parts per billion based on inlet concentrations of 30 parts per billion.

C. Housing: 1. Shall be a minimum of 15 inches high and 24 inches wide. Size as required for

scheduled outside air volume. Outside units shall be fitted with a weather hood and bird screen. Material shall be aluminum. a. Unit panels and filter racks shall be gasketed and sealed to prevent

bypassing of untreated outside air. b. Coordinate with A/C manufacturer to determine the required transition to

the A/C unit. Coordinate with Contractor to provide easy access for replacement of filters.


c. Provide a 0 to 1 inch water column manometer or magnehelic gage across the entire package. Maximum loss through the package, at the flow indicated, shall be less than 0.25 inches when clean.


A. Completely factory test each unit in cooling and heating (if unit is supplied with heating option) modes including economizer operation. Coils and cooling system shall then be evacuated for 30 minutes prior to final charging of unit before shipment.

PART 3 EXECUTION

3.01 EXAMINATION

A. Examine and verify that Work is in condition to receive installation specified in this Section. 1. Take measurements and verify dimensions to ascertain fit of installation. 2. Ascertain structural sufficiency to support installation. 3. Ascertain that supports and openings are correctly located; otherwise cut new

openings where required. a. Submit details of proposed cutting and patching.

4. Confirm specified thermostat or other controls are compatible with specified equipment.

B. Examine and verify structural details and sections indicated on the Drawings, ascertain adequacy, and determine conflicts in dimensions and clearances.

3.02 PREPARATION

A. Before installation, remove dust and debris from equipment and ducts.

B. During installation and until equipment is operated, protect equipment and ducts from dust and debris by covering openings with tape or plastic.

3.03 INSTALLATION

A. Observe applicable installation requirements as specified in Section 15050.

B. Anchoring and support: 1. Provide anchoring and support designed in accordance with current

engineering practice for equipment and appurtenances by attaching or connecting to supporting members or by providing other supports.

C. Adjust alignment of ducts where necessary to resolve conflicts with architectural features or to resolve conflicts with the work of other trades.


D. Install and wire unit air conditioners, controls, and thermostats in accordance with manufacturer's recommendations. 1. Provide local disconnect switches.

E. Provide flexible duct and flexible piping connections at connections to unit air conditioners.

F. Install roof curb and unit as recommended by unit manufacturer.

G. Install NRCA approved flashing and counterflashing.

H. Provide venting in accordance with building code, mechanical code, and plumbing code as specified in Section 01410 and in accordance with NFPA 54.

I. Upon completion of installation, clean duct, and debris from ductwork, and equipment.


A. Test equipment and installation to verify tightness, operation, and outdoor sound power at levels.

B. Test equipment performance and balance equipment as specified in Section 15954.

3.05 COMMISSIONING


B. Manufacturer (each) services for each type of unit. 1. Provide Manufacturer’s Certificate of Source Testing. 2. Provide Manufacturer’s Certificate of Installation and Functionality

Compliance. 3. Training and other on-site services.


Source Testing (Witnessed or Non-witnessed)



Functional Testing

Process Operational

Period





Days (each trip)

Non-Witnessed 2 1 1 2 1 1 Not Required

3.06 SCHEDULES

A. Air Conditioning Unit Schedule.


Air Conditioning Unit Schedule

Equip. No. Location

Evaporator Condenser Heating Unit Power

OSA (cfm)

Other Requirements Total/

Sensible (MBH)

Air Fan CFM

Fan ESP, "WC

Inlet DB/WB (F)

Outlet DB/WB (F)

Inlet Air DB (F)

Gas Btu/hr

Volts/ Phases/ MCA

See Notes at end of Schedule for Requirements

HB-SST-AHU-003

ELEC. BLDG.-

MECH RM.

80 3,000 0.5 86.6/67.1 59.5/57.7 105 N/A 460/3/5.0 0 5,6,12,15,20,27

HB-SST-CU-003

ELEC. BLDG.-

OUTSIDE

80 N/A N/A N/A N/A 105 N/A 460/3/18 N/A 4,23

HB-SST-PPU-001

ELEC. BLDG.-

MECH RM.

N/A 500 0.15 N/A N/A N/A N/A 460/3/2FLA 150 2

Notes: 1. Roof Mounted Single Unit Package. 2. Base/floor Mounted Single Unit Package. 3. Roof Mounted Condenser Split System. 4. Base/floor Mounted Condenser Split System. 5. Side/Top Supply Discharge Connection. 6. Side Return Connection. 7. Bottom Supply Discharge Connection. 8. Bottom Return Connection. 9. Provide Electric Heating. 10. Provide Natural Gas Heating. 11. Provide LPG Gas Heating. 12. 120 Volt Control Voltage. 13. 24 Volt Control Voltage. 14. Provide Indoor Air Handling Unit with Direct Drive Fan.

15. Provide Indoor Air Handling Unit with Belt Drive Fan and Adjustable

Sheaves. 16. Provide duct mounted Fan Coil Unit sized for scheduled conditions. 17. Provide Outside Air Manual Damper. 18. Provide Economizer. 19. Provide blank off plate. 20. Thermostat Provided by Contractor. 21. Thermostat Provided by AC Unit Manufacturer. 22. Control system specified in Section 15936. 23. Provide condensing unit sized per air handler manufacturer to

provide cooling requirements as indicated for associated air handler. 24. Provide condensing unit sized per air handler manufacturer to

provide cooling requirements as indicated for associated air handler. 25. Wall mounted unit with self-contained controls 26. Supply/return grilles and ductwork provided by air conditioning

manufacturer. 27. Include service option with return-air smoke detector sensor to be

wired in field to shut down unit upon detection of smoke.

END OF SECTION


SECTION 15740

HEAT PUMPS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Mini-split system heat pumps:

a. Ducted floor mounted heat pump.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01410 - Regulatory Requirements. 3. Section 01610 - Project Design Criteria. 4. Section 01612 - Seismic Design Criteria. 5. Section 01614 - Wind Design Criteria. 6. Section 01650 – Facility Startup/Commissioning. 7. Section 01730 - Operation and Maintenance Data. 8. Section 01783 - Warranties and Bonds. 9. Section 15050 - Common Work Results for Mechanical Equipment. 10. Section 15082 - Piping Insulation. 11. Section 15936 - Instrumentation and Control Devices for HVAC. 12. Section 15954 - Testing, Adjusting, and Balancing for HVAC. 13. Section 15958 - Mechanical Equipment Testing. 14. Section 16150 - Raceways, Fittings and Supports. 15. Section 16200 - Wiring (600 Volts and below). 16. Section 16250 - Boxes and Cabinets. 17. Section 16300 - Wiring Devices. 18. Section 16550 - Grounding. 19. Section 16660 - Disconnect Switches and Enclosures.

1.02 REFERENCES

A. Air-Conditioning, Heating, and Refrigeration Institute (AHRI): 1. 210-240 - Performance Rating of Unitary Air-Conditioning and Air-Source Heat

Pump Equipment. 2. 270 - Sound Rating of Outdoor Unitary Equipment.

B. Air Movement and Control Association International, Inc. (AMCA): 1. 210 - Laboratory Methods for Testing Fans for Certified Aerodynamic

Performance Rating.

C. American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE): 1. 15 - Safety Standard for Refrigeration Systems. 2. 52.2 - Method of Testing General Ventilation Air-Cleaning Devices for

Removal Efficiency by Particle Size. 3. 62.1 - Ventilation for Acceptable Indoor Air Quality.


D. Federal Specification (FS): 1. Standard 141 - Paint, Varnish, Lacquer and Related Materials: Methods of

Inspection, Sampling and Testing.

E. National Fire Protection Association (NFPA): 1. 54 - National Fuel Gas Code. 2. 90A - Standard for the Installation of Air Conditioning and Ventilating Systems.

F. National Roofing Contractors Association (NRCA).


A. Design requirements: 1. Seismic supports: Design supports to comply with the criteria specified in

Section 01612. 2. Wind supports: Design supports to comply with the criteria specified in

Section 01614. 3. Electrical components: UL listed and meeting the design and installation

requirements of the NEC. 4. Water piping, drains, and venting: In accordance with building code,

mechanical code, and plumbing code as specified in Section 01410 and in accordance with NFPA 90A.

5. Fans supplied with heat pump units: Rated in accordance with AMCA 210. 6. Unit heat pumps: Rated in accordance with AHRI Standards 210-240 and

AHRI 270 and in accordance with the latest version of ASHRAE 15. 7. Insulation and adhesives: In accordance with NFPA 90A requirements for

flame spread and smoke generation. 8. Refrigerant: HCFC R-410A.

B. Performance requirements: 1. Performance requirements as specified and as scheduled on the Heat Pump

Schedule in this Section. 2. Maximum sound power levels in the 8 octave band ranges, measured in

accordance with AHRI Standard 270:

OCTAVE BANDS Unit Nominal

Capacity (Tons) 63 125 250 500 1,000 2,000 4,000 8,000 0 to 5 64 70 71 74 74 7871 67 67

7-1/2 to 10 65 70 73 80 84 78 73 65

12 and larger 84 88 84 83 84 78 72 68

3. Capable of starting and providing cooling from 45 to 125 degrees Fahrenheit ambient outdoor air temperature and exceeding the maximum load criteria of AHRI Standard 210-240.

4. Capable of starting and providing heating at or above 0 degrees Fahrenheit outdoor ambient air temperature.

5. Minimum cooling and heating capacities, energy efficiency ratios (EER), and coefficient of performance (COP), as rated in accordance with AHRI 210-240 and 270:


Heating High

Temperature(1) Heating Low

Temperature(2) Nominal Capacity

(Tons) Standard

cfm

Cooling Capacity

(Btuh) EER(3) Capacity

(Btuh) COP Capacity

(Btuh) COP 3 1,200 36,400 11.0 35,200 3.0 18,400 2.0

4 1,750 47,000 11.0 47,000 3.0 26,400 2.0

5 2,000 59,000 11.0 59,000 3.0 26,400 2.1

6 2,400 72,800 11.0 70,400 3.0 36.800 2.0

7-1/2 3,000 87,000 11.0 89,000 3.0 49,000 2.0

10 4,000 113,000 11.0 116,000 3.0 65,000 2.0 Notes: (1) high temperature heating standard: a. 70 degrees Fahrenheit dB indoor entering air temperature. b. 47 degrees Fahrenheit dB, 43 degrees Fahrenheit wet bulb outdoor entering air temperature. (2) Low temperature heating standard: a. 70 degrees Fahrenheit dB indoor entering air temperature. b. 17 degrees Fahrenheit dB, 15 degrees Fahrenheit wet bulb outdoor entering air temperature. (3) EER value: a. Deduct 0.2 from the required EER’s for units with a heating section other than electric

resistance heat. b. EER value based on CCR Title 24 requirements.

6. Unit air flows for cooling, unless scheduled otherwise: a. Minimum: 300 cubic feet per minute per ton of cooling. b. Maximum: 500 cubic feet per minute per ton of cooling.

7. Air filters: 25 to 30 percent efficiency when rated in accordance with ASHRAE Tested Standard 52.2.


thermostats, components, and wiring to make a complete functioning system. Comply with referenced electrical Sections and design to perform the system cooling only or cooling/heating requirements as specified in Section 15936.

2. Electrical power and control systems: As specified in the following sections: a. Section 16150. b. Section 16200. c. Section 16250. d. Section 16300. e. Section 16600.

1.04 SUBMITTALS

A. Submit as specified in Section 01300 and Section 15050.

B. Product data.

C. Shop drawings: 1. System layout, mechanical, electrical power, and control diagrams.


2. Materials. 3. Supports and seismic bracing calculations and details. 4. Cut sheets on primary and ancillary equipment. 5. Proposed cutting and patching. 6. Noise levels in 8 octave bands showing compliance with specified levels. 7. Factory test results.

D. Calculations.

E. Quality control submittals.

F. Commissioning submittals: 1. Provide Manufacturer’s Certificate of Source Testing as specified in Section

01650. 2. Provide Manufacturer’s Certificate of Installation and Functionality Compliance


G. Project closeout documents: 1. Provide vendor operation and maintenance manual as specified in Section

01730.

H. Warranties.


A. Deliver units in 1 piece, factory assembled, piped, internally wired, charged with refrigerant and compressor oil, and tested.

B. Protect equipment from dust and atmospheric exposure: 1. Provide temporary closures for equipment openings designed for airflow.



1.07 WARRANTY


B. Special warranties: 1. Refrigerant compressors and closed or sealed refrigerant systems warranty

duration: Provide 5 year warranty. 2. Electric heaters (if supplied) warranty duration: Provide 5 year warranty. 3. Evaporator and condensing coils warranty duration: Provide 5 year warranty.

1.08 MAINTENANCE

A. Spare parts: Provide 2 extra sets of filters per unit installed.


PART 2 PRODUCTS

2.01 MINI-SPLIT SYSTEM HEAT PUMPS

A. Manufacturers: One of the following or equal: 1. Mitsubishi, Series MXZ-3C24NA; when indoor air handling unit scheduled,

Series MVZ-A18AA4 (ducted). 2. Samsung, similar series. 3. Daikin, similar series. 4. Trane, similar series.

B. Compressors: 1. Fully hermetically sealed, high efficiency, reciprocating or rotary or scroll type,

with rubber grommet vibration isolation.

C. Fans: 1. Indoor air fan:

a. Direct driven with capacitor start motor; , steel with corrosion resistant finish, statically and dynamically balanced.

b. Bearings: permanently sealed ball bearing type and permanently lubricated.

2. Outdoor condenser fan: a. Propeller type, direct drive, aluminum blades, dynamically balanced. b. Bearings: permenantly sealed ball bearing type and permenantly

lubricated.

D. Coils: 1. Evaporator and condenser coils: seamless copper tubes with mechanically

bonded aluminum plate fins. 2. Provide corrosion resistant finish, suitable for marine environment.

E. Refrigerant components: Refrigerant circuit including: 1. Accumulator and filter/drier. 2. Expansion device. 3. Reversing valve. 4. Flow control valves. 5. Service and gauge connections on compressor suction and discharge, and

liquid lines to charge, evacuate, and contain refrigerant.

F. Controls and equipment safety features: 1. Provide system controls for a complete functioning system:

a. High and low evaporator fan speed control for cooling and heating modes. b. Fan only operation. c. Space temperature condition setting. d. Vapor bellows thermostat to cycle unit to maintain space condition.

2. Equipment safety features: a. Thermostatic basepan drain to prevent freeze up of the fan in collected

condensate. 3. Provide with a low ambient cooling option.


G. Electrical: 1. Provide for single external power connection of voltage and phases as

scheduled; control power wiring internal to the unit.

H. Unit casing: 1. outdoor casing shall be constructed from galvanized steel plate, finished with

an electrostatically applied, polyester powder coating for corrosion protection. 2. Weatherproof design, reinforced and braced for maximum rigidity. 3. Provided with:

a. Filter rack for filters accessible through the front of the unit. b. Non-corrosive drain pan in accordance with ASHRAE Standard 62.1. c. Horizontal drain connection. d. Provide mini condensate pump suitable to be powered from

indoor/outdoor unit. e. Knockouts for power connections. f. Provide wall sleeve of galvanized steel coated similar to unit casing.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect all components for shipping damage, conformance to specifications, and proper torques and tightness of fasteners, as specified in Section 15050.

B. Examine and verify that Work is in condition to receive installation specified in this Section. 1. Take measurements and verify dimensions to ascertain fit of installation. 2. Ascertain structural sufficiency to support installation. 3. Ascertain that supports and openings are correctly located; otherwise cut new

openings where required. a. Submit details of proposed cutting and patching.

4. Confirm specified thermostat or other controls are compatible with specified equipment.

C. Examine and verify structural details and sections indicated on the Drawings, ascertain adequacy, and determine conflicts in dimensions and clearances.

3.02 PREPARATION

A. Before installation remove dust and debris from equipment and ducts.

B. During installation and until equipment is operated, protect equipment and ducts from dust and debris by covering openings.

3.03 INSTALLATION

A. Install equipment as indicated on the Drawings and as specified in Section 15050 and the manufacturer's written installation instructions.

B. Adjust alignment of ducts where necessary to resolve conflicts with architectural features or to resolve conflicts with the work of other trades.


C. Install roof curb and unit as recommended by unit manufacturer.

D. Install NRCA approved flashing and counterflashing.

E. Provide venting in accordance with building code, mechanical code, and plumbing code as specified in Section 01410, and in accordance with NFPA 54.

F. Upon completion of installation, remove debris from ductwork and equipment and clean ducts.

3.04 COMMISSIONING



a. Manufacturer’s Certificate of Source Testing. b. Manufacturer’s Certificate of Installation and Functionality Compliance.

2. Manufacturer’s Representative onsite requirements: a. Installation: 1 trip, 1 day minimum. b. Functional Testing: 1 trips, 1 day minimum each.

3. Training: a. Maintenance: 2 hours per session, 2 sessions. b. Operation: 1 hours per session, 2 sessions.

4. Process Operational Period. a. As required by Owner or Contractor.

C. Source testing: 1. Test as specified in Section 15958. 2. AHUs and CUs:

a. Test witnessing: Witnessed. b. Conduct Level 1 General Equipment Performance Test. c. Conduct Level 1 Vibration Test. d. Conduct Level 1 Noise Test. e. Factory test in cooling and heating modes including economizer

operation. Evacuate coils and refrigerant system for 30 minutes prior to final charging of unit before shipment.

3. Electrical Instrumentation and Controls: a. Test witnessing: Witnessed. b. Conduct testing as specified in Section 16800.

D. Functional testing: 1. AHUs and CUs:

a. Test witnessing: Witnessed. b. Conduct Level 2 General Equipment Performance Test. c. Conduct Level 2 Vibration Test. d. Conduct Level 2 Noise Test. e. Test equipment and installation to verify tightness, operation, and unit

heat pump vibration is within manufacturer's submitted maximum. f. Test equipment performance and balance equipment as specified in

Section 15954.



3.05 SCHEDULES

A. Heat Pump Schedule:


Equip. No. Location

Cooling Mechanical Heating

Aux. Heat kW

Unit Power Air Fan

OSA (cfm)

Additional Requirements (see Notes at

End of Schedule)

Net Total/

Sensible (MBH)

Evaporator

Condenser Inlet DB

(°F)

Total Capacity Minimum

MBH

Condenser

Evaporator Inlet DB

(°F) V Ph. Amp cfm

ESP “WC

Inlet DB/WB

(°F)

Outlet DB/WB (°F)

Inlet DB/WB (°F)

Outlet DB/WB

(°F)

HB-SST-AHU-001

BLOWER BLDG.-HVAC

EQUIP. RM.

18 76/62.4 Per mfr

105 20 Mfr Std Mfr Std 26.6 NA 208 1 1 585 0.5 50 2,5,8,11,12,15,19

HB-SST-AHU-002

BLOWER BLDG.-HVAC

EQUIP. RM.

18 86.5/67.1 Per mfr

105 20 Mfr Std Mfr Std 26.6 NA 208 1 1 585 0.5 50 2,5,8,11,12,15,19

HB-SST-CU-001

BLOWER BLDG.-

GROUND

18 NA NA 105 20 NA NA 26.6 NA 208 1 22.1 NA NA NA 4,21

HB-SST-CU-002

BLOWER BLDG.-

GROUND

18 NA NA 105 20 NA NA 26.6 NA 208 1 22.1 NA NA NA 4,21

Notes: 1. Roof Mounted Single Unit Package. 2. Base/floor Mounted Single Unit Package. 3. Roof Mounted Condenser Split System. 4. Base/floor Mounted Condenser Split System. 5. Side/Top Supply Discharge Connection. 6. Side Return Connection. 7. Bottom Supply Discharge Connection. 8. Bottom Return Connection. 9. Provide Auxilary Electric Heating. 10. 120 Volt Control Voltage. 11. 24 Volt Control Voltage. 12. Provide Indoor Air Handling Unit with Direct Drive Fan. 13. Provide Indoor Air Handling Unit with Belt Drive Fan and Adjustable

Sheaves.

14. Provide duct mounted Fan Coil Unit sized for scheduled conditions. 15. Provide Outside Air Manual Damper. 16. Provide Economizer. 17. Provide blank off plate. 18. Thermostat Provided by Contractor. 19. Thermostat Provided by AC Unit Manufacturer. 20. Control system specified in Section 15936. 21. Provide condensing unit sized per air handler manufacturer to

provide cooling requirements as indicated for associated air handler. 22. Wall mounted unit with self-contained controls. 23. Supply/return grilles and ductwork provided by air conditioning

manufacturer. 24. Include service option with return-air smoke detector sensor to be

wired in field to shut down unit upon detection of smoke.

END OF SECTION


SECTION 15762

HEATING UNITS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Electric unit heaters (EUH). 2. Thermostats for unit heater.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01410 - Regulatory Requirements. 3. Section 01610 - Project Design Criteria. 4. Section 01612 - Seismic Design Criteria. 5. Section 01614 - Wind Design Criteria. 6. Section 01650 – Facility Startup/Commissioning. 7. Section 01730 - Operation and Maintenance Data. 8. Section 01783 - Warranties and Bonds. 9. Section 15050 - Common Work Results for Mechanical Equipment. 10. Section 15170 - Electrical Motor, Induction, 600 Volts and Below. 11. Section 15936 - Instrumentation and Control Devices for HVAC. 12. Section 15954 - Testing, Adjusting, and Balancing for HVAC. 13. Section 15958 - Mechanical Equipment Testing. 14. Section 16800 - Calibration, Testing and Settings.

1.02 REFERENCES

A. Air Movement and Control Association International, Inc. (AMCA): 1. 302 - Application of Sone Ratings for Non-Ducted Air Moving Devices.

B. American Gas Association (AGA).

C. National Electrical Code (NEC).

D. National Fire Protection Association (NFPA): 1. 54 - National Fuel Gas Code.

E. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (100 V Maximum).

F. Underwriters’ Laboratories, Inc. (UL).

1.03 DEFINITIONS

A. NEMA Type 3R enclosure in accordance with NEMA 250.



A. Design requirements: 1. Provide seismic and wind supports meeting the seismic design criteria as

specified in Section 01612 and wind design criteria for exterior units as specified in Section 01614.

2. Electrical components: UL listed and meeting the design and installation requirements of the NEC.

3. Hot water piping, gas piping, drains, venting, and other appurtenances of unit heaters: Install in accordance with building code, mechanical code, and plumbing code as specified in Section 01410, and the NFPA.

4. Noise levels for unit heaters installed in offices, hallways, or entry areas: Not to exceed 10 Sones as measured in accordance with AMCA Publication 302.

5. Motors supplied with heating units: As specified in Section 15170.

B. Performance requirements are included in the Heating Unit Schedules at the end of this Section.

C. Design and supply necessary electrical power and control systems, components, and wiring to make a complete functioning system. 1. Comply with referenced electrical Sections and design to perform system

heating functions as specified in Section 15936.

1.05 SUBMITTALS

A. Submit as specified in Section 01300 and Section 15050.

B. Product data: 1. Samples: Manufacturer's standard color chips for cabinets finish. 2. Certificates: Successful testing of burners used in gas unit heaters.

C. Shop drawings: 1. System layout, mechanical, electrical power, and control diagrams. 2. Materials. 3. Supports and seismic bracing calculations and details. 4. Cut sheets on primary and ancillary equipment. 5. Sound ratings of fans in Sones in accordance with AMCA Publication 302.

D. Commissioning submittals: 1. Provide Manufacturer’s Certificate of Source Testing as specified in Section

01650. 2. Provide Manufacturer’s Certificate of Installation and Functionality Compliance as


E. Project closeout documents: 1. Provide vendor operation and maintenance manual as specified in Section

01730.

F. Warranties.



A. Protect equipment from dust and atmospheric exposure as recommended by the unit manufacturer. 1. Provide temporary closures for equipment openings designed for airflow.



1.08 WARRANTY


PART 2 PRODUCTS

2.01 ELECTRIC UNIT HEATERS (EUH)

A. Manufacturers: One of the following or equal. 1. Trane, Type UHEC. 2. Markel, Series 5100. 3. Chromalox, Type LUH or VUH.

B. Fan type: Aluminum axial flow: 1. Provide fan guards. 2. Dynamically balance. 3. Fan designed for quiet operation. 4. Permanently lubricated ball bearings. 5. Automatic reset thermal overload protection.

C. Heating element characteristics: 1. Rated capacity at entering air temperature of 65 degrees Fahrenheit. 2. Fin type, steel plated heater elements, with elements brazed to common fins,

designed for maximum strength and maximum heat transfer. 3. 3-phase designed for balanced phases. 4. Over temperature cutout with automatic reset.

D. Features: 1. Built-in magnetic contactors. 2. Control transformer for 24 or 120-volt control as indicated in the Heating Unit

Schedules. 3. Required mounting brackets. 4. Individually adjustable outlet louvers. 5. Cabinet formed of minimum thickness 18-gauge steel with steel stiffeners. 6. Controls:

a. Provide thermostat as specified in this Section. b. Provide control transformer suitable for 24-volt or 120-volt control as

indicated in the Heating Unit Schedules.

E. Finishes: 1. Casing finish backed enamel in manufacturer's standard color.


2.02 THERMOSTATS FOR UNIT HEATERS

A. Type: Wall mounted, heat only with fan AUTO-ON selector switch when fan part of unit and separate system ON-OFF selector switch.

B. Dial or lever temperature setpoint adjustment with 45 to 90 degrees Fahrenheit setpoint range.

C. Setpoint and temperature indication.

D. Control voltage as indicated in the attached Heating Unit Schedules.

E. Bi-metallic contacts suitable for 1- or 2-stage unit heater control as specified for the heater size or as scheduled. The use of mercury within the thermostat is not acceptable.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect all components for shipping damage, conformance to specifications, and proper torques and tightness of fasteners, as specified in Section 15050.

B. Examine and verify that Work is in condition to receive installation specified in this Section. 1. Take measurements and verify dimensions to ascertain fit of installation. 2. Verify structural sufficiency to support installation. 3. Verify that chassis, shafts, and openings are correctly located.

a. Otherwise cut new openings where required. 4. Confirm specified thermostat and other controls are compatible with specified

equipment.

C. Examine and verify structural details and sections indicated on the Drawings, ascertain adequacy, and determine possible conflicts in dimensions and clearances.

3.02 PREPARATION



3.03 INSTALLATION

A. Install equipment as indicated on the Drawings and as specified in Section 15050 and the manufacturer's written installation instructions. 1. Provide disconnect switches at the unit heaters wherever indicated on the

Drawings, specified in this Section, scheduled and wherever required by code.

B. Anchoring and support: Install anchoring for seismic and wind forces to meet the design criteria specified in Sections 01612 and 01614.


C. Alignment: Adjust ductwork alignment when necessary to resolve conflicts with architectural and structural features or to resolve conflicts with work of other trades.

D. Adjust heater units with louvers for optimum air circulation.

E. Provide gas unit heater venting in accordance with mechanical code and plumbing code as specified in Section 01410 and in accordance with NFPA 54.

3.04 COMMISSIONING



a. Manufacturer’s Certificate of Source Testing. b. Manufacturer’s Certificate of Installation and Functionality Compliance.

2. Manufacturer’s Representative onsite requirements: a. Installation: 1 trip, 1 day minimum. b. Functional Testing: 1 trips, 1 day minimum each.

3. Training: a. Maintenance: 1 hours per session, 1 session. b. Operation: 1 hours per session, 1 session.

4. Process Operational Period. a. As required by Owner or Contractor.

C. Source testing: 1. Test as specified in Section 15958. 2. Electrical Unit Heaters:

a. Test witnessing: Witnessed. b. Conduct Level 1 General Equipment Performance Test. c. Conduct Level 1 Vibration Test. d. Conduct Level 1 Noise Test.


D. Functional testing: 1. Electrical Unit Heater:

a. Test witnessing: Witnessed. b. Test equipment performance and balance equipment as specified in

Section 15954. c. Conduct Level 2 General Equipment Performance Test. d. Conduct Level 2 Vibration Test. e. Conduct Level 2 Noise Test.


3.05 HEATING UNIT SCHEDULES

A. Electric Heating Unit Schedule.


ELECTRIC HEATING UNIT SCHEDULE

Equip. No. Location

Capacity Fan Additional Requirements

(see Schedule Notes) Input

kW / V / Ph. Output MBH cfm Hp

HB-SST-UH-001 BLOWER ROOM 10 / 480 / 3 34.1 850 1/15 3, 5, 7, 11, 13




HEATING UNIT SCHEDULE NOTES

1. Steam service 2 Hot water service. 3. Electric service. 4. Thermostat provided by Contractor. 5. Thermostat provided by heater manufacturer. 6. Horizontal mounting. 7. Vertical mounting. 8. Wall mounting. 9. Floor mounting. 10. Recessed mounting. 11. 24-volt control voltage. 12. 120-volt control voltage. 13. Fan direct drive.

14. Fan belt drive. 15. Unit located inside building (indoors). 16. Unit located on roof or building exterior. 17. Natural gas fired. 18. Liquefied petroleum gas fired. 19. Unit flange mounted. 20. Unit slip-in mounted. 21. Provide stainless steel UH exchanger. 22. Provide stainless steel UH gas burner. 23. Side air intake to fan. 24. Side air discharge. 25. Down air discharge from unit. 26. Down air inlet. 27. Provide unit suitable for NEC Group D, Class I, Division 1

hazardous location.

END OF SECTION


SECTION 15772

PROCESS PIPING AND EQUIPMENT HEAT TRACKING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Heat tracing cable for outdoor water and chemical piping including the following: 1. Heating cables. 2. Control panels. 3. Temperature sensors. 4. Temperature controllers. 5. Contactors. 6. Enclosures. 7. All other auxiliary equipment and controls required to complete a heat tracing

system.

1.02 REFERENCES

A. National Electrical Manufacturers' Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

B. Underwriters' Laboratories, Inc.(UL): 1. 746B - Polymeric Materials - Long Term Property Evaluations.

1.03 DEFINITIONS

A. NEMA Type 4X enclosure in accordance with NEMA 250.


A. Design requirements: 1. General: Heat tracing applications up to a maintain temperature of 250

degrees Fahrenheit and intermittent exposure to 420 degrees Fahrenheit shall use self-regulating heating cables and pads.

2. Self-regulating heating cable shall vary its heat output relative to the temperature of the surface of the pipe or the tank allowing cable to be crossed over itself without overheating and to be cut to length in the field.

3. Design for a useful life of 20 years or more with "power on" continuously. a. The criteria for life shall be to retain at least 75 percent of its original

power when tested according to UL 746B. 4. Pipe shall be heat traced and insulated in accordance with Section 15082 -

Piping Insulation to maintain an operating temperature of 75 degrees Fahrenheit for a minimum ambient temperature of 32 degrees Fahrenheit.

5. Heat trace system controller: a. Provided with a single power source, as described below. b. Provide all necessary components for heat tracing all of the piping as

specified in Section 15052 - Common Work Results for General Piping and as indicated on the Drawings.


c. A limited number of electrical conduits are as indicated on the Drawings as a guide for the Contractor.

d. Contractor shall determine the quantities for all components including electrical conduit, conductors, and the sizes of the breakers for this particular application as required and recommended by manufacturer, subject to Engineer acceptance, for a complete operable system at no additional cost to the Owner.

e. Provide: Power connecting kits with junction boxes. f. End seal kits. g. Fittings kits. h. Electric traced labels. i. Aluminum tapes. j. Line sensing thermostats:

1.05 SUBMITTALS

A. Product data: 1. Catalog number, wattage output, voltage rating, and product data. 2. Wiring diagrams and power distribution plan. 3. Installation Instructions. 4. Warranty.

B. Shop drawings: Include isometric drawings for each heat traced pipe showing installation details, and size and type of heat tracing cable.


A. Regulatory requirements and reference standards: 1. The electric heat tracing system shall as specified in this Section and shall be

designed, manufactured, and tested in accordance with the minimum applicable requirements of the latest edition of the following codes and standards.

2. Additional specific requirements shall be further defined in the testing requirements for each Section.

1.07 WARRANTY

A. Cables: All cables shall be warranted for a period of 10 years for manufacturing defects.

PART 2 PRODUCTS

2.01 HEAT TRACING CABLE

A. Manufacturers: One of the following or equal: 1. Raychem, BTV. 2. Chromalox, Type SRL Rapid Trace. 3. Eaton Corp., equivalent product. 4. Dekoron, equivalent product.


B. Type: Self-regulating and self-limiting, 5 watts per foot, 120 volts, 60 hertz, flexible twin 16 American Wire Gauge copper bus wires, with tinned copper braid overshield. 1. Provide wattage of cable suitable for maintaining specified temperature at the

minimum site ambient temperature for the pipe size and insulation as stated in this Specification Section.

2.02 CONTROLLER

A. Manufacturers: The following or equal: 1. Raychem Digitrace 910/920.

B. Operating characteristics: 1. Controller shall provide continuous monitoring of heat tracing circuit analyzing

temperature through a hard-wired RTD. 2. Controller shall energize system automatically if the temperature drops below

a preset point. a. Controller shall be equipped with local alarm to alert maintenance

personnel if heat trace circuit is interrupted. 3. Controller shall have the capability of performing a self-diagnostic check on the

system and advising maintenance personnel of the exact nature of any circuit problems.

C. Controller shall be fully compatible with heat trace and provided by same manufacturer as heat trace. 1. One single 120-volt 1-phase power source will be provided to each heat

tracing control system panel: a. Provide any required transformers for any secondary voltages. b. Provide a configurable dry contact for heat trace fault.

2. Controller shall have double pole solid-state switching, temperature control from -40 degrees Fahrenheit to 125 degrees Fahrenheit, and a 30-amp rating from -40 degrees Fahrenheit to 125 degrees Fahrenheit ambient temperature.

3. Power supply: Provide controller power supply with adjustable ground fault detection.

4. Controller shall have battery backup system to retain programmed parameters in the event of a power failure.

5. Enclosure: Unit shall be enclosed in a NEMA Type 4X stainless steel panel. 6. Network capabilities: Controller shall have network capabilities enabling

monitoring and programming from a central location.

2.03 CONNECTION KITS, END SEALS, SPLICE AND TEE KITS

A. Heat trace connection, end, splice, and tee kits shall be designed to meet or exceed the life of the heat trace and shall be given equal consideration and evaluation.

B. Provide wiring, conduits, junction boxes, and any other electrical components as required.

2.04 ACCESSORIES

A. Power connection kits.

B. Termination kits.


C. Splice kits.

D. End seal kits.

E. Straps.

F. Thermostat.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install heat tracing cable on water pipes: 1. Heat tracing cable for outdoor aboveground water piping. 2. Install heat tracing cable on water piping subject to freezing.

B. Wrap heat-tracing tape with aluminum tape prior to installing insulation.

C. Install pipe insulation as specified in Section 15082 - Piping Insulation.

D. Install heat tape and controls in accordance with manufacturer's published installation instructions.


A. Manufacturer's field service: 1. Inspect installed systems for proper installation. 2. Instruct Owner's personnel on operations and maintenance of the systems.

END OF SECTION


SECTION 15812

METAL DUCTS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Aluminum ductwork.

B. Related section: 1. Section 01300 - Submittals. 2. Section 01612 - Seismic Design Criteria. 3. Section 01650 – Facility Startup/Commissioning. 4. Section 15820 - Ductwork Accessories. 5. Section 15954 - Testing, Adjusting, and Balancing for HVAC.

1.02 REFERENCES

A. ASTM International (ASTM): 1. B 209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and

Plate.

B. Sheet Metal and Air Conditioning Contractors' National Association (SMACNA): 1. HVAC Systems-Duct Design. 2. Seismic Restraint Manual Guidelines for Mechanical Systems.

C. Underwriters Laboratories, Inc. (UL): 1. 181A – Closure Systems for Use With Rigid Air Ducts.


A. Design requirements: 1. Custom design and fabricate metal ductwork for the applications indicated on

the Drawings and for the conditions specified. 2. In accordance with SMACNA Manual for gauge of sheet metal, joint types,

reinforcement, bracing, hangers and supports, fabrication, and installation. a. Sheet metal thicknesses: The greater of that thickness required to in

accordance with SMACNA for the design pressure specified and the following minimum thicknesses:

Diameter or Largest Dimension of Rectangular Duct (Inches)

Minimum Sheet Thickness, Inches (B&S Gauge)

Up to 12 0.025 (22)

13 to 30 0.032 (20)

Larger than 31 0.040 (18)

b. Spacing of hangers and supports: 1) Provide supports as indicated on the Drawings.


2) When supports are not shown, provide supports as required in accordance with SMACNA but no greater than the spacing indicated on the Drawings or the following requirements; whichever is less:

3) Ducts 18 inches and smaller in largest dimension: 8 feet on center. 4) Ducts over 18 inches in largest dimension: 4 feet on center.

c. Support connections: 1) Provide as indicated on the Drawings. 2) When not indicated on the Drawings, provide in accordance with

SMACNA. 3) As a minimum, all support connections to metal or wood roofs shall

be located at roof framing members only. 4) No penetrations through roof deck, roof membrane, or connections to

roof membrane are acceptable. 3. Design pressure: 2 inches water column unless otherwise indicated on the

Drawings or specified. 4. Seismic design criteria: As specified in Section 01612 and in accordance with

SMACNA Seismic Restraint Manual Guidelines for Mechanical Systems. 5. Hanger reinforcement:

a. Ducts 18 inches and smaller in largest dimension: None. b. Ducts over 18 inches and under 30 inches in largest dimension:

1-1/2 inches by 1-1/2 inches by 1/8-inch angles, 8 feet on center. c. Ducts 30 inches and larger in largest dimension: 1-1/2 inches by

1-1/2 inches by 1/8-inch angles, 4 feet on center. 6. When ducts are specified with insulation on interior walls, size duct to provide

clear inside dimensions indicated on the Drawings.

B. Miscellaneous design details: 1. Changes in duct size:

a. Use uniformly tapering sections. b. Taper not more than 1 inch in 5 inches of run unless otherwise indicated

on the Drawings. 2. Bends: With the exception of miter bends, design bends with inside radii equal

to duct width or diameter. a. Install turning vanes at miter bends.

3. Duct sleeves: Install duct sleeve when ducts pass through concrete or masonry walls, slabs, or ceilings.

4. Access openings: Install in locations that allow access to dampers, fusible links, controllers, and similar devices.

5. Flexible connections: Install at connections to air handling equipment and at locations indicated on the Drawings.

1.04 SUBMITTALS


B. Product data: 1. Duct and component material and details of construction. 2. System layout including floor and wall penetrations. 3. Supports and anchoring details. 4. Components used in the duct system including turning vanes, dampers,

flexible connections, and access doors.


C. Design data - seismic design calculations. 1. Design calculations for duct construction as specified in Section 01612 and in

accordance with SMACNA.


PART 2 PRODUCTS

2.01 MATERIALS

A. Ducts: Aluminum alloy 3003 H14 in accordance with ASTM B 209.

B. Flexible connectors: As specified in Section 15820.

C. Turning vanes: Match duct material.

D. Reinforcing: Formed or extruded aluminum angles.

E. Ductwork insulation: As specified in Section 15820.

2.02 COMPONENTS

A. Duct sleeves: 1. Sleeve flanges: 4 inches wide. 2. Size: 2 inches larger than the duct or duct with external insulation.

B. Access openings: 1. Size: 2 inches less than duct size. 2. Doors:

a. Gauge not less than duct sheet. b. Provide continuous hinge and latch on outside.

3. Gasket: Along door periphery. 4. Visual panel: 1/8-inch thick, clear plexiglass.

C. Turning vanes: 1. Material: Same as ductwork. 2. Type:

a. Single-blade vanes for duct widths less than 36 inches. b. Airfoil type vanes for duct widths of 36 inches and greater.

1) No trailing edge. 3. Mounted in side rails. 4. Provide turning vanes for square-turn elbows and splitters. 5. Size: 2-inch blades for ducts up to 18 inches, 4-1/2 inch blades for larger

ducts.

D. Splitter dampers: Provide at branch take-offs where necessary for balancing system.

E. Extractors: 1. Components:

a. Synchronized steel curved blades. b. Heavy side rails.


c. Screw operator. 2. Provide extractors at take-off from main supply duct adjacent to diffusers,

registers, or grilles where splitter is not used.

2.03 FABRICATION

A. Fabricate ductwork to the configuration and dimensions indicated on the Drawings.

B. Dimensions indicate net free area. Increase duct dimensions by thickness of insulation when internal insulation is specified.

C. Do not utilize S clips, duct tape, or externally applied mastic on medium pressure duct systems.

D. Do not use snap lock seams.

E. Provide flexible duct connectors at all connections to fans and other air movement equipment.

PART 3 EXECUTION

3.01 EXAMINATION

A. Examine and verify that Work is in condition to receive metallic ductwork as specified in this Section. 1. Take measurements and verify dimensions on shop drawings to verify fit of

installation. 2. Verify that supports and openings are correctly located.

B. Examine and verify structural details and determine conflicts in dimensions and clearances.

3.02 INSTALLATION

A. Cover ductwork openings with tape, plastic, or sheet metal to reduce the amount of dust or debris which may collect in the system at each of the following times: 1. At the time of rough installation. 2. During storage on the construction site. 3. Until final start-up of the heating and cooling equipment.

B. Before installation remove dust and debris from ducts.

C. Adjust duct alignment where necessary to resolve conflicts with architectural features or to resolve conflicts with the work of other trades.

D. Install ductwork to provide a system free of buckling, warping, or vibration.

E. Hangers: 1. Install hangers as indicated on the Drawings. 2. When hangers are not detailed, conform to SMACNA HVAC System Duct

Design and Seismic Restraint Manual standards and the following requirements:


a. Rectangular ducts concealed in ceiling spaces: 1) Use metal strap hangers. 2) Fasten to sides of duct with 2 screws. 3) Fasten to bottom of duct with 1 screw.

b. Rectangular ducts in exposed areas: 1) Install shelf angle trapeze hangers or Unistrut type hangers. 2) Install sway bracing as required by seismic calculations, minimum 1

brace at right angle to each duct run. c. Round ducts in exposed areas:

1) Install 2 half-round bands with rods bolted to panels. 2) Install sway bracing as required by seismic calculations, minimum 1

brace at right angle to each duct run. 3. Flexible connections: As specified in Section 15820.

F. Provide closed-cell neoprene gaskets at flanged joints.

G. Tapes and mastics used to seal ductwork shall be listed and labeled in accordance with UL 181A and shall be marked.


A. Inspect ductwork under operating conditions. 1. Correct audible leaks and leaks that can be felt with the hand.

B. Test and balance ducting systems as specified in Section 15954.

END OF SECTION


SECTION 15820

DUCTWORK ACCESSORIES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Dampers and damper operators. 2. Diffusers, grilles, and registers. 3. Screens. 4. Flexible duct connectors. 5. Other ductwork accessories.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 15050 - Common Work Results for Mechanical Equipment. 3. Section 15954 - Testing, Adjusting, and Balancing for HVAC.

1.02 REFERENCES

A. National Electrical Manufacturers Association (NEMA): 1. 250 - Enclosures for Electrical Equipment (1000 V Maximum).

B. National Fire Protection Association (NFPA): 1. 90B - Standard for the Installation of Warm Air Heating and Air-Conditioning

Systems. 2. 255 - Standard Method of Test of Surface Burning Characteristics of Building

Materials.

C. Uniform Building Code (UBC).

D. Underwriters Laboratories, Inc. (UL): 1. 555 - Fire Dampers. 2. 555S - Smoke Dampers.

1.03 DEFINITIONS

A. Dampers, diffusers, grilles, and registers specified are indicated on the Drawings by the abbreviations listed below. Each abbreviation is followed by a hyphen and a number to designate the required style of unit: 1. BD: Balancing Damper. 2. BDD: Backdraft Damper. 3. DG: Door Grille. 4. FD: Fire Damper. 5. FL: Flexible Duct Connector. 6. RR: Return Register or Grille. 7. SD: Smoke Damper. 8. SFD: Smoke and Fire Damper combination. 9. SR: Supply Register, Grille, or Diffuser.


B. NEMA Type 1 enclosure in accordance with NEMA 250.

C. Return registers: 1. RR designation includes wall, ceiling, and duct mounted air exhaust or return

devices including diffusers and grilles with or without control dampers. 2. When no return register style is indicated on the Drawings, provide Style RR-4;

provide 4 inch flanged drop frame when duct mounting indicated.

D. Supply registers: 1. SR designation includes wall, ceiling, and duct mounted air supply devices

including diffusers and grilles with or without control dampers. 2. When no supply register style is indicated on the Drawings, provide Style SR-

4; provide 4 inch flanged drop frame when duct mounting indicated.

1.04 SUBMITTALS



PART 2 PRODUCTS

2.01 DAMPERS

A. Manufacturers: 1. Provide dampers manufactured by the same manufacturer. 2. Dampers:

a. Manufacturer’s: One of the following or equal: 1) One manufacturer's model is listed with each style, similar models

from other listed vendors are acceptable: a) Ruskin Manufacturing. b) American Warming and Ventilating. c) Swartwout.

B. Materials: 1. Metallic ductwork: Aluminum for aluminum duct work; aluminum or galvanized

steel for galvanized steel ductwork unless specified otherwise with styles. 2. Fiberglass reinforced plastic ductwork: Fiberglass reinforced plastic where not

otherwise specified.

C. Components: Include specified damper type with frame actuators, clips, connectors, and other accessories necessary for mounting; provide locking quadrant manual actuator or electric actuator as indicated on the Drawings.

D. Volume control and balancing dampers (BD): 1. BD-1, Style 1 Balancing Damper, Commercial Rectangular Balancing Damper:

a. Service: Manual balancing of office or laboratory air distribution systems; suitable for up to 1,500 feet per minute velocity and 1 inch water column pressure.

b. Size and installation: Size as indicated on the Drawings suitable for mounting in rectangular ducting.


c. Frame: 22 gauge minimum galvanized steel suitable for in-line duct mounting.

d. Blade: Single 22 gauge minimum galvanized steel. e. Blade axle: Square plated steel with molded synthetic bearings; provide

factory mounted locking hand quadrant. f. Finish: Mill galvanized. g. Manufacturers: One of the following or equal:

1) Ruskin, Model MD25. 2) Greenheck, similar model.

2. BD-2, Style 2 Balancing Damper, Commercial Round Manual Balancing Damper: a. Service: Manual balancing of office or laboratory air distribution systems;

suitable for up to 1,500 feet per minute velocity and 3 inch water column pressure.

b. Size and installation: Size as indicated on the Drawings suitable for in-line mounting in round ducting.

c. Frame: 20 gauge minimum galvanized steel. d. Blade: 20 gauge minimum galvanized steel. e. Blade axle: Square plated steel with molded synthetic bearings; provide

factory mounted locking hand quadrant. f. Finish: Mill galvanized. g. Manufacturers: One of the following or equal:

1) Ruskin, Model MDRS25. 2) Greenheck, similar model.

2.02 DIFFUSERS, GRILLES, AND REGISTERS

A. Manufacturers: 1. Provide diffusers, grilles, and registers manufactured by the same

manufacturer. 2. Diffusers, grilles, and registers: One of the following or equal. One

manufacturer's model is listed with each style, similar models from other listed vendors are acceptable: a. Titus Manufacturing Corp. b. Tuttle and Bailey. c. Kees, Inc. d. Metal Industries, Inc. (MetalAire). e. Krueger.

B. Materials: 1. For metallic ductwork: Aluminum for aluminum duct work; aluminum or

galvanized steel for galvanized steel ductwork unless specified otherwise with styles.

C. Components: Include specified style with frame, clips, connectors, and other accessories necessary for mounting.

D. Appearance: Similar for units in same room or space.


E. Finishes: 1. In chlorine, hypochlorite, or sodium bisulfite storage or pumping rooms and

building exhaust systems for these areas: Coat with two 1-1/2 mils thick coats of synthetic vinyl plastic coating suitable for use in gas contaminated exhaust system including chlorine, sulfur dioxide, ozone, or a combination thereof of such gases: a. Manufacturers: One of the following or equal:

1) Bisonite M, Amercoat Number 23 and 55. 2) Plasite, 2441.

2. In laboratory room exhaust systems: Coat with 2 finish coats of synthetic resin over prime applied on clean surface suitable for use in a laboratory exhaust system: a. Manufacturers: The following or equal:

1) Carboline Eisen-Heiss. 3. In other locations, specified factory standard with the style requirements of a

color selected by Engineer from standard manufacturer's colors.

F. Supply diffuser, grille, and register styles: 1. SR-3, Supply Register Style 3:

a. Size and installation: Rectangular grille size as indicated on the Drawings framed for surface mounting on gypsum or directly mounted on exposed ducting; provide 4 inch flanged drop frame when duct mounted.

b. Faceplate: Removable grille with double deflection blades spaced at 3/4 inch; front blades parallel to long dimension; provide gasket at frame for sealing.

c. Core: Adjustable vanes with rectangular or round neck to match ducting. d. Damper: Provide opposed blade volume control damper suitable for use

with ducting type; damper to be adjustable through the face of the unit. e. Materials: Aluminum frame, core, damper, and faceplate. f. Manufacturers: The following or equal:

1) Titus, Model 272FL. 2) Krueger, Model 5880H.

2. SR-4, Supply Register Style 4: a. Size and installation: Round grille size as indicated on the Drawings

framed for surface mounting on gypsum or directly mounted on exposed ducting.

b. Faceplate: Three cones; Removable two inner cones with a spring lock mechanism.

c. Core: 360 degree discharge pattern three cones with round neck to match ducting.

d. Damper: External damper shall be provided for test and balance at branch takeoffs.

e. Materials: 1) Core and faceplate: Aluminum.

f. Manufacturers: The following or equal: 1) Titus, Model TMR-AA.

G. Return diffuser, grille, and register styles: 1. RR-4, Return Register Style 4:

a. Size and installation: Size as indicated on the Drawings suitable for ceiling or sidewall surface mounting on gypsum or T-bar ceiling.


b. Face: High free area eggcrate with 1/2 inch by 1/2 inch by 1 inch deep grid.

c. Core: When connected to ducting, provide suitable rectangular or round neck to match ducting; when filter indicated on the Drawings, provide 1-inch deep filter frame and hinged face.

d. Damper: When connected to ducting, provide opposed blade volume control damper suitable for use with ducting type; damper to be adjustable through the face of the unit.

e. Materials: Aluminum frame, core, damper, and faceplate. f. Manufacturers: The following or equal:

1) Titus, Model 50F or 50FF.

2.03 SCREENS

A. Characteristics and features: 1. Bird screen: 1/2-inch mesh by 14 gauges. 2. Insect screens: 18 by 14 mesh. 3. Screens and frames, same material as ductwork, hood, louver, fan, or

equipment connected to screen. 4. Screens secured in frames.

2.04 FLEXIBLE CONNECTIONS

A. Provide flexible duct connectors at all connections to fans and other air movement equipment as indicated on the Drawings.

B. FL-1, Duct to Duct Flexible Connection: 1. Fabric shall be fire resistant, waterproof, mildew-resistant, and airtight. At least

4 inches of fabric shall be exposed. Flexible connections shall be in accordance with the requirements of UL and NFPA.

2. Interior locations: a. Fabric for flexible connections installed inside office areas shall be

Neoprene coated glass fabric suitable for a temperature range of -20 degrees Fahrenheit to 180 degrees Fahrenheit and shall have a weight of at least 27 ounces per square yard and a thickness of 0.024 inches.

b. Manufacturers: The following or equal: 1) Ventfabrics “Ventglas”.

3. Exterior locations: a. Fabric for flexible connections exposed to sunlight or the weather shall be

glass fabric coated with chlorosulfurated polyethylene suitable for a temperature range of -10 degrees Fahrenheit to 250 degrees Fahrenheit and shall have a weight of at least 24 ounces per square yard and a thickness of 0.019 inches.

b. Manufacturers: The following or equal: 1) Ventfabrics “Ventlon”.


PART 3 EXECUTION

3.01 PREPARATION

A. Before installation, remove dust and debris from ducts and accessories.

3.02 INSTALLATION

A. Install items in accordance with manufacturer’s instructions.

B. FL-1 and FL-2, Flexible Connections: 1. Install at building expansion joints and as indicated on the Drawings. 2. Install with collar and metal band to form airtight joints. 3. Install with minimum 4 inches of slack in fabric. 4. Exterior locations: Install sheet metal weather cover over fabric. 5. Duct alignment shall be a maximum of 1/2 inch offset. 6. The minimum/maximum gap shall be 2-inches and 6-inches. 7. Lap longitudinal joints and glue per manufacturer’s recommendations.


A. Set grilles, dampers, and diffusers to achieve flows and flow patterns indicated on the Drawings and test finished system as specified in Section 15954.

B. Mark final balance positions on all manual damper actuators with paint pen in a distinctive color.

END OF SECTION


SECTION 15830

FANS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Fans, including: 1. Type 4 - Sidewall propeller fans. 2. Fire/smoke control systems.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01612 - Seismic Design Criteria. 3. Section 01614 - Wind Design Criteria. 4. Section 01650 – Facility Startup/Commissioning. 5. Section 01730 - Operation and Maintenance Data. 6. Section 09960 - High-Performance Coatings. 7. Section 15050 - Common Work Results for Mechanical Equipment. 8. Section 15170 - Electrical Motor, Induction, 600 Volts and Below 9. Section 15852 - Louvers. 10. Section 15936 - Instrumentation and Control Devices for HVAC. 11. Section 15954 - Testing, Adjusting, and Balancing for HVAC. 12. Section 16150 - Raceways, Fittings and Supports. 13. Section 16200 - Wiring (600 Volts and below). 14. Section 16250 - Boxes and Cabinets. 15. Section 16300 - Wiring Devices. 16. Section 16550 - Grounding. 17. Section 16660 - Disconnect Switches and Enclosures.

1.02 REFERENCES

A. American Bearing Manufacturers Association (ABMA): 1. 9, Load Ratings and Fatigue Life for Ball Bearings. 2. 11, Load Ratings and Fatigue Life for Roller Bearings.

B. Air Movement and Control Association International, Inc. (AMCA): 1. 210, Laboratory Methods of Testing Fans for Certified Aerodynamic

Performance Rating. 2. 211, Certified Rating Program- Product Rating Manual for Fan Air

Performance. 3. 300, Reverberant Room Method for Sound Testing of Fan. 4. 301, Methods for Calculating Fan Sound Ratings from Laboratory Test Data.

C. American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE): 1. 52.2 - Method of Testing General Ventilation Air-Cleaning Devices for

Removal Efficiency by Particle Size. 2. 68 - Laboratory Methods of Testing to Determine Sound Power in a Duct.


D. ASTM International (ASTM): 1. A108 - Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished. 2. D4167 - Standard Specification for Fiber Reinforced Plastic Fans and Blowers. 3. E84 - Standard Test Method for Surface Burning Characteristics of Building

Materials.

E. National Electrical Code (NEC).

F. National Electrical Manufacturers Association (NEMA): 1. 250 – Enclosures for Electrical Equipment (1000 V Maximum).

G. National Fire Protection Association (NFPA): 1. 90A - Standard for Installation of Air Conditioning and Ventilating Systems. 2. 820 - Standard for Fire Protection in Wastewater Treatment and Collection

Facilities.

H. National Roofing Contractors Association (NRCA).

I. Occupational Safety and Health Administration (OSHA).

J. Underwriters' Laboratories, Inc. (UL).

1.03 DEFINITIONS

A. As used in this Section and on the drawings, abbreviations and Fan Schedule headings have the following meaning: 1. SF or SPF: Supply Fan. 2. EF or EXF: Exhaust Fan. 3. Type: Fan type as specified in this Section. 4. SP or ESP: Fan External Static Pressure in inches water column. 5. Size: Nominal fan blade or wheel diameter in inches. 6. Hp: Fan motor horsepower. 7. V/Ph: Fan motor voltage and power phases.

B. Institute of Electrical and Electronics Engineers (IEEE): 1. 841 - IEEE Standard for Petroleum and Chemical Industry--Premium-

Efficiency, Severe-Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors--Up to and Including 370 kW(500hp).

C. NEMA: 1. Type 1 enclosure in accordance with NEMA 250. 2. Type 3R enclosure in accordance with NEMA 250.


A. Design requirements: 1. Provide fans that have sharply rising pressure characteristics which extend

throughout the operating range and continue to rise beyond the efficiency peak.

2. Provide fans that peak as close as possible to the maximum efficiency and whose operating range is within the normal fan selection range.


3. When scheduled, provide guided vibration isolator for fans, so that not more than 10 percent of the vibration amplitude of the fan and motor is transmitted to the supporting structure.

4. Design fan inner scroll and air stream surfaces to maintain smoothness for entire fan service life.

5. Seismic supports: Seismic design criteria as specified in Section 01612. 6. Wind supports for exterior units: Wind design criteria as specified in

Section 01614. 7. Electrical components: UL listed and meeting the design and installation

requirements of the NEC. 8. Applicable portions as specified in Section 15050. 9. Motors supplied with fans: TEFC, IEEE 841 Compliant, NEMA premium

efficiency, Class F insulation, Class B temperature rise, 1.15 service factor; provide motor voltage phases and speed as scheduled; non-overloading on any point of the fan curve including belt losses.

10. Roof curbs: Designed in accordance with NRCA standards. 11. Insulation and adhesives: Meet NFPA 90A requirements for flame spread and

smoke generation. 12. Belt drive systems: Adjustable for minimum within 5 percent speed change,

rated for 1.5 times maximum horsepower motor available for the scheduled fan size or model.

13. Screens: Provide bird or insect screen as specified with the fan type or as listed on the Fan Schedule: a. Bird screen: Stainless steel; 0.5-inch mesh 18 gauge. b. Insect screen: Stainless steel mesh and frame.

14. Finishes: When not specified with fan type, coat ferrous metals as specified in Section 09960.

15. Accessories: Provide accessories specified and those scheduled. 16. Provide fans with fire/smoke control system as specified under paragraph

Fire/Smoke Control System Design Requirements.

B. Performance requirements: 1. Performance requirements are included in the Fan Schedule located at the

end of this Section. 2. Fan performance: Rated and licensed to bear the AMCA label in accordance

with AMCA 210 and AMCA 211. 3. Total sound power levels in the 8 octave band range as measured in

accordance with ASHRAE 68, AMCA 301, or AMCA 300 as appropriate for each fan: Not to exceed the lesser of the following or the Sones levels on the Fan Schedule.

Sound Power Level, decibel levels referenced to 10-12 watts Frequency, Hz 63 125 250 500 1,000 2,000 4,000 8,000

General 100 98 94 88 84 84 78 75

4. Air filters supplied with fans: 25 to 30 percent dust spot efficiency when rated per ASHRAE Testing Standard 52.2.

5. Bearings: Rated per ABMA 9 or 11 for a L10 life rating of not less than 50,000 hours; provide greater life when specified with each fan type.



components, and wiring to make a complete functioning system. Design to perform the system ventilating functions with the control systems as specified in Section 15936 or as indicated on the Drawings and as specified in the following Sections: a. Section 15170 b. Section 16150. c. Section 16200. d. Section 16300. e. Section 16600.

D. Fire control system design requirements: 1. Provide all supply, exhaust, and odor control fans greater than or equal to

2,000 cubic feet per minute with smoke control system including the following minimum components. a. Duct or fan mounted smoke detector as specified in Section 15936. b. Fan interlock to shut down fan upon smoke detection. c. Signals for fans and smoke detectors to and from local fire alarm control

panel if a fire alarm control panel is part of project design. d. Provide all wire, conduit, end of line resistors, and other electrical

equipment for complete functioning smoke control system. Provide in conformance with the electrical, mechanical, and instrumentation Drawings. When no electrical design for smoke control system is indicated, Contractor shall provide design and installation of the smoke control system.

1.05 SUBMITTALS


B. Product data: 1. Materials. 2. Primary and ancillary equipment. 3. Sound Power Level in each of 8 octave bands and overall Sones. 4. Fan system layout, mechanical, electrical power, and control diagrams. 5. Supports, vibration isolators, and seismic bracing calculations and details. 6. Calculated fan vibration levels and field-testing method. 7. Bearing life. 8. Fan performance curves showing specified operating condition.

C. Provide vendor operation and maintenance manual as specified in Section 01730. 1. Furnish bound sets of installation, operation, and maintenance instructions for

each type fan.



A. Provide fans: 1. Listed by UL. 2. Rated in accordance with AMCA.



A. Deliver units in 1 piece, factory assembled, internally wired, and lubricated.

B. Protect equipment from dust and atmospheric exposure as recommended by the unit manufacturer. 1. As a minimum provide temporary closures for equipment openings designed

for airflow.

1.08 EXTRA MATERIALS

A. Provide 2 extra sets (3 sets total) of filters per installed fan for fans specified with filters.

B. Provide 1 extra set of belts per installed fan for fans specified with belt drives.

PART 2 PRODUCTS

2.01 TYPE 4, SIDEWALL PROPELLER FANS

A. Manufacturers: One of the following or equal: 1. Greenheck, Model SE2-24-625-B15-VGD. 2. Loren Cook, similar model. 3. Penn Ventilator, similar model.

B. Type: Wall-mounted, low noise propeller type, packaged unit. 1. Fan: Statically and dynamically balanced propeller with aluminum blades,

unless noted otherwise. 2. Motor: Permanently lubricated; selected to avoid running in the service factor.

C. Accessories: 1. Motor and fan side OSHA guards. 2. Wall mount collar when necessary for installation as indicated on the

Drawings. 3. Dampers with damper guards when damper scheduled. 4. Weather hood when scheduled. 5. Bird screen: Provide bird screen if no screen is listed on the Fan Schedule. 6. Finish: Coat fan, housing, and accessories with polyester finish. 7. Diffusers and louvers when scheduled. 8. Mounting hardware.


A. Factory test fans listed on the Fan Schedule for proper operation, performance, and electrical controls.


PART 3 EXECUTION

3.01 EXAMINATION

A. Examine and verify that Work is in condition to receive installation specified in this Section.

B. Take measurements and verify dimensions to ascertain fit of installation.

C. Ascertain support and openings are correctly located.

3.02 PREPARATION



3.03 INSTALLATION

A. Observe applicable installation requirements as specified in Section 15050.

B. Anchoring and support: 1. Provide anchoring and support for fans and appurtenances. 2. Provide anchoring to sustain seismic and wind forces as specified in

Sections 01612 and 01614.

C. Adjust alignment of ducts where necessary to resolve conflicts with architectural features or to resolve conflicts with the work of other trades.

D. Install and wire unit fans and controls in accordance with manufacturer's recommendations.

E. Install flexible connections to fans.

F. Install roof curb and fan as recommended by fan manufacturer.

G. For fan housings with threaded water trap drain, provide drain piped from fan housing to the nearest drain channel, floor drain, or sump.


A. Test equipment and installation to verify tightness, operation, and unit vibration is within manufacturer's submitted maximum.

B. Test equipment performance and balance equipment as specified in Section 15954.

3.05 COMMISSIONING


B. Manufacturer (each) services for each type of fan. 1. Provide Manufacturer’s Certificate of Source Testing.




Non-witnessed)



Functional Testing

Process Operational

Period





Days (each trip)

Non-Witnessed Not Required Not Required Not Required Not Required

3.06 SCHEDULES

A. Fan Schedule:


August 15, 2018 15830-8

9080B11 pw://Carollo/Documents/Client/TX/Austin/9080B11/Specifications/15830 (CONFORMED)

Equip. No. Location

Fan Motor Additional Requirements

(See listed Notes) Type Drive Min. CFM

Min. ESP"

Max. RPM

Fan Diam. Noise Sones Hp V / Ph.

Max. RPM

HB-SST-VF-001

BLOWER BLDG. - W. WALL

4 DIRECT 8,500 0.10 1,160 24 in 26 1.5 460/3 1,160 1,4,8,12,14,22

HB-SST-VF-002

BLOWER BLDG. - W. WALL

4 DIRECT 8,500 0.10 1,160 24 in 26 1.5 460/3 1,160 1,4,8,12,14,22

Notes: (1) Provide bird screen. (2) Provide insect screen. (3) Provide backdraft damper, counterbalanced for minimum

pressure loss. (4) Provide exterior weather hood. (5) Provide adjustable belt sheaves. (6) Provide vibration isolators. (7) Provide manufacturer std. motor enclosure. (8) Provide TEFC motor enclosure and wiring suitable for

Class I, Div. 2 locations. (9) Provide explosion proof motor and wiring suitable for Class

I, Div. 1 locations. (10) Provide variable frequency drive speed controller as

specified in this Section. (11) Provide SCR speed controller as specified in this Section. (12) Provide exterior disconnect switch at fan, NEMA Type 3R. (13) Provide NEMA Type 1 disconnect switch at fan inside

housing.

(14) Provide 120 volt, line voltage thermostat Type 2 as specified in Section 15936. (15) Provide 24 volt, low voltage thermostat type T-5 as specified in Section 15936. (16) Interlock fan with motorized louver dampers, other fans, or equipment as

indicated on the Drawings. (17) Provide replaceable filters. (18) Provide motorized backdraft damper. (19) Provide exterior weather louver, Type L-1 as specified in Section 15852. (20) Provide fiberglass canopy hood, size as indicated on the Drawings. (21) Fan selection based on existing opening; field verify opening size and select

maximum sized, slowest rpm fan to fit opening and meet performance conditions.

(22) Provide fire/smoke control system for all fans greater than 2,000 cfm.

END OF SECTION


SECTION 15852

LOUVERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Stationary weather louvers.

B. Related sections: 1. Section 15954 - Testing, Adjusting, and Balancing for HVAC.

1.02 REFERENCES

A. Air Movement and Control Association International, Inc. (AMCA): 1. 500-L - Laboratory Methods of Testing Louvers for Rating. 2. 500-D - Laboratory Methods of Testing Dampers for Rating. 3. 511 - Certified Ratings Program - Product Rating Manual for Air Control

Devices.

B. ASTM International (ASTM): 1. D 2584 - Standard Test Method for Ignition Loss of Cured Reinforced Resins.

C. Underwriters Laboratories, Inc. (UL).


A. Performance: In accordance with AMCA 511 when tested in accordance with AMCA 500.

B. Designed for 20 pounds per square foot wind load.

1.04 SUBMITTALS

A. Shop drawings: Include dimensions, anchorage details, and relationships to adjacent materials.

B. Product data.


A. Provide louvers with the following, unless otherwise specified: 1. AMCA certification and rating in accordance with AMCA 511 for air

performance and water penetration.


PART 2 PRODUCTS

2.01 GENERAL

A. Louver types: Louvers are marked on the drawings with a letter L followed by a number referring to a louver type in this Section. Individual louver size and airflow rates are as indicated on the Drawings.

B. Accessories: 1. Provide installation clips and flanged or jamb-mounting styles suitable for the

mounting locations as indicated on the Drawings. 2. Provide extended sills for louvers indicated as installed recessed from the

exterior wall surface. 3. Provide stainless steel fasteners unless noted otherwise. 4. Corrosion protection. 5. Provide gravity damper for all outside air intake and exhaust louvers unless

noted otherwise.

C. Protective coatings for aluminum in contact with concrete or masonry: 1. Manufacturers: One of the following or equal: 2. Koppers Company, Inc. 3. Tarmastic 100. 4. Porter Coatings.

2.02 STATIONARY WEATHER LOUVERS, TYPE L-1

A. Manufacturers: One of the following or equal: 1. Greenheck, Model ESD-603. 2. Ruskin, Model ELF 6375DXH. 3. Airolite Company, equivalent product.

B. Requirements: 1. Type: Stationary louver with drainable blades. 2. Frame: 6 inches deep, minimum 0.125-inch thick, Type 6063-T5 aluminum

with downspouts and caulking channel provided. 3. Blades: Minimum 0.125-inch thick, Type 6063-T5 aluminum drainable blades

spaced at 6-inch centers, stationary mounted at 37.5 degrees. 4. Screens: Removable aluminum frame with aluminum wire; insect screens on

intakes and bird screens on exhausts. 5. Pressure drop (without screen): Maximum 0.15-inch water column for exhaust

service and 0.15-inch water column for intake service at 1,000 feet per minute free area velocity.

6. Water penetration: Maximum 0.01-ounce water per square foot at 1,027 feet per minute free area velocity.

7. Mullions: Hidden. 8. Finish: Kynar finish; color as selected. 9. Filter Rack: Suiable for 2" deep wire mesh filters.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install louvers in accordance with manufacturer's instructions; caulk all frames to make weathertight.

B. Install louvers for machinery, engines, and similar equipment to allow easy louver removal for machinery or engine removal through the louver opening space without louver projections on floors or walls.

C. Anchor louvers to concrete or masonry with concrete anchors through jambs.

D. Corrosion protection: 1. Aluminum in contact with concrete or masonry: Apply 2 coats bitumastic black

solution. 2. Aluminum in contact with dissimilar metal, except stainless steel: Isolate from

dissimilar metal with neoprene gaskets, sleeves, or washers. Utilize stainless steel fasteners.

3. Field-testing: As specified in Section 15954.

END OF SECTION


SECTION 15936

INSTRUMENTATION AND CONTROL DEVICES FOR HVAC

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Controls for Heating, Ventilating, and Air Conditioning (HVAC) Systems: 1. Thermostats. 2. Airflow switches. 3. Duct mounted smoke detectors. 4. HVAC control descriptions.

B. Related sections: 1. Section 01300 - Submittals. 2. Section 01610 - Project Site Conditions. 3. Section 01650 - Facility Startup/Commissioning. 4. Section 01730 - Operation and Maintenance Data. 5. Section 13390 - Packaged Control Systems 6. Section 15050 - Common Work Results for Mechanical Equipment. 7. Section 15732 - Air Conditioning Units. 8. Section 15740 - Heat Pumps. 9. Section 15812 - Metal Ducts. 10. Section 15830 - Fans. 11. Section 15954 - Testing, Adjusting, and Balancing for HVAC 12. Section 16150 - Raceways, Fittings and Supports. 13. Section 16200 - Wiring (600 Volts and below). 14. Section 16300 - Wiring Devices. 15. Section 16660 - Disconnect Switches and Enclosures.

1.02 REFERENCES

A. CSA International (CSA).

B. National Electrical Code (NEC).

C. National Electrical Manufacturers Association (NEMA). 1. 250 - Enclosures for Electrical Equipment (1,000 Volts Maximum).

D. National Fire Protection Association (NFPA): 1. 90A - Standard for the Installation of Air-Conditioning and Ventilating Systems.

E. Underwriters' Laboratories, Inc. (UL). 1. 268A - Standard for Smoke Detectors for Duct Application. 2. 1479 - Fire Tests of Through-Penetration Firestops.



A. General requirements: 1. All electrical components shall be UL listed and meet the design and

installation requirements of the NEC. 2. Complete, functional system: Provide all necessary electrical power and

control systems, components, and wiring to make a complete functioning system.

3. Comply with electrical Sections for electrical power and control systems. 4. System control functions to perform as described in Products. 5. Materials: New, free from defects, and of the quality specified. 6. Common manufacturer: Provide components, component accessories, and

devices, as much as possible, by the same manufacturer throughout the work. 7. Mounting: Mount control components and devices in accessible locations for

maintenance and as recommended by the manufacturer; provide necessary manufacturer approved mounting and configuration hardware for mounting and operation of control components and devices.

B. Fire detection system design requirements: 1. Provide all supply and exhaust fans greater than 2,000 cubic feet per minute

with a smoke control system including the following minimum components. a. Fan and air handling unit interlocks interlock to shut down upon smoke

detection signal from fire alarm control panel. b. Field wiring terminal blocks for connection of shut down signals from local

fire alarm control panel.

1.04 SUBMITTALS



C. Shop drawings: 1. Manufacturer's information including:

a. Catalog information clearly marked to show specific products, models, and sizes being furnished.

b. Component cut sheets.


A. The control system shall be designed in accordance with UL and CSA standards.


A. The system control products shall be stored and handled per manufacturer's recommendations.


A. Elevation and ambient conditions as specified in Section 01610.


1.08 WARRANTY

A. Special warranties: Warranty period begins at date of Project Acceptance or first date of Beneficial Use by the Owner: 1. 1 year: Parts and on-site labor for components, systems, and programming.

PART 2 PRODUCTS

2.01 THERMOSTATS

A. General: 1. Thermostat types: Thermostat types are called out on the drawings by the

letter T followed by a number; this designation refers to the specified thermostat types specified in this Section; where no type is called out, provide 1 of the specified types that will match the controlled equipment requirements and provide a functioning system.

2. Manufacturers: One of the following or equal: a. Johnson Controls, model as specified with each type. b. Honeywell, Tradeline, equivalent models.

B. T-1, Type 1 Thermostat, Heating Only, Line Voltage: 1. Johnson Controls Model:

a. Dry locations (no hose bibs or open water processes in room): Model A19BAC-1 in NEMA 1 enclosure.

b. Wet Locations (hose bibs or open water processes in room): Model A19PRC-1 in NEMA 4X enclosure.

2. Switch action: Single pole double throw, open on rising temperature. 3. Sensing element: Coiled bulb and capillary. 4. Setpoint: 30 to 110 degrees Fahrenheit with knob adjuster and visible scale. 5. Electrical ratings: 16 amps alternating current at 120 volts, 9.2 amps

alternating current at 208 volts.

C. T-2, Type 2 Thermostat, Cooling Only, Line Voltage: 1. Johnson Controls Model:

a. Dry locations (no hose bibs or open water processes in room): Model A19BBC-2 in NEMA 1 enclosure.

b. Wet locations (hose bibs or open water processes in room): Model A19KNC-1 in rain and dusttight enclosure.

2. Switch action: Single pole double throw, close on rising temperature. 3. Sensing element: Coiled bulb and capillary. 4. Setpoint: 30 to 110 degrees Fahrenheit with knob adjuster and visible scale. 5. Electrical ratings: 16 amps alternating current at 120 volts, 9.2 amps

alternating current at 208 volts. 6. Differential range: For dry locations, 3 to 12 degrees Fahrenheit adjustable; for

wet locations, 5 degrees Fahrenheit fixed.

D. T-5, Type 5 Thermostat, Electronic Controller: 1. Johnson Controls Model:

a. Model A350P with Y350R transformer, D350 display module and SETA99BC-25C sensor.

2. Electronic unit with proportional plus integral temperature control with 3 selectable integration constants plus integration off position.


3. Output: Selectable, direct or reverse acting, 0 to 10 volts direct current or 4 to 20 milliamp output signal.

4. Input power: 120-volt alternating current with transformer to supply 24-volt direct current as required.

5. Setpoint range: Minus 30 to 130 degrees Fahrenheit, adjustable by face-mounted dial.

6. Sensor: positive temperature coefficient silicon sensor with wall mounting bracket.

7. Display module: Digital, 3 digit, Fahrenheit scale, LCD display, selectable to display room temperature or setpoint temperature.

8. Mounting: Provide wall-mounting bracket for mounting modules together as 1 unit; provide interconnecting cables as necessary.

9. Field selectable heat or cool mode. 10. Module cases: High impact plastic cases.

2.02 AIR FLOW SWITCHES

A. Paddle type: 1. Manufacturers: The following or equal:

a. McDonnell & Miller Division of ITT, Model AF1-S. When normal airflow velocities are below 500 feet per minute, provide McDonnell & Miller Model AF3 with similar features as specified.

2. Characteristics and features: a. Provide 7.25-inch stainless steel paddle suitable for 8 inch and larger

ducts (6 inch with trimmed paddle). b. Provide anti-corrosion treatment of exposed parts. c. Provide field adjustable switch setting from 480 to 1,335 feet per minute in

horizontal duct applications and 910 to 1,610 feet per minute in vertical duct applications; paddle can be trimmed to 5 inches with correspondingly higher velocity ranges.

d. Provide single pole double throw (SPDT) snap switch rated at 7.4 full load amps at 120 volts alternating current.

e. Provide adjustable time delay relay to prevent momentary low flows from tripping the flow switch output.

f. Provide weather protected general purpose exterior switch component enclosure.

2.03 DUCT MOUNTED SMOKE DETECTORS

A. Manufacturers: The following or equal: 1. System Sensor Series D4120.

B. General: 1. Provide duct mounted smoke detectors in air ducting with flows greater than

2,000 cubic feet per minute whether or not smoke detectors are indicated on the Drawings. a. Supply ducting: Locate smoke detectors downstream of fans and ahead of

branch connections. b. Exhaust ducting: Locate smoke detectors after branch connections and

upstream of fans. 2. Smoke detectors shall be UL listed for use in air distribution/collection systems

and in accordance with NFPA 90A.


3. Connect the smoke detector to: a. Building fire alarm system. b. Fan control circuit to shut down respective fan upon detection of smoke. c. Damper control circuits to close respective air dampers to prevent spread

of smoke.

C. Characteristics: 1. Photoelectric type. 2. Operating temperature range of 32 degrees Fahrenheit to 150 degrees

Fahrenheit. 3. Operate at airflow velocities of 100 to 4,000 feet per minute. 4. Power supply voltage 120 volts alternating current, 60 hertz. 5. Capable of mounting to rectangular or round ducts. 6. Integral filter to reduce dust. 7. Comply in accordance with UL 268A for air handling systems.

D. Accessories: 1. Provide metal sampling tube and end cap to match duct width. Sampling tube

shall be able to be installed without use of tools. 2. Provide mounting base and hardware. 3. Provide duct access door as specified in Section 15812. Provide similar for

nonmetalic ducting. 4. Provide a 120 volt 10 amp DPDT auxiliary contact and a 30 VDC 10 amp

DPDT auxiliary contact. 5. Provide remote annunciator with alarm and power LEDs. 6. Provide remote test station.

2.04 HVAC CONTROL DESCRIPTIONS

A. General: Provide control systems that will maintain room or area comfort under changing ambient conditions and varying use; descriptions in this Section are general in nature and do not cover every mode of operation. Any control panels are to conform with requirements outlined in Specification 13390.

B. Blower Building (Area 09) 1. Blower Room Control Sequences:

a. Exhaust Fan HB-SST-EF-001 AND HB-SST-EF-002 will be controlled by a wall-mounted thermostat with adjustable set points. The cooling set point for HB-SST-EF-001 AND HB-SST-EF-002 will be 85 degrees F. When the temperature rises 2 degrees above the set point, the unit will energize. When the temperature drops 2 degrees below the set point, the unit will de-energize. 1) HB-SST-EF-001 AND HB-SST-EF-002 will have smoke detectors

powered directly from HB-SST-EF-001 AND HB-SST-EF-002. When the detector senses smoke, the unit will send a “General HVAC Fault” alarm and a “smoke” alarm to the SCADA system and shut down the units.


b. Electrical Unit Heater HB-SST-UH-001 thru HB-SST-UH-004 will be controlled by wall-mounted thermostats. The heating set point for HB-SST-UH-001 thru HB-SST-UH-004 will be 55 degrees F. When the temperature drops 2 degrees below the set point, the unit will energize. When the temperature rises 2 degrees above the set point, the unit will de-energize.

2. Office and Sample Room Control Sequences: a. Floor mounted heat pump HB-SST-AHU-001/HB-SST-CU-001 will be

controlled by a wall-mounted thermostat with adjustable set points. The cooling set point for HB-SST-AHU-001/HB-SST-CU-001 will be 75 degrees F. When the temperature rises 2 degrees above the set point, the unit will energize. When the temperature drops 2 degrees below the set point, the unit will de-energize. The heating set point for HB-SST-AHU-001/HB-SST-CU-001 will be 70 degrees F. When the temperature drops 2 degrees below the set point, the unit will energize. When the temperature rises 2 degrees above the set point, the unit will de-energize.

HB-SST-AHU-001/HB-SST-CU-001 will send a “General HVAC Fault” alarm to the SCADA system upon unit failing to energize upon receiving signal to energize.

b. A room RTD sensor will be provided in the Office and Sample Room to monitor the temperature inside the room. The information will be sent to the SCADA system.

3. Blower Control Room Control Sequences: a. Floor mounted heat pump HB-SST-AHU-002/HB-SST-CU-002 will be

controlled by a wall-mounted thermostat with adjustable set points. The cooling set point for HB-SST-AHU-002/HB-SST-CU-002 will be 85 degrees F. When the temperature rises 2 degrees above the set point, the unit will energize. When the temperature drops 2 degrees below the set point, the unit will de-energize. The heating set point for HB-SST-AHU-002/HB-SST-CU-002 will be 55 degrees F. When the temperature drops 2 degrees below the set point, the unit will energize. When the temperature rises 2 degrees above the set point, the unit will de-energize. 1) AHU-002/HB-SST-CU-002 will send a “General HVAC Fault” alarm

to the SCADA system upon unit failing to energize upon receiving signal to energize.

b. A room RTD sensor will be provided in the Control Room to monitor the temperature inside the room. The information will be sent to the SCADA system.

C. Electrical Building (Area 12) 1. Electrical Room Control Sequences:

a. Floor mounted air conditioning unit HB-SST-AHU-003/HB-SST-CU-003 will be controlled by a wall-mounted thermostat with adjustable set points. The cooling set point for HP-6013-3/CU-6013-3 will be 85 degrees F. When the temperature rises 2 degrees above the set point, the unit will energize. When the temperature drops 2 degrees below the set point, the unit will de-energize. 1) HB-SST-AHU-003/HB-SST-CU-003 will have smoke detectors

powered directly from HB-SST-AHU-003/HB-SST-CU-003. When the detector senses smoke, the unit will send a “General HVAC Fault” alarm and a “smoke” alarm to the SCADA system and shut down the units.


2) HB-SST-AHU-003/HB-SST-CU-003 will send a “General HVAC Fault” alarm to the SCADA system upon unit failing to energize upon receiving signal to energize.

b. Positive pressurization unit HB-SST-PPU-001 will operate continuously to provide positive pressurization within the space. 1) HB-SST-PPU-001 will send a "General HVAC Fault" alarm to the

SCADA system upon high-pressure indication from differential pressure switch.

c. A room RTD sensor will be provided in the Electrical Room to monitor the temperature inside the room. The information will be sent to the SCADA system.

PART 3 EXECUTION

3.01 PREPARATION

A. Before installation remove dust and debris from equipment and accessories.

B. During installation and until equipment is operated, protect equipment and accessories from dust and debris.

3.02 INSTALLATION

A. Install as indicated on the Drawings, in accordance with NFPA 90A, and per the manufacturer’s written instructions.

B. Coordinate installation of HVAC control systems with other trades. 1. Prior to installation, coordinate wiring and conduit requirements with electrical

subcontractor.

C. Mount remote annunciator and test station on wall near smoke detector. 1. Devices shall be easily accessible from floor level. 2. Label annunciator and test station.

D. Provide all electrical work to support smoke detector. 1. Coordinate with electrical subcontractor.

E. Sensor and control station mounting: 1. Where not otherwise indicated, mount 5 feet above floor or walking level. 2. Provide insulating back plates when mounting is on an exterior wall or a wall

adjoining an unconditioned space. 3. Shield outside thermostats or sensors from the sun; provide thermostats with

remote bulb and compensated capillary. 4. Install locking covers where indicated on the Drawings.

3.03 COMMISSIONING



B. Functional testing: 1. HVAC Instrumentation and Controls:

a. Test witnessing: Witnessed. b. Test each control component and system as part of HVAC system testing,

adjusting, and balancing as specified in Section 15954.

END OF SECTION


SECTION 15954

TESTING, ADJUSTING, AND BALANCING FOR HVAC

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Heating, ventilation, and air conditioning systems testing, adjusting, and

balancing.

B. Related sections: 1. Section 01650 - Facility Startup/Commissioning.

1.02 REFERENCES

A. Associated Air Balance Council (AABC): 1. National Standards for Field Measurements and Instrumentation, Total System

Balance, Air Distribution-Hydronic Systems.

B. National Environmental Balancing Bureau (NEBB): 1. Procedural Standards for Testing, Adjusting, and Balancing Environmental

Systems.

C. Sheet Metal and Air Conditioning Contractors' National Association (SMACNA): 1. Heating, Ventilating, and Air Conditioning Systems - Testing, Adjusting, and

Balancing.

D. Testing, Adjusting, and Balancing Bureau (TABB): 1. International Standards for Environmental Systems Balance.

1.03 TESTING, ADJUSTING, AND BALANCING WORK REQUIREMENTS

A. Procure the services of an independent air balance and testing agency belonging to and in good standing with the AABC, NEBB, or the TABB to perform air balancing, testing, and adjustment of building and process air conditioning, heating, and ventilating air systems.

B. The Work includes: Balancing new air systems installed as part of this contract and existing air systems affected by the installation of new equipment.

C. Perform testing of heating, ventilating, and air conditioning equipment, balancing of distribution systems, and adjusting of air terminal units and ductwork accessories to ensure compliance with Specifications and Drawings. Perform tests for following: 1. Air conditioning units. 2. Heat pump units. 3. Heating units. 4. Fans. 5. Condensers. 6. Ductwork accessories.


7. Ducting. 8. HVAC controls. 9. Other specified HVAC equipment.

D. Test each mode of operation of thermostats, electronic controllers, and pneumatic, electric or electronic heating, ventilating, and air conditioning instruments to ensure operation as specified.

E. Test and adjust room distribution patterns at air outlets.

F. Provide instruments required for testing, adjusting, and balancing operations; retain possession of instruments; remove instruments from site at completion of services.

G. Make instruments available to the Engineer to facilitate spot checks during testing.

H. Provide test holes for pressure and pitot flow measurements; provide plugs for all test holes after testing.


A. Test, balance, and adjust environmental systems in accordance with either: 1. AABC: National Standards for Field Measurements and Instrumentation, Total

Systems Balance, Air Distribution System. 2. NEBB: Procedural Standards for Testing, Adjusting, and Balancing of

Environmental Systems. 3. TABB: International Standards for Environmental Systems Balance.

B. Perform services under direction of AABC, NEBB, or TABB certified supervisor.

C. Calibrate and maintain instruments in accordance with requirements of standards. Make calibration histories of instruments available for examination.

D. Make measurements in accordance with accuracy requirements of standards.

E. Testing, adjusting, and balancing performance requirements: 1. Comply with procedural standards of certifying association. 2. Execute each step of prescribed testing, balancing, and adjusting procedures

without omission. 3. Accurately record required data. 4. Make measurements in accordance with recognized procedures and practices

of certifying association. 5. Measure air volume discharged at each outlet and adjust air outlets to design

air volumes within 5 percent over.

1.05 SUBMITTALS

A. Resumes of proposed supervisor and personnel showing training and qualifications.

B. Interim reports: At least 30 days prior to starting field work, submit the following: 1. Set of report forms filled out as to design flow values and installed equipment

pressure drops, and required cubic feet per minute for air terminals. 2. Develop heating, ventilating, and air conditioning system schematic similar to

Figure 6-1 in SMACNA Testing, Adjusting, and Balancing.


3. Complete list of instruments proposed to be used, organized in appropriate categories, with data sheets for each showing: a. Manufacturer and model number. b. Description and use when needed to further identify instrument. c. Size or capacity range. d. Latest calibration date.

C. Final report: At least 15 days prior to Contractor's request for final inspection, submit 3 copies of final reports, on applicable reporting forms. Include: 1. Identify instruments which were used and last date of calibration of each. 2. Procedures followed to perform testing, adjusting, and balancing. 3. Identification and succinct description of systems included in report. 4. Initial balance test results made with all dampers and air control devices in full

open positions. 5. Description of final locations and sizes, including opening area and

dimensioned configuration of orifices and other restrictions used to achieve final balanced flows.

6. Description of final location and opening positions of dampers, registers, louvers, and valves.

7. Schematics of systems included in report; use schematics as part of testing, adjusting, and balancing report to summarize design and final balanced flows.

8. Testing, adjusting, and balancing report forms. 9. Final field results established for system balancing including airflow, fan

speeds, and fan static pressures at the fan inlet and outlet. 10. Appendices. 11. Include appendices for:

a. Raw field data taken during testing. b. Sample calculation sheet for each type of calculation made to convert raw

field data to final results. c. Initial air balance results with dampers and registers in full open position;

include airflow at all inlets and outlet, initial fan speed and fan suction and discharge pressures.

D. Proposed schedule for testing and balancing.



A. Prior to start of testing, adjusting, and balancing, verify that: 1. Systems installation is complete and in full operation. 2. Outside conditions are within reasonable range relative to design conditions. 3. Lighting fixtures are energized. 4. Special equipment such as computers, laboratory equipment, and electronic

equipment are in full operation. 5. Requirements for preparation for testing and balancing have been met for

elements of each system which require testing.

PART 2 PRODUCTS Not Used.


PART 3 EXECUTION


A. Perform Functional Tests as specified in Section 01650.

B. Testing, adjusting, and balancing acceptance criteria: Consider testing, adjusting, and balancing procedures successful and complete when heating, ventilating, and air conditioning systems and components are functioning properly and system air flows are within specified tolerances of design flows.

3.02 TESTING, ADJUSTING, AND BALANCING

A. Test, adjust, and balance separate complete heating, ventilating, and air conditioning systems.

B. Include in testing, adjusting, and balancing related existing heating, ventilating, and air conditioning components.

C. Perform testing, adjusting, and balancing cycles until airflows meet acceptance criteria. 1. Ascertain airflow balance between overall requirements and flow in individual

supply and exhaust grilles.

D. Initial testing, adjusting, and balancing: Perform first test on each system with dampers, grilles, orifices, and other variable airflow devices in their full open position; measure and report initial airflows, fan speed, and fan static pressures at fan inlet and outlet. 1. Adjust total system flow downward or upward by adjusting fan speed until

1 inlet or outlet is at indicated flow and all other flows exceed indicated flows. 2. Adjust fan speed by changing fan drives or sheaves as necessary.

E. Subsequent testing, adjusting, and balancing: Perform adjustments in subsequent testing, adjusting, and balancing by adjusting dampers, louvers, or size of orifices or plates. 1. Measure and record air volume discharged at each inlet and outlet and adjust

air inlets and outlets to design air volumes within 0 to 5 percent over design rates.

2. Adjust fan speeds and motor drives within drive limitations, for required air volume.

3. Measure cubic feet per minute and static pressures and adjust air supply and exhaust fan units to deliver at least 100 to 105 percent of the design air volume.

4. Measure and record static air pressure conditions on fans, including filter and coil pressure drops, and total pressure across the fan.

5. Evaluate building and room pressure conditions to determine adequate supply and return air conditions.

6. Evaluate space and zone temperature of conditions to determine adequate performance of the systems to maintain temperatures without draft.

7. Permanently mark final balance positions of balancing dampers.

F. Develop heating, ventilating, and air conditioning system schematics similar to Figure 6-1 in SMACNA Testing, Adjusting, and Balancing.


G. Accurately record the required data on AABC, NEBB, or TABB test and balance report forms.

H. Test primary source equipment in accordance with AABC, NEBB, or TABB procedures. 1. Primary source equipment includes items listed in this Section not previously

tested as part of this testing, adjusting, and balancing work. 2. Complete appropriate AABC, NEBB, or TABB equipment test forms for each

piece of equipment. 3. Calculate cooling and heating capacities to show conformance with specified

capacities. 4. Adjust equipment as needed to deliver specified cooling and heating loads. 5. Record final equipment performing characteristics and adjustment settings in

the final design report.

END OF SECTION


SECTION 15958

MECHANICAL EQUIPMENT TESTING

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: Testing of mechanical equipment and systems.

B. Related sections: 1. Section 01650 - Facility Startup/Commissioning. 2. Section 02318 - Trenching. 3. Section 15956 - Piping Systems Testing. 4. Section 16222 - Low Voltage Motors up to 500 Horsepower.

1.02 REFERENCES

A. American National Standards Institute (ANSI): 1. S1.4 Specification for Sound Level Meters.

B. Hydraulic Institute (HI).

C. National Institute of Standards and Technology (NIST).

1.03 SUBMITTALS

A. Schedule of source (factory) tests, Owner training, installation testing, functional testing, clean water facility testing, closeout documentation, process start-up and process operational period as specified in this Section and in Section 01650 and equipment sections.

B. Test instrumentation calibration data:

C. Operation and maintenance manual: 1. Include motor rotor bar pass frequencies for motors larger than 500

horsepower.

D. Facility Startup/Commissioning and Process Start-up Plan: As specified in Section 01650.

E. Test plan as specified in Section 01650 and equipment sections.

F. Test reports as specified in this Section and in Section 01650 and equipment sections.



PART 3 EXECUTION

3.01 GENERAL

A. Facility Startup/Commissioning and process start-up of equipment as specified in: 1. This Section. 2. Section 01650. 3. Equipment sections.

a. If testing requirements are not specified, provide Level 1 Tests.

B. Comply with latest version of applicable standards.

C. Test and prepare piping as specified in Sections 02318 and 15956.

D. Provide necessary test instrumentation that has been calibrated within 1 year from date of test to recognized test standards traceable to the NIST or approved source. 1. Properly calibrated field instrumentation permanently installed as a part of the

Work may be utilized for tests. 2. Prior to testing, provide signed and dated certificates of calibration for test

instrumentation and equipment.

E. Test measurement and result accuracy: 1. Use test instruments with accuracies as recommended in the appropriate

referenced standards. When no accuracy is recommended in the referenced standard, use 1 percent or better accuracy test instruments. a. Improved (lower error tolerance) accuracies specified elsewhere prevail

over this general requirement. 2. Do not adjust results of tests for instrumentation accuracy.

a. Measured values and values directly calculated from measured values shall be the basis for comparing actual equipment performance to specified requirements.

F. Report features: 1. Report results in a bound document in generally accepted engineering format

with title page, written summary of results compared to specified requirements, and appropriate curves or plots of significant variables in English units.

2. Include appendix with a copy of raw, unmodified test data sheets indicating test value, date and time of reading, and initials of person taking the data.

3. Include appendix with sample calculations for adjustments to raw test data and for calculated results.

4. Include appendix with the make, model, and last calibration date of instrumentation used for test measurements.

5. Include in body of report a drawing or sketch of the test system layout showing location and orientation of the test instruments relative to the tested equipment features.

G. Provide necessary fluids, utilities, temporary piping, temporary supports, temporary access platforms or access means and other temporary facilities and labor necessary to safely operate the equipment and accomplish the specified testing. 1. With Owner's permission, some utilities may be provided by fully tested

permanently installed utilities that are part of the Work.

H. Prepare and submit test reports as specified.


I. Testing levels: 1. Level 1 Tests:

a. Level 1 General Equipment Performance Test: 1) For equipment, operate, rotate, or otherwise functionally test for

15 minutes minimum after components reach normal operating temperatures.

2) Operate at rated design load conditions. 3) Confirm that equipment is properly assembled, equipment moves or

rotates in the proper direction, shafting, drive elements and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual power consumption, lubrication temperatures, bearing temperatures, or other conditions are observed.

b. Level 1 Pump Performance Test: 1) Measure flow and head while operating at or near the rated

condition; for factory testing, testing may be at reduced speeds with flow and head corresponding to the rated condition when adjusted for speed using the appropriate affinity laws.

2) Use of a test driver is permitted for factory tests when actual driver is given a separate test at its point of manufacture as specified in Section 16222 or the applicable equipment section. Use actual driver for field tests.

3) Record measured flow, suction pressure, discharge pressure, and make observations on bearing temperatures and noise levels.

c. Level 1 Vibration Test: 1) Test requirement:

a) Measure filtered vibration spectra versus frequency in 3 perpendicular planes at each normally accessible bearing housing on the driven equipment, any gears and on the driver; 1 plane of measurement to be parallel to the axis of rotation of the component.

b) Vibration spectra versus frequency shall be in accordance with Vibration Acceptance Criteria.

2) Equipment operating condition: Test at specified maximum speed. d. Level 1 Noise Test:

1) Measure unfiltered overall A-weighted sound pressure level in dBA at 3 feet horizontally from the surface of the equipment and at a mid-point of the equipment height.

2. Level 2 Tests: a. Level 2 General Performance Test:

1) For equipment, operate, rotate, or otherwise functionally test for at least 2 hours after components reach normal operating temperatures.

2) Operate at rated design load conditions. 3) Confirm that equipment is properly assembled, equipment moves or

rotates in the proper direction, shafting, drive elements and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual power consumption, lubrication temperatures, bearing temperatures, or other conditions are observed.


b. Level 2 Pump Performance Test: 1) Test 2 hours minimum for flow and head at the rated condition; for

factory testing, testing may be at a reduced speeds with flow and head corresponding to the rated condition when adjusted for speed using the appropriate affinity laws.

2) Use of a test driver is permitted for factory tests when actual driver is given a separate test at its point of manufacture as specified in Section 16222. Use actual driver for field tests.

3) Test for flow and head at 2 additional conditions; 1 at 25 percent below the rated flow and 1 at 10 percent above the rated flow.

4) Record measured flow, suction pressure, discharge pressure, and observations on bearing temperatures and noise levels at each condition.

c. Level 2 Vibration Test: 1) Test requirement:

a) Measure filtered vibration spectra versus frequency and measure vibration phase in 3 perpendicular planes at each normally accessible bearing housing on the driven equipment, any gears and on the driver; 1 plane of measurement to be parallel to the axis of rotation of the component; measure actual rotational speeds for each vibration spectra measured using photometric or other tachometer input connected directly to the vibration data collector.

b) Vibration spectra versus frequency shall be in accordance with Vibration Acceptance Criteria.

2) Equipment operating condition: Repeat test requirements at design specified maximum speed and at minimum speed for variable speed equipment.

3) Natural frequency test of field installed equipment: a) Excite the installed equipment and support system in

3 perpendicular planes, use same planes as operating vibration measurement planes, and determine the as-installed natural resonant frequency of the driven equipment, the driver, gears and supports.

b) Perform test at each bearing housing, at each support pedestal, and for pumps on the suction and discharge piping.

c) Perform with equipment and attached piping full of intended service or process fluid.

d. Level 2 Noise Test: 1) Measure filtered A-weighted overall sound pressure level in dBA for

each of 8 octave band mid-points beginning at 63 hertz measured at 3 feet horizontally from the surface of the equipment at mid-point height of the noise source.

3. Level 3 Tests: a. Level 3 General Equipment Performance Tests:


2) Operate at rated design load conditions for 1/2 the specified time; operate at each of any other specified conditions for a proportionate share of the remaining test time.


3) Confirm that equipment is properly assembled, equipment rotates in the proper direction, shafting and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual noise, vibration or temperatures are observed.

4) Take appropriate capacity, power or fuel consumption, torque, revolutions per minute, pressure and temperature readings using appropriate test instrumentation to confirm equipment meets specified performance requirements at the design rated condition.

5) Bearing temperatures: During maximum speed or capacity performance testing, measure and record the exterior surface temperature of each bearing versus time.

b. Level 3 Pump Performance Test: 1) Test 4 hours minimum for flow and head at or near the rated

condition; for factory testing, testing may be at a reduced speeds with flow and head corresponding to the rated condition when adjusted for speed using the appropriate affinity laws.

2) Use of a test driver is permitted for factory tests when actual driver is given a separate test at its point of manufacture as specified in Section 16222. Use actual driver for field tests.

3) Test each specified flow and head condition at the rated speed and test at minimum as well as maximum specified speeds; operate at each test condition for a minimum of 15 minutes; for factory testing, test at other speeds may be omitted if test driver at reduced speeds is used for rated condition testing.

4) Record measured shaft revolutions per minute, flow, suction pressure, discharge pressure; record measured bearing temperatures (bearing housing exterior surface temperatures may be recorded when bearing temperature devices are not required by the equipment section) and record observations on noise levels.

c. Level 3 Vibration Test: 1) Requirements: Same as Level 2 vibration test except data taken at

each operating condition tested and with additional requirements below.

2) Perform High Frequency Enveloping Analysis for gears and bearings. a) Measure bearing element vibration directly on each bearing cap

in a location close as possible to the bearing load zone that provides a smooth surface and direct path to the bearing to detect bearing defects.

b) Report results in units of acceleration versus frequency in cycles per minute.

3) Perform Time Wave Form analysis for gears, low speed equipment and reciprocating equipment; plot true peak amplitude velocity and displacement versus time and label the period between peaks with the likely cause of the periodic peaks (relate the period to a cause).

4) Plot vibration spectra on 3 different plots; peak displacement versus frequency, peak acceleration versus frequency and peak velocity versus frequency.

d. Level 3 Noise Test: Measure filtered, un-weighted overall sound pressure level in dB at 3 feet horizontally from the surface of the equipment at mid-point height and at 4 locations approximately 90 degrees apart in plan view; report results for each of 8 octave band mid-points beginning at 63 hertz.


4. Level 4 Tests: a. Level 4 General Equipment Performance Test:


2) Operate at rated design load conditions for 1/2 the specified time; operate at each of any other specified conditions for a proportionate share of the remaining test time.

3) Confirm that equipment is properly assembled, equipment rotates in the proper direction, shafting and bearings are installed and lubricated in accordance with proper tolerances, and that no unusual noise, vibration or temperatures are observed.

4) Take appropriate capacity, power or fuel consumption, torque, revolutions per minute, pressure and temperature readings using appropriate test instrumentation to confirm equipment meets specified performance requirements at the design rated condition.

5) Bearing temperatures: During maximum speed or capacity testing, measure and record the exterior surface temperature of each bearing versus time.

b. Level 4 Pump Performance Test: 1) Test 8 hours minimum for flow and head; begin tests at or near the

rated condition; for factory and field-testing, test with furnished motor at full speed.

2) Test each specified flow and head condition at the rated speed and test at minimum as well as maximum specified speeds; operate at each test condition for a minimum of 20 minutes or longer as necessary to measure required performance, vibration and noise data at each test condition.

3) Record measured shaft revolutions per minute, flow, suction pressure, discharge pressure; record measured bearing temperatures (bearing housing exterior surface temperatures may be recorded when bearing temperature devices not required by the equipment section) and record observations on noise levels.

4) Bearing temperatures: During maximum speed or capacity testing, measure and record the exterior surface temperature of each bearing versus time.

5) Perform efficiency and/or Net Positive Suction Head Required (NPSHr) and/or priming time tests when specified in the equipment section in accordance with the appropriate HI standard and as follows: a) Perform NPSHr testing at maximum rated design speed, head

and flow with test fluids at ambient conditions; at maximum rated speed, test at 15 percent above rated design flow, and 25 percent below rated design flow.

b) Perform efficiency testing with test fluids at maximum rated speed.

c) Perform priming time testing with test fluids at maximum rated speed.

c. Level 4 Vibration Test: Same as Level 3 vibration test. d. Level 4 Noise Test: Same as Level 3 Noise Test except with data taken at

each operating condition tested.


J. Variable speed equipment tests: 1. Establish performance over the entire speed range and at the average

operating condition. 2. Establish performance curves for the following speeds:

a. The speed corresponding to the rated maximum capacity. b. The speed corresponding to the minimum capacity. c. The speed corresponding to the average operating conditions.

K. Pump tests, all levels of testing: 1. Test in accordance with the following:

a. Applicable HI Standards. b. This Section. c. Equipment sections.

2. Test tolerances: In accordance with appropriate HI Standards, except the following modified tolerances apply: a. From 0 to plus 5 percent of head at the specified flows rated design point

flow. b. From 0 to plus 5 percent of flow at the rated design point head. c. No negative tolerance for the efficiency at the specified flows rated design

point. d. No positive tolerance for vibration limits. Vibration limits and test methods

in HI Standards do not apply, use limits and methods specified in this or other Sections of the Specifications.

L. Drivers tests: 1. Test motors as specified in Section 16222. 2. Test other drivers as specified in the equipment section.

M. Noise requirements and control: 1. Perform noise tests in conjunction with vibration test analysis. 2. Make measurements in relation to reference pressure of 0.0002 microbar. 3. Make measurements of emitted noise levels on sound level meter meeting or

exceeding ANSI S1.4, Type II. 4. Set sound level meter to slow response. 5. Unless otherwise specified, maximum free field noise level not to exceed

85 dBA measured as sound pressure level at 3 feet from the equipment.

N. Pressure testing: 1. Hydrostatically pressure test pressure containing parts at the appropriate

standard or code required level above the equipment component specified design pressure or operating pressure, whichever is higher.

O. Inspection and balancing: 1. Statically and dynamically balance each of the individual rotating parts as

required to achieve the required field vibration limits. 2. Statically and dynamically balance the completed equipment rotating assembly

and drive shaft components. 3. Furnish copies of material and component inspection reports including

balancing reports for equipment system components and for the completed rotating assembly.


P. Critical speed of rotating equipment: 1. Satisfy the following:

a. The first lateral and torsional critical speed of all constant, variable, and 2-speed driven equipment that is considered rigid such as horizontal pumps, all non-clog pumps, blowers, air compressors, and engines shall be at least 25 percent above the equipment’s maximum operating speed.

b. The first lateral and torsional critical speed of all constant, variable, and 2-speed driven equipment that is considered flexible or flexibly mounted such as vertical pumps (vertical in-line and vertical non-clog pumps excluded) and fans shall at least 25 percent below the equipment’s lowest operating speed.

c. The second lateral and torsional critical speed of all constant, variable, and 2-speed equipment that is considered flexible or flexibly mounted shall be at least 25 percent above the maximum operating speed.

Q. Vibration tests: 1. Definitions:

a. Root mean square: for pumps operating at speeds greater than 600 rpm, the vibration measurement shall be measured as the overall velocity in inches per second root mean square (RMS).

b. Peak-to-peak displacement: The root mean squared average of the peak-to-peak displacement multiplied by the square root of 2.

c. Peak velocity: The root mean squared average of the peak velocity multiplied by the square root of 2.

d. Peak acceleration: The root mean squared average of the peak acceleration multiplied by the square root of 2.

e. High frequency enveloping: A process to extract very low amplitude time domain signals associated with impact or impulse events such as bearing or gear tooth defects and display them in a frequency spectrum of acceleration versus frequency. 1) Manufacturers: One of the following or equal:

a) Rockwell Automation, Entek Group, "Spike Energy" analysis. b) CSI, "PeakVue."

f. Low speed equipment: Equipment or components of equipment rotating at less than 600 revolutions per minute.

g. High speed equipment: Equipment and equipment components operating at or above 600 revolutions per minute.

h. Preferred operating range: Manufacturer’s defined preferred operating range (POR) for the equipment.

i. Allowable operating range: Manufacturer’s defined allowable operating range (AOR) for the equipment.

2. Vibration instrumentation requirements: a. Analyzers: Use digital type analyzers or data collectors with anti-aliasing

filter, 12 bit A/D converter, fast fourier transform circuitry, phase measurement capability, time wave form data storage, high frequency enveloping capabilities, 35 frequency ranges from 21 to 1,500,000 cycles per minute, adjustable fast fourier transform resolution from 400 to 6,400 lines, storage for up to one hundred 3,200 line frequency spectra, data output port, circuitry for integration of acceleration data to velocity or double integration to displacement.


1) Manufacturers: One of the following or equal: a) Computational Systems Inc., (CSI) Division of Emerson Process

Management, Model 2120A, Data Collector/analyzer with applicable analysis software.

b) Pruftechnik, VIBXPERT II. b. Analyzer settings:

1) Units: English, inches/second, mils, and gravitational forces. 2) Fast fourier transform lines: Most equipment 1,600 minimum; for

motors, enough lines as required to distinguish motor current frequencies from rotational frequencies, use 3,200 lines for motors with a nominal speed of 3,600 revolutions per minute; 3,200 lines minimum for High Frequency Enveloping; 1,600 lines minimum for low speed equipment.

3) Sample averages: 4 minimum. 4) Maximum frequency (Fmax): 40 times rotational frequency for rolling

element bearings, 10 times rotational frequency for sleeve bearings. 5) Amplitude range: Auto select but full scale not more than twice the

acceptance criteria or the highest peak, whichever is lower. 6) Fast fourier transform windowing: Hanning Window. 7) High pass filter: Minus 3 dB at 120 cycles per minute for high speed

equipment. Minus 3 dB at 21 cycles per minute for low speed equipment.

c. Accelerometers: 1) For low speed equipment: Low frequency, shear mode

accelerometer, 500 millivolts per gravitational force sensitivity, 10 gravitational force range, plus/minus 5 percent frequency response from 0.5 hertz to 850 hertz, magnetic mount. a) Manufacturers: One of the following or equal:

(1) Wilcoxon Research, Model 797L. (2) PCB, Model 393C.

2) For high speed equipment: General purpose accelerometer, 100 millivolts per gravitational force sensitivity, 50 gravitational force range, plus/minus 3dB frequency response range from 2 hertz to 12,000 hertz when stud mounted, with magnetic mount holder. a) Manufacturers: One of the following or equal:

(1) Wilcoxon Research, Model 793. (2) Entek-IRD Model 943.

3. Accelerometer mounting: a. Use magnetic mounting or stud mounting. b. Mount on bearing housing in location with best available direct path to

bearing and shaft vibration. c. Remove paint and mount transducer on flat metal surface or epoxy mount

for High Frequency Enveloping measurements. 4. Vibration acceptance criteria:

a. Testing of rotating mechanical equipment: Tests are to be performed by an experienced, factory trained, and independent authorized vibration analysis expert.

b. Vibration displacement limits: Unless otherwise specified, equipment operating at speeds 600 revolutions per minute or less is not to exhibit unfiltered readings in excess of following:


Operating Conditions & Application Data Overall Peak-to-Peak Displacement

Field, mils Factory, mils Operation within the POR 3.0 4.0 Operation within the AOR 4.0 5.0

Additive value when measurement location is greater than 5 feet above foundation. 2.0 2.0 Additive value for solids-handling pumps 2.0 N/A Additive value for slurry pumps 2.0 N/A

c. Vibration velocity limits: Unless otherwise specified, equipment operating at speeds greater than 600 revolutions per minute is not to exceed the following peak velocity limits:

HI Pump Type Horsepower Field Test Factory Test

Overall RMS Overall RMS Horizontal Solids Handling Centrifugal Pumps

Below 33 hp 0.25 0.28

Horizontal and Vertical In-Line Centrifugal Pumps (other than Non-Clog type) Vertical Solids Handling Centrifugal Pumps

Between 33 and 100 hp 0.28 0.31

100 hp and above 0.31 0.34

Below 33 hp 0.30 0.33

Vertical Turbine, Mixed Flow, and Propeller Pumps

Between 33 and 100 hp 0.32 0.35

100 hp and above 0.34 0.35 Non-Solids Handling Centrifugal Pumps HI Types BB1, BB2, BB3, BB4, BB5, OH1, OH2, OH3, OH4, OH5, and OH7

Below 268 hp 0.15 0.19

268 hp and above 0.19 0.22

Vertical Turbine, Mixed Flow, and Propeller Pumps HI Types VS1, VS2, VS3, VS4, VS5, VS6, VS7, and VS8

Below 268 hp 0.13

Gear Reducers, Radial 268 hp and above 0.17

Slurry Pumps 0.25 0.30

Motors See Applicable Motor Specification

See Applicable Motor

Specification


HI Pump Type Horsepower Field Test Factory Test

Overall RMS Overall RMS Gear Reducers, Radial Not to exceed AGMA

6000-B96 limits Not to exceed AGMA 6000-

B96 limits

Other Reducers, Axial 0.1 N/A

d. Equipment operation: Measurements are to be obtained with equipment installed and operating within capacity ranges specified and without duplicate equipment running.

e. Additional criteria: 1) No narrow band spectral vibration amplitude components, whether

sub-rotational, higher harmonic, or synchronous multiple of running speed, are to exceed 40 percent of synchronous vibration amplitude component without manufacturer's detailed verification of origin and ultimate effect of such excitation.

2) The presence of discernable vibration amplitude peaks in Test Level 2 or 3 vibration spectra at bearing inner or outer race frequencies shall be cause for rejection of the equipment.

3) For motors, the following shall be cause for rejection: a) Stator eccentricity evidenced by a spectral peak at 2 times

electrical line frequency that are more than 40 percent of the peak at rotational frequency.

b) Rotor eccentricity evidenced by a spectral peak at 2 times electrical line frequency with spectra side bands at the pole pass frequency around the 2 times line frequency peak.

c) Other rotor problems evidenced by pole pass frequency side bands around operating speed harmonic peaks or 2 times line frequency side bands around rotor bar pass frequency or around 2 times the rotor bar pass frequency.

d) Phasing problems evidenced by 1/3 line frequency side band spectral peaks around the 2 times electrical line frequency peak.

4) The presence of peaks in a High Frequency Enveloping spectra plot corresponding to bearing, gear or motor rotor bar frequencies or harmonics of these frequencies shall be cause for rejection of the equipment; since inadequate lubrication of some equipment may be a cause of these peaks, lubrication shall be checked, corrected as necessary and the high frequency envelope analysis repeated.

5. Vibration testing results presentation: a. Provide equipment drawing with location and orientation of measurement

points indicated. b. For each vibration measurement take and include appropriate data on

equipment operating conditions at the time vibration data is taken; for pumps, compressors, and blowers record suction pressure, discharge pressure, and flow.

c. When Vibration Spectra Data required: 1) Plot peak vibration velocity versus frequency in cycles per minute.


2) Label plots showing actual shaft or part rotation frequency, bearing inner and outer race ball pass frequencies, gear mesh frequencies and relevant equipment excitation frequencies on the plot; label probable cause of vibration peaks whether in excess of specification limits or not.

3) Label plots with equipment identification and operating conditions such as tag number, capacity, pressure, driver horsepower, and point of vibration measurement.

4) Plot motor spectra on a log amplitude scale versus frequency. d. For low speed equipment, plot peak vibration displacement versus

frequency as well as velocity versus frequency. e. Provide name of manufacturer and model number of the vibration

instrumentation used, including analyzer and accelerometer used together with mounting type.

3.02 PLANNING PHASE

A. Submit test plans as specified in Section 01650 and this Section. 1. Indicate test start time and duration, equipment to be tested, other equipment

involved or required; temporary facilities required, number and skill or trade of personnel involved; safety issues and planned safety contingencies; anticipated effect on Owner's existing equipment and other information relevant to the test.

2. Provide locations of all instruments to be used for testing. Provide calibration records for all instrumentation.

3.03 COMMISSIONING PHASE

A. Source testing: 1. Witnessing not required unless specified otherwise in equipment section. 2. Witnessed tests: Schedule test date and notify Engineer at least 30 days prior

to start of test. 3. Test equipment as specified in Section 01650 and equipment sections. 4. Test fluids as specified in Section 01650. 5. Submit reports as specified in Section 01650

B. Installation testing: 1. Test equipment as specified in Section 01650 and equipment sections.

C. Functional testing: 1. Witnessing required as specified in Section 01650. 2. Schedule test date and notify Engineer at least 7 days prior to start of test. 3. Test equipment as specified in equipment sections. Test fluids as specified in

Section 01650. 4. Submit reports as specified in Section 01650.

D. Clean Water Facility Testing: 1. Test equipment as specified in Section 01650 and equipment sections.

E. Closeout documentation: 1. Provide closeout documentation as specified in Section 01650 and equipment

sections.


3.04 PROCESS START-UP PHASE

A. Process start-up: 1. Process start-up equipment as specified in Section 01650 and equipment

sections.

B. Process Operational Period: 1. Operate equipment as specified in Section 01650 and equipment sections. 2. Test fluids as specified in Section 01650.

END OF SECTION


SECTION 16120

480 VOLT MOTOR CONTROL CENTERS

PART 1 GENERAL

1.01 SUMMARY

A. Scope of Work 1. The Contractor shall furnish and install the motor control centers as specified

herein and as shown on the PLANS. 2. Motor control center shall be close coupled with a switchboard as specified in

Section 16140 “Switchboards” and as shown on the PLANS. Refer to Section 16140 “Switchboards” of the Specifications.

1.02 RELATED WORK NOT INCLUDED

A. The PLANS designate the type, number, size and rating of devices included in the Motor Control Centers (MCCs)

B. Related work as called for on the PLANS, as specified herein or in other Sections of the Specifications.

1.03 QUALIFICATIONS

A. The manufacturer of the MCCs shall also manufacture the majority of components and subsystems therein (i.e., circuit breakers, starters, controls relays, etc.). The manufacturer of the MCCs shall also manufacture the Switchboards specified in Section 16140.

B. The MCCs shall be designed, constructed, and tested in accordance with the latest applicable requirements of NEMA, ANSI, UL, and NEC standards.

C. MCCs shall be as manufactured by Square D Company, Asea Brown Boveri, Eaton Cutler Hammer Corporation, or approved equal.

1.04 SUBMITTALS

A. Submit shop drawings in accordance with the requirements of Section 01330 of the Contract Specifications. Include: 1. Dimensioned/scaled top and bottom views, front elevations, and internal

component/device layouts 2. One-line diagrams and wiring diagrams, 3. Catalog cut sheets. Include protective device coordination curves and current

limiting circuit breaker/fuse peak current let through curves, where applicable. 4. Key interlock scheme drawing and sequence of operations, where applicable.


1.05 OPERATION AND MAINTENANCE MANUALS

A. Furnish Operation and Maintenance Manuals in accordance with the requirements of Section 01730 of the Contract Specifications. Include: 1. Installation and operation manuals. 2. Renewal parts bulletin. 3. As built drawings, including approved shop drawings. 4. Test data.

B. Additional information as required by subsection 1.08, this section of the Specifications.

1.06 STORAGE AND HANDLING

A. Protection 1. The Contractor, and hence the MCC supplier, shall be responsible for safety of

the MCC during storage, transporting and handling. 2. The MCC shall be environmentally protected and stored in climate controlled

(temperature and humidity, etc.) environment. 3. At all times the MCC shall be housed inside a moisture free, non-porous, extra

heavy duty plastic weatherproof housing. 4. Interior and exterior of MCC shall be kept clean at all times. 5. Energize the space heaters within the MCC and energize during storage and





b. Ambient Relative Humidity: Maximum: 50%. c. Ambient Corrosion Level: International Society of Automation Class: G1


3. Upon arrival of equipment onto job site, a maximum of one day shall be allowed for equipment to be left without to allow proper transition of power of equipment, especially any 120 VAC powered equipment, to ensure all air conditioning, heating, and gaseous air scrubbing equipment are fully operational with a maximum of a 10 minute down time during this transition of power.




A. Furnish the following spare parts with the equipment for each MCC in conformance with the specifications: 1. One (1) – Set of fuses (minimum 3) for each type and size used. 2. One (1) – Set of starter contacts for every three (3) like starters used (a

minimum of 1 for each size used). If contacts are not replaceable a spare starter for each size used shall be supplied.

3. Two (2) - Contactor coils for every NEMA size and type starter installed, a minimum of one coil per size.

4. Two (2) - Spare control relays for each type used. Control relay shall be furnished complete with relay coils, Four (4) Normally Open (N.O.) contacts, Four (4) Normally Closed (N.C.) contacts, and shall be furnished with Relay Manufacturer’s Transient Voltage Suppression Module.

5. One (1) - Spare timing relay. 6. Two (2) – Sets of overload heaters for each size and type used. 7. One (1) quart of manufacturer’s standard touch-up paint.

B. Furnish the following tools with the equipment for each MCC in conformance with the specifications: 1. Provide breaker test set for Solid-State-Trip units for each type used.

1.08 SPECIAL MANUFACTURER SERVICES

A. Furnish the services of a qualified, experienced, factory trained technical (non-sales type) representative to assist in the installation of the equipment. Include checking alignment of parts, wiring connections, operation of all parts (relays, starters, monitoring relays, etc.). Include time to correct and recheck any discrepancies which are discovered. Also include providing the OWNER with a report certifying that the equipment was installed, adjusted, properly tested, and set in accordance with the manufacturer’s recommendations and is in satisfactory operating condition. Format and quantity of reports shall be per the requirements of Section 01330 of the Contract Specifications.

B. Manufacturer's technical representative is to set, adjust and test all protective relays, etc. in the presence of a representative of the Owner. The settings will be based on coordination, short circuit, and motor starting studies performed in compliance with Section 16140 of the Specifications “Switchboards”, Subsection 1.08 “Special Manufacturer’s Services”. Provide the Owner with test report certified by the manufacturer. Include a record of all settings. Format and quantity of reports shall be per the requirements of Section 01330 of the Specifications. The Manufacturer shall furnish the protective device of the appropriate characteristics that shall be the most suitable for the proper protection and coordination of the system at No Additional Cost to the Owner.

C. Any problems encountered with the operation of equipment, parts, components, etc. installed within the MCC line-up shall be repaired/remedied by the manufacturer's technical representative.


PART 2 PRODUCTS

2.01 GENERAL

A. For additional construction notes and special requirements, refer to the PLANS. Also refer and adhere to the requirements of the PLANS.

B. Motor Control Center shall not exceed the dimensions shown on the PLANS. Compartment/component arrangement shall be as shown on the elevation drawings. Provide for incoming feeder entering from below or above, and for outgoing circuits exiting from above and below, as shown on the PLANS.

2.02 CONSTRUCTION

A. Structure 1. Enclosures shall be NEMA Type 1, Gasketed. Enclosure shall be the totally

enclosed, dead front, free standing type suitable for back-to-wall mounting. 2. MCC shall consist of required number of vertical sections bolted together to

form a rigid self supporting assembly. Each vertical section shall be nominally 90 inches high. Each vertical section shall be subdivided into compartments (units). Refer to the PLANS for additional dimensional requirements.

3. The MCC shall contain a top horizontal wireway and a bottom horizontal wireway running the full width of the MCC. The bottom horizontal wireway shall be covered by hinged doors. Each vertical section shall include a top plate and a bottom plate; plates shall be removable.

4. Each vertical section containing a plug-in unit shall also contain a vertical wireway that interconnects the top and bottom horizontal wireways. The vertical wireway shall be covered by a hinged door.

5. Each unit within each vertical section shall have a hinged door. Each unit shall have a padlockable disconnect operating handle. Include provisions for up to three padlocks. Handle shall be mechanically interlocked with the door to prevent personnel from opening the door when the unit disconnect is in the ON position. Provide handle-door interlock defeating (bypass) feature. Provide non-defeatable interlock to prevent the installation of a plug-in unit unless the unit disconnect is in the OFF position.

6. Unused unit spaces in each vertical section shall be covered by hinged blank doors and equipped to accept future units.

7. All combination starter and feeder units of plug-in construction shall utilize mechanical guides to insure positive alignment of the unit stabs to the section vertical bus. For each unit, shutters shall be provided to cover bus access openings when unit is removed. Unused structure openings shall have plugs or covers to prevent entry of foreign objects into the bus area.

8. Structure finish shall be primed and painted using the manufacturer’s standard finishing process. Finish shall be applied at the manufacturing plant. Color shall be manufacturer’s standard.

9. Provide each vertical section with an accessible space heater wired to terminal blocks in the respective section. Size the space heater per manufacturer’s standard.

10. Structure shall include field removable lifting means. 11. Where an incoming line section is required by the PLANS, the Incoming Line

Section shall include lugs for the connection of the field wiring shown on the PLANS.


B. Buses 1. All buses shall be tin plated copper. 2. The main horizontal bus shall extend the entire length of the motor control

center. Buses shall be fully rated and the rating shall be based on 65 degrees C maximum temperature rise in a 40 degree C ambient. The main bus shall be rated as shown on the drawings and/or data sheets. Provisions shall be provided to facilitate future extension of the buses.

3. The vertical bus in each section shall be rated for 300 ampere, at minimum. 4. The minimum RMS symmetrical short circuit current rating of the buses shall

be as indicated on the one-line diagram drawings. 5. The power buses shall be isolated by barriers from starters, wire troughs, and

other areas. 6. A continuous ground bus shall be furnished for the entire length of the MCC.

The ground bus shall be rated for 50 percent of the main horizontal power (phase) bus rating, at minimum. Stack multiple ground bus bars as required to provide the required ground bus rating. Provide ground bolted connectors for the size and quantity of wire at each end of the bus as shown on the PLANS.

C. Wiring 1. Unless otherwise noted, the MCC shall be wired Class II, type B construction

with terminal blocks for each cubicle. 2. All Control wiring shall be tin-plated stranded copper not smaller than #14. 3. All wiring shall be neatly bounded with tie-wraps and supported to wire ways

supports. 4. Wiring shall be terminated to split-type terminal blocks.

D. Identification 1. All component and control identification labels shall include the device name

and number exactly as it appears on the PLANS. Refer to the PLANS. 2. All control wires shall be tagged and coded with an identification number.

Tagging type and wire coding shall be per manufacturer’s standard. 3. All terminal blocks shall be identified. 4. Properly label the devices mounted inside each section using manufacturer’s

standard laminated labels installed in accordance with the manufacturer’s standard method. Minimum text height shall be 3/16 inch.

5. Nameplates: a. Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose

paper base engraving stock per ASTM D-709, Type I. Nameplates shall be ASTM Grade ES-1, ES-2, or ES-3 as applicable for the face and lettering colors specified hereinafter. Flexible or acrylic tags will be not be accepted.

b. Color: White-Black-White c. Lettering: Engraved through the face layer to the melamine middle layer.

Nameplates located on the face of each section/compartment of each MCC shall be legible at a distance of six feet from the nameplate. Minimum text height shall be 3/16 inch.

d. Accessories: Provide holes for mechanical fastening e. Attachment Means: Secured with two Stainless Steel screws/bolts per

manufacturer’s standard; use of adhesives shall not be accepted. 6. Furnish and install nameplates for:

a. Each equipment/device/etc. installed/mounted on the face of the MCC.


b. Each exterior section/compartment of each MCC. c. Overall entire lineup of MCC, i.e. a master nameplate. Master nameplate

shall include the tag of the MCC as shown on the PLANS, at minimum, in addition to manufacturer’s standard information for master nameplates.

2.03 BRANCH FEEDER CIRCUIT BREAKERS

A. Provide thermal magnetic molded case circuit breakers with the following minimum requirements: 1. U.L. listed minimum RMS symmetrical short circuit current rating equal to or

greater than that of the main bus. 2. Circuit breaker shall be three pole, 600 volt with a maximum continuous

current carrying capacity shown on the PLANS. 3. Breakers shall operate continuously when operating/running current is equal to

80% of the long time trip setting (or frame rating, as applicable) of the breakers.

4. Breakers shall have an overcenter, toggle handle-operated, trip free mechanism with quick make, quick break action independent of the speed of the toggle handle operation. The design shall provide common tripping of all poles. Breakers shall be suitable for reverse feeding.

5. Provide complete with rating plug and other accessories as required for proper operation of circuit breaker.

6. Provide mechanical padlock attachment for each circuit breaker. 7. Furnish lugs for feeders where required to facilitate field wiring termination,

sizes shall be as required by the PLANS. 8. All circuit breakers shall be unit mounted

B. Additional requirements for branch/feeder circuit breakers only: All circuit breakers shall be unit mounted.

C. Provide where specifically shown on the PLANS: 1. Current limiting circuit breaker. 2. Electronic trip attachment. Trip unit shall be solid state type with field

adjustable long time, short time, ground fault and pick up settings. Where available from the manufacturer, coat all printed circuit assemblies with a UL 746 recognized conformal coating.

3. Auxiliary contacts rated for 120 volts A.C. Contacts shall satisfy the requirements of the PLANS.

2.04 COMBINATION UNITS

A. Each combination motor controller and feeder unit shall have the following characteristics: 1. Molded case circuit breakers for branch circuit protection. Circuit breakers

shall have the following characteristics: a. U.L. listed minimum RMS symmetrical short circuit current rating equal to

or greater than that of the main bus. b. Three pole, 600 volt, type and maximum continuous current carrying

capacity as shown on the PLANS. 2. Starters shall have the following characteristics:


a. Starters shall be magnetic type, NEMA rated, with 120 volts A.C. operating coils. International type starters (IEC rated), will not be accepted, even if the starters were to show equivalent NEMA ratings.

b. Size and configuration (full voltage non-reversing, full voltage reversing, reduced voltage auto-transformer non-reversing, etc.) as shown on the PLANS.

c. Thermal switch(es) shall be embedded in the auto-transformers. Thermal switches shall be interlocked with the starting circuit and shall open the circuit (stop the motor) upon excessive temperature rise in the transformer winding. Thermal switch contacts shall be rated 5 amp (minimum) at 120VAC.

d. Provide each starter coil with the manufacturer’s standard transient voltage surge suppression module.

e. Provide auxiliary contacts as required by the PLANS. Contacts shall be rated for 120 volts A.C and shall satisfy the requirements of the PLANS. Provide each starter with one (1) normally open auxiliary contact wired to terminal blocks over the number of contacts required by the PLANS.

3. Provide Overload relays where required by the PLANS. Overload relays shall have the following characteristics: a. Standard class 20, bimetallic, ambient compensated, b. Manually reset by push-button located on front of the compartment door. c. Provide with auxiliary contact rated for 120 volts A.C. Contact shall satisfy

the requirements of the PLANS. d. The overload relay heaters will be selected by the Contractor after

delivery of the MCC. Include all necessary delivery, packaging, and administrative costs associated with the delivery of overload heaters.

4. Control Power Transformer. The transformer shall have the following characteristics: a. Adequately sized to serve all loads shown on the PLANS. Minimum size

shall be as follows unless noted otherwise on the PLANS: 1) NEMA Size 4 and larger starters: 750 VA 2) All other starters, 200VA

b. Connect as shown on the PLANS. 5. Provide one single pole fuse block with fuse for each motor space heater. 6. Where required by the PLANS, provide three phase power factor correction

capacitor (PFCC) banks. Furnish and install additional requirements as follows: a. Manufacturer’s standard overload protection for PFCC banks. b. Each PFCC bank is dedicated to correct the power factor of a specific

pumping unit. The kVAR size/rating shown on the PLANS is a minimum requirement for bidding purposes. The manufacturer shall properly select the kVAR size/rating of the capacitor bank based upon the actual motor load data to ensure an improved operating power factor of greater than or equal to 95 percent (lagging) when the associated distribution pump motor load is in full operating condition. The PFCC banks shall be 480 volt rated.

c. Connect as shown on the PLANS. d. Provide for auxiliary contacts as required by the PLANS. Contacts shall

be rated for 120 volts A.C and shall satisfy the requirements of the PLANS.


e. Each PFCC bank shall be installed in an individual compartment/section of the Motor Control Center directly adjacent and close-coupled with its associated starter assembly, as also shown on the PLANS.

7. Provide additional requirements as shown on the PLANS.

2.05 MOTOR PROTECTION AND MANAGEMENT RELAY “MPR/MMR”

A. Where required by the PLANS, furnish and install Motor Protection and Management Relay (MPR/MMR) in the MCC. The Motor Protection and Management Relays shall be as manufactured by General Electric - MULTILIN Model 869 complete with the Ethernet communication capability and harsh environment UL 746C recognized conformal coating on all printed circuit assemblies as also shown on the PLANS, No Equal. Connect per manufacturer’s recommendations and as shown on the PLANS. Protective relaying features will be enabled as determined during the performance of the studies performed per Subsection 1.08, “Special Manufacturer’s Services”, this Section of the Specifications. In addition, the protective relay is to have the following features as provided by Manufacturer: 1. Minimum 12 RTD inputs, 2. Phase Current Inputs (refer to PLANS), 3. Ground Current Inputs (refer to PLANS), 4. 2 Form A and 3 Form C Output Contacts rated minimum 120VAC, 10A

continuous, 2A inductive, as well as 7 Discrete inputs (120VAC) 5. 7 Analog Outputs (4-20mA) as well as 4 Analog Inputs (4-20mA) plus one(1)

RTD input 6. Additional I/O, as required, per control schematics as shown in PLANS, 7. Standard Front Panel (Rugged Key Pad), 8. Standard option for current protection, 9. Advanced option for Voltage Monitoring, 10. Control to be standard control plus flex logic, 50BF 11. Standard option for monitoring (including broken rotor), 12. Advanced option for communications, 13. Advanced Cyber Security.

2.06 INSTRUMENT TRANSFORMERS

A. General 1. All instrument transformers specified shall be installed and connected at the

factory.

B. Instrument current transformers (C.T.’s): 1. Provide current transformers where required by the PLANS. Connect as

shown on the PLANS. 2. Current transformers shall be the window type and shall have an ANSI 60 Hz

Metering Accuracy Class of 0.3 measured at burden of B0.1, at minimum. 3. Install a shorting terminal block for each current transformer (C.T.). Prewire all

terminals of each C.T. to its respective shorting terminal block. Shorting terminal blocks shall be as manufactured by “G.E.”, or approved equal.

C. Instrument Potential Transformers (P.T.’s): 1. Provide potential transformers where required by the PLANS. Connect as

shown on the PLANS.


2. Potential transformers shall have the following characteristics: a. Primary voltage: 480 volts A.C. b. Secondary voltage: 120 volts A.C. c. Accuracy rating: 0.6 Y at burden of 1.2X d. Thermal Burden: 150 VA at 30 degrees C ambient e. Frequency: 60 Hz.

3. Install with primary and secondary disconnect devices, grounding device, and accessories in conformance with IEEE and NEMA standards.

4. Provide current limiting type primary fuses.

2.07 MISCELLANEOUS ACCESSORIES

A. Pilot Lights: 1. Type: Transformer Type Light Emitting Diode (LED), 2. Style: Push-to-test 3. Lens Color: Furnish and install the colors as shown on the PLANS. 4. Rating: NEMA 4/13, oil tight and water tight, Heavy Duty 5. Size: NEMA Style full size 30-millimeter (30mm), 6. Contacts: 10 ampere minimum at 120 volts A.C. Provide number of contacts

to satisfy the requirements of the PLANS. 7. Legend Plate: Furnish and install per manufacturer’s standard with inscription

as shown on the PLANS. 8. Manufacturer: Allen Bradley Bulletin 800T, or approved equal.

B. Control relays shall have the following characteristics: 1. 600 volts, standard NEMA Size, AC Heavy-Duty industrial type with 120 volt

AC coils. 2. Minimum contact rating of 10A, continuous, at 120 volts AC. 3. Furnish each relay with one additional Normally Open (N.O.) and one

additional Normally Closed (N.C.) contacts over the number required by the PLANS.

4. Provide each relay with Relay Manufacturer’s Transient Suppression Module. 5. Relays shall be “Allen Bradley Bulletin 700”, Type-700P, or approved equal

relays of the MCC manufacturer.

C. Timing Relays shall have the following characteristics: 1. Solid state, multi-time, and multi-function type relay 2. Both timing ranges and timing modes shall be field selectable. Each relay

shall be capable of the following timing modes: a. On Delay b. Off Delay c. One Shot d. Repeat Cycle e. Interval

3. Minimum relay contact rating shall be 10 amps, continuous, at 120 VAC. 4. Timing relays shall be Square D Class 9050 model No. JCK70 complete with

Type NR61 Socket, or approved equal.

D. Elapsed Time Meters shall have the following characteristics: 1. Totally sealed black polymer rectangular, flush panel mounted enclosure with

mounting clip. 2. Non-resettable quartz electronic clock timing.


3. Operating voltage: 90-264 volts AC. 4. Temperature range: -40 degrees C to +85 degrees C 5. Reading at least to 99999.9 hours and at least to nearest one-tenth of an hour. 6. White digits on black background 7. U. L. recognized. 8. Manufacturer: Redington Model 722-0002 Totally Sealed AC Hour Meter,

complete with Model 5003-009 NEMA 4X gasket, or approved equal.

E. MCC Space Heater Circuitry: 1. The space heater of each vertical section of the MCC shall operate at 120

VAC. The 120 VAC circuit shall originate from the space heater control power transformer specified in Section 16140 “Switchboards”, Subsection 2.05 C. Connect the MCC space heater circuitry to the space heater circuitry of the close coupled Switchboard.

2. The space heater circuitry shall be thermostatically controlled by centrally located thermostat(s). Provide the quantity of thermostats necessary to serve the load of the space heater circuitry.

F. Provide control power transformer, fuses, power supplies, etc., and associated interconnect wiring as required to provide functional control power service to the circuit breaker trip circuitry for proper operation of circuitry, per manufacturer’s standard.

G. Provide key interlocks where required by the PLANS.

H. Patch Panel: Where shown on the PLANS, provide a dedicated patch panel for termination of the Ethernet data highway (serial communication) cabling for each Motor Protective Relay. Patch panels shall be two-port, surface mounted, fully enclosed type, Category 6, with RJ-45 connectors, as manufactured by “Panduit”, Model Mini-Com #CBXJ2IW-A, with “Mini-Com” UTP Coupler Module Model CC688IW and blank cover plates, or approved equal. Secure patch panel to backpanel with screws. Ethernet patch cords shall be furnished and installed between the patch panel and the respective motor protective relay per the requirements of Section 17600 “Distributed Control System”. Length of patch cords shall be such to have one full coil of slack cable at a minimum to reduce physical strain on cable termination.

PART 3 EXECUTION


A. Standard factory tests shall be performed on the equipment specified in this section. All tests shall be in accordance with the latest version of ANSI and NEMA standards. The manufacturer shall provide certified copies of factory test reports prior to shipment of the equipment to the project site. Format and quantities of the test report shall be in accordance to Section 01330 and Section 01730 of the Contract Specifications.



A. Install per manufacturer’s instructions and recommendations. Install all required safety labels.

B. Perform manufacturer’s field services as previously specified.

C. Size, furnish and install the overload relay heaters based on actual motor nameplate current. Set overload relay settings at maximum values permitted by the NEC 430-32.

D. Size, furnish and install the motor space heater fuses based on actual motor space heater load current.

3.03 FIELD TEST AND CHECKS

A. Verify proper rotation of all motor loads

B. Verify motor space heater circuits are operational..

C. The following minimum test and checks shall be made before energizing the MCCs. These tests shall be performed by a Factory Trained Field Technician (non sales type): 1. Thoroughly inspect the MCC. 2. Test for proper phasing of power connections. 3. Set, adjust, and test all protective relays based on the results of the

coordination study, refer to sub-section 1.08, this Section of the Specifications. 4. Megger terminals and buses for grounds, test per manufacturer’s

recommendations. 5. Verify ratios of all CT’s, and proper operation of all metering. 6. Verify MCC enclosure space heater circuits are operational. 7. Test key interlock system functionality 8. Check tightness of accessible bolted bus joints using calibrated torque wrench

per manufacturer's recommended torque values.

D. Submit documentation of all tests outlined above.

E. Submit manufacturer’s certification report per sub-section 1.08, this Section of the Specifications.

3.04 EQUIPMENT PROTECTION AND RESTORATION

A. Clean and vacuum all interior of the equipment.

B. Touch-up and restore damaged surfaces to factory finish.

C. Energize the space heaters within the MCC and energize during storage and installation for humidity control.


3.05 TRAINING

A. Provide training sessions for owner’s representatives for Two (2) FULL normal workdays at the job-site location and/or at a location determined by the OWNER. If training is conducted in less than the time required by these specifications, the remaining time shall be utilized at the discretion of the OWNER.

B. The training session shall be conducted by the MCC manufacturer’s non-sales-type technical representative, who performed the field installation and start-up/setting/adjustment services.

C. At minimum, the training session shall include: 1. Operation and maintenance procedure for the equipment and all components

installed within the MCCs. 2. Factory contact persons phone numbers, persons names, ordering procedures

and procedures to follow to obtain meaningful results from the factory. 3. Potential of arc-flash hazards associated with working on energized

equipment.

D. Training session may be concurrent with the training session for the Switchboards specified in Section 16140 “Switchboards”, Subsection 3.05.



END OF SECTION


SECTION 16140

SWITCHBOARDS

PART 1 GENERAL

1.01 SUMMARY

A. This section specifies 480-Volt Switchboards (SWBDs) and Metal Enclosed Overhead Bus Duct. The Contractor shall furnish and install SWBDs and Metal Enclosed Overhead Bus Duct as herein specified and shown on the PLANS.

B. Where Bus Duct is required by the PLANS, the Contractor shall furnish and install the Bus Duct system including all necessary fittings, hangers, and accessories as specified herein and as shown on the PLANS.

C. Each SWBD shall be close coupled with a low voltage motor control center as specified in Section 16120 “480 Volt Motor Control Centers” and as shown on the PLANS. Refer to Section 16120 “480 Volt Motor Control Centers” of the Specifications.


A. The Contract Documents are complementary; what is called for by one is as binding as if called for by all.

B. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors. Suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work.

C. The PLANS designate the type, number, size and rating of devices included in the SWBDs.

D. Related work as called for on the PLANS, as specified herein or in other Sections of the Specifications.

1.03 (NOT USED)


A. All SWBDs on the project shall be manufactured by a single SWBD manufacturer. The manufacturer of the SWBDs shall also manufacture the majority of components and subsystems therein (i.e., circuit breakers, etc.). The manufacturer of the SWBD shall also manufacture the bus duct as well as the 480 Volt Motor Control Center specified in Section 16120.

B. The SWBDs and bus duct shall be designed, constructed, and tested in accordance with the latest applicable requirements of NEMA, ANSI, UL, and NEC standards.


C. SWBDs and bus duct shall be as manufactured by Square D Company, Asea Brown Boveri, Eaton Cutler Hammer Corporation, or approved equal.

1.05 SUBMITTALS

A. Submit shop drawings in accordance with the requirements of Section 01330 of the Contract Specifications. Include: 1. Dimensioned/scaled top and bottom views, front elevations, and overhead bus

duct connection 2. One-line diagrams and wiring diagrams 3. Catalog cut sheets. Include protective device coordination curves and current

limiting circuit breaker/fuse peak current let through curves, where applicable. 4. Key interlock scheme drawing and sequence of operations, where applicable.

B. Furnish Operation and Maintenance Manuals in accordance with the requirements of Section 01730 of the Contract Specifications. Include: 1. Installation and operation manual. 2. Renewal parts bulletin. 3. As built drawings, including approved shop drawings. 4. Test data.


A. Protection: 1. The Contractor, and hence the SWBD supplier, shall be responsible for safety

of the SWBD and associated bus duct during storage, transporting and handling.

2. The MCC shall be environmentally protected and stored in climate controlled (temperature and humidity, etc.) environment.

3. At all times the SWBD shall be housed inside a moisture free, non-porous, extra heavy duty plastic weatherproof housing.

4. Interior and exterior of SWBD shall be kept clean at all times. 5. Energize the space heaters within the SWBD and energize during storage and











A. Furnish the following spare parts with the equipment for each SWBD in conformance with the specifications: 1. One (1) – Set of fuses (minimum 3) for each type and size used. 2. One (1) Power Monitoring Unit (PMU). 3. Provide breaker test set for Solid-State-Trip units for each type used. 4. One (1) quart of touch-up paint.

1.08 SPECIAL MANUFACTURER’S SERVICES

A. Furnish the services of a qualified, experienced, factory trained technical (non-sales type) representative to assist in the installation of the equipment. Include checking alignment of parts, wiring connections, operation of all parts (relays, starters, monitoring relays, etc.). Include time to correct and recheck any discrepancies which are discovered. Also include providing the Owner with a report certifying that the equipment was installed properly tested and set in accordance with the specifications and is in satisfactory operating condition. Format and quantity of reports shall be per the requirements of Section 01330 of the Contract Specifications.

B. Manufacturer's technical representative is to set, adjust and test all circuit breakers, relays, motor circuit protectors, etc. in the presence of a representative of the OWNER. The settings will be based on coordination and short circuit studies performed per subsection 1.08.D, this Section of the Specifications. Provide the OWNER with test report certified by the manufacturer. Include a record of all settings. Format and quantity of reports shall be per the requirements of Section 01330 and 01730 of the Contract Specifications. The Manufacturer shall furnish the protective device of the appropriate characteristics that shall be the most suitable for the proper protection and coordination of the system at No Additional Cost to the OWNER.

C. Any problems encountered with the operation of equipment, parts, components, etc. installed within the SWBDs line-up, and associated bus duct, shall be repaired/remedied by the manufacturer's technical representative.


D. Prepare load analysis studies, motor starting studies, arc-flash hazard analysis studies, harmonic studies, and coordination studies, complete with short circuit calculations and coordination curves reflecting calculated fault values and recommended and/or proposed fuse type/ratings, motor protective relay settings, equipment/cable thermal (damage) limits, equipment/device settings (as applicable) as follows: 1. From the Austin Energy 480V level (with close coordination with Austin Energy

upstream devices) through the 208/120V subsystem level equipment and devices of the proposed Side Stream Treatment Plant Electrical Building. Coordination with Austin Energy is required. Additional details concerning the implementation of the studies such as main-tie-main circuit breaker states to be assumed, etc., will be provided after Bid Award during the Pre-Submittal conference. Thevenin equivalent system characteristics for the 480V system at the Electrical Building will be provided by the Owner after Bid Award to facilitate the Contractor’s system study effort.

E. Prepare motor starting studies for the proposed Blower Building, Pump Building, Primary Pump Station, and Electrical Building complete with load calculations and voltage dip curves reflecting calculated load, voltage, motor and load speed-torque characteristics and values, tabulated voltage dip duration and magnitude at the utility service 480V level, and recommended and/or proposed protective relay settings, reduced voltage auto-transformer starter tap settings, start to run transition time settings, variable frequency drive ramp settings, equipment/device settings (as applicable), etc. for all proposed motor starters/distribution equipment as well as all modified starters/distribution equipment on the project. In the studies, include the previously mentioned Thevenin equivalent system characteristics provided by the Owner. All studies shall be performed assuming each pump starts against a closed discharge valve. Assume that the pump discharge valve will open once the pump motor reaches full speed. Verify and coordinate the validity of these assumptions and the sequence of valve operation with the Owner after Bid Award and follow the recommendations of the Owner regarding the process system operation. Repeat all motor starting studies for each type of variable speed drive ramp profile (current limit, voltage ramp, etc.) available for the proposed variable speed drive, and also among each ramp profile with a minimum of five different limiting settings as applicable for each ramp profile, to determine the optimal setpoints to successfully start the load while minimizing service voltage dip. Additionally, perform all motor starting studies assuming one main utility service is energized, the tie circuit breakers are closed, and the second main utility service is de-energized. Perform the motor starting studies for the sequential progressive starting of the proposed pumping units. Repeat studies for each process area electrical service.

F. Perform the arc flash hazard analysis in conjunction with the short circuit and coordination analysis previously described herein and also in compliance with IEEE 1584 and NFPA 70E standards. The flash protection boundary and incident energy shall be calculated at all points in the distribution system (transformers, motor control centers, panelboards, etc.) where work could be performed on energized parts. The following additional requirements apply for the arc flash hazard analysis: 1. Perform arc flash hazard studies assuming one main utility service is

energized, the tie circuit breakers are closed, and the second main utility service is de-energized.

2. Repeat studies for each main utility electrical service.


3. Additionally, perform arc flash hazard studies assuming both main utility services are energized and the tie circuit breakers are open

4. Repeat arc flash hazard studies using reduced short circuit current magnitudes where applicable per IEEE 1584 recommendations.

5. Calculations to address worst case (maximum) hazard analysis for each scenario. Describe scenarios employed and tabulate associated arc flash hazard results in submittals.

G. The arc flash hazard analysis effort shall also include: 1. Reporting incident energy values based upon recommended protective device

settings for all equipment, 2. Reporting recommendations to reduce AFIE levels and enhance worker safety 3. Furnish and install label(s) for all equipment included in the study indicating

the following, at minimum: a. System voltage b. Shock and Flash protection boundaries c. Personal protective equipment requirements for each electrical task based

upon hazard category (including flame resistant clothing requirements). d. Arc flash incident energy value (cal/cm2) e. Limited, restricted, and prohibited approach boundaries f. Study report number and issue date g. Additional information required by the applicable NFPA and IEEE

standards. h. Labels shall be manufacturer’s standard labels with quantity and mounting

location per manufacturer’s standard.

H. Perform a harmonic study in accordance with IEEE 519 from the 12470V level (with close coordination with the Owner’s upstream 12470V protective devices) through the 208/120V subsystem level equipment and devices of the proposed Side Stream Treatment Plant. In the studies, include the previously mentioned Thevenin equivalent system characteristics for the 12470V system provided by the Owner. Including all necessary equipment (motor control center, SWBD, panelboard, transformer, feeders, loads, power factor correction capacitors, etc.) as required to demonstrate compliance with the harmonic performance requirements of IEEE 519 at the point of common coupling with Austin Energy, as well as the additional locations as defined on the PLANS, and associated recommendations. Refer to the PLANS. Include effort to adjust filter sizes (as applicable) and determine optimal VFD settings in accordance with the actual installed equipment

I. THE ARC-FLASH STUDIES, THE SHORT CIRCUIT CALCULATIONS AND ANALYSIS, THE COORDINATION STUDY, AND THE MOTOR STARTING STUDIES, AND HARMONIC STUDY SHALL BE PERFORMED: 1. UTILIZING SKM SOFTWARE, LATEST RELEASE – MICROSOFT

WINDOWS VERSION. In addition to the hard copy submittal, an electronic copy of the FINAL VERSION of the short circuit analysis/calculations and the protective device setting curves (time-current curves) and summary setting tables, etc. shall be submitted on a Universal Serial Bus (USB) external flash drive.

2. By a State of Texas Registered Professional Engineer. The final version of the studies shall be signed and sealed by a Professional Engineer who is Licensed in the State of Texas as an Electrical Engineer.


PART 2 PRODUCT

2.01 GENERAL

A. For additional construction notes and special requirements, refer to the PLANS. Also refer and adhere to the requirements of the PLANS.

B. SWBD shall not exceed the dimensions shown on the PLANS. Compartment/component arrangement shall be as shown on the elevation drawings. Provide for incoming feeder entering from below or above, and for outgoing circuits exiting from above and below, as shown on the PLANS.

2.02 CONSTRUCTION

A. Structure 1. Enclosures shall be NEMA Type 1, Gasketed. Enclosure shall be the totally

enclosed, dead front, free standing type suitable for back-to-wall mounting. SWBDs shall be FRONT ACCESS ONLY. SWBDs shall be front and rear aligned.

2. SWBD shall consist of required number of vertical sections bolted together to form a rigid self support assembly. Each vertical section shall be nominally 90 inches high. Each vertical section shall be subdivided into compartments. Refer to the PLANS for additional dimensional requirements.

3. Each vertical section may be rolled, moved, or lifted into position. 4. All SWBD sections shall have open bottoms and field removable top plates. 5. A hinged door shall be provided for each of the following compartments:

a. Metering compartment b. Incoming line section compartment.

6. SWBD shall comply with UL Service Entrance requirements for SWBDs. 7. Unused spaces in each vertical section shall be covered by blank covers. 8. Unused structure openings shall have plugs or covers to prevent entry of

foreign objects into the SWBD. 9. Structure finish shall be primed and painted using the manufacturer’s standard

finishing process. Finish shall be applied at the manufacturing plant. Color shall be manufacturer’s standard.

10. Provide each vertical section with a space heater wired to terminal blocks in the respective section. Size the space heater per manufacturer’s standard.

11. Structure shall include field removable lifting means. 12. Incoming line section shall include lugs for the connection of the field wiring

shown on the PLANS.

B. Buses 1. All buses shall be tin plated copper. 2. The main horizontal bus shall extend the entire length of the SWBD. Buses

shall be fully rated and the rating shall be based on 65 degrees C maximum temperature rise in a 40 degree C ambient. The main bus shall be rated as shown on the PLANS and/or data sheets. Provisions shall be provided to facilitate future extension of the buses.

3. The minimum RMS symmetrical short circuit current rating of the buses shall be as indicated on the one-line diagram drawings.

4. A continuous ground bus shall be furnished for the entire length of the SWBD. The ground bus shall be rated for 50 percent of the main horizontal power


(phase) bus rating, at minimum. Stack multiple ground bus bars as required to provide the required ground bus rating. Provide ground bolted connectors for the size and quantity of wire at each end of the bus as shown on the PLANS.

C. Wiring 1. Control and/or discrete signal wiring includes wiring to instrument current

transformers, 600 volt wiring to secondary of instrument potential transformers, ammeters, power monitoring units “PMU’s”, lights, receptacles, control relays, control devices (pilot lights, selector switches, etc.), relaying etc. Control wiring shall be extra flexible 41 strand, tin-plated copper, 600 volt insulation, dual rated type XLPE (3173) 125° C, SIS 90° C., SIS wire manufactured by General Cable Company, The Okonite Company or approved equal. Minimum acceptable size to be #14 AWG.

2. Instrument signal wiring shall be twisted pair, #16 AWG stranded copper conductors with 600 volt PVC insulation over each conductor, a tinned copper drain wire, an overall aluminum mylar shield and an outer PVC jacket. Instrument wiring cables shall be manufactured by “Samuel Moore and Company, DeKoron Division, Cat. No. 1852”. All instrument signal wiring shall be installed and tested at the factory.

3. All control/metering wiring shall be neatly bounded with tie-wraps and supported to wire ways supports.

4. Control/metering wiring shall be terminated to terminal blocks.

D. Identification 1. All component and control identification labels shall include the device name

and number exactly as it appears on the PLANS. Refer to the PLANS. 2. All control/metering wires shall be tagged and coded with an identification

number. Tagging type and wire coding shall be per manufacturer’s standard. 3. All terminal blocks shall be identified. 4. Properly label the control/metering devices mounted inside the each section

using manufacturer’s standard laminated labels installed in accordance with the manufacturer’s standard method. Minimum text height shall be 3/16 inch.



b. Color: White-Black-White c. Lettering: Engraved through the face layer to the melamine middle layer.

Nameplates located on the face of each section/compartment of each MCC shall be legible at a distance of six feet from the nameplate. Minimum text height shall be 3/16 inch.

d. Accessories: Provide holes for mechanical fastening e. Attachment Means: Secured with two Stainless Steel screws/bolts per

manufacturer’s standard; use of adhesives shall not be accepted. 6. Furnish and install nameplates for:

a. Each equipment/device/etc. installed/mounted on the face of the SWBD. b. Each exterior section/compartment of each SWBD. c. Overall entire lineup of SWBD, i.e. a master nameplate. Master

nameplate shall include the tag of the SWBD as shown on the PLANS, at


minimum, in addition to manufacturer’s standard information for master nameplates.

2.03 CIRCUIT BREAKERS

A. Provide thermal magnetic molded case circuit breakers with the following minimum requirements: 1. U.L. listed minimum RMS symmetrical short circuit current rating equal to or

greater than that of the main bus. 2. Circuit breaker shall be three pole, 600 volt with a maximum continuous

current carrying capacity shown on the PLANS. 3. Breakers shall operate continuously when operating/running current is equal to

80% of the long time trip setting (or frame rating, as applicable) of the breakers.

4. Breakers shall have an overcenter, toggle handle-operated, trip free mechanism with quick make, quick break action independent of the speed of the toggle handle operation. The design shall provide common tripping of all poles. Breakers shall be suitable for reverse feeding.


6. Provide mechanical padlock attachment for each circuit breaker. 7. Furnish lugs for feeders where required to facilitate field wiring termination,

sizes shall be as required by the PLANS.

B. Additional requirements for Main/Tie circuit breakers only: 1. All Main and Tie circuit breakers shall be furnished with solid state type

electronic trip attachment. The attachment shall have the following minimum features: a. Alpha-numeric display b. Circuit breaker test receptacle c. Field adjustable settings:

1) Long time pickup 2) Long time delay 3) Short time pickup 4) Short time delay 5) Instantaneous pickup 6) Ground fault pickup 7) Ground fault delay

C. Additional requirements for branch/feeder circuit breakers only: 1. All branch circuiting circuit breakers shall be group mounted.

D. Provide where specifically shown on the PLANS: 1. Current limiting circuit breaker 2. Electronic trip attachment. Trip unit shall be solid state type with field

adjustable long time, short time, ground fault and pick up settings. 3. Auxiliary contacts rated for 120 volts A.C. Contacts shall satisfy the

requirements of the PLANS.


2.04 SURGE PROTECTION DEVICE

A. Provide Surge Protective Device (SPD) system were required by the PLANS. The SPD shall have the following characteristics: 1. SPD shall be tested with the ANSI/IEEE Category C high exposure waveform

of 10 kA for 8 x 20 microseconds, at minimum. 2. Integrated surge protective device recognized in accordance with UL 1449. 3. Minimum surge current withstand shall be 160 kA per phase (80 kA per mode) 4. Has a minimum pulse life of 5000 ANSI/IEEE Category C high transients

without failure or degradation of clamping voltage by more than 10 percent. 5. Provide with manufacturer’s standard line side disconnect. 6. Provide visual indication of SPD status. 7. Surge counter. 8. Provide dry contact failure status output contact. Contact shall be rated for

120 volts A.C. and shall satisfy the requirements of the PLANS. 9. 5 year warranty, at minimum.

2.05 CONTROL POWER TRANSFORMERS AND MISCELLANEOUS ACCESSORIES.

A. Provide control power transformer, fuses, power supplies, etc., and associated interconnect wiring as required to provide functional control power service to the circuit breaker trip circuitry for proper operation of circuitry, per manufacturer’s standard.

B. SWBD Space Heater control power transformer for the SWBD, where required by the PLANS, shall have the following characteristics: 1. Adequately sized to drive the entire space heater circuitry of the SWBD and

the associated close-coupled MCC. Refer to the requirements specified in Section 16120 “480 Volt Motor Control Centers”, paragraph 2.08 D.

2. 120 volt AC grounded secondary 3. Connect as shown on the PLANS. 4. The space heater of each vertical section of the SWBD and associated close-

coupled MCC shall be individually protected with a fuse mounted in the control power transformer compartment.

5. The space heater circuitry shall be thermostatically controlled by centrally located thermostat(s). Provide the quantity of thermostats necessary to serve the load of the space heater circuitry.

C. Patch Panel: Where patch panel shown on the PLANS, furnish and install a dedicated patch panel for termination of the Ethernet data highway (serial communication) cabling for each Power Metering Unit (PMU) and Protective Relay. Patch panels shall be two-port, surface mounted, fully enclosed type, Category 6A, with RJ-45 connectors, as manufactured by “Panduit”, Model Mini-Com #CBXJ2IW-A, with “Mini-Com TX6A” UTP Coupler Module Model CJK6X88TGBU and blank cover plates, or approved equal. Ethernet patch cords shall be furnished and installed between the patch panel and the respective protective relay/power monitoring unit per the requirements of Section 17600 “Distributed Control System”.

D. Provide key interlocks where required by the PLANS.

E. Lightning and Surge Arresters:


1. Provide station class (type), 3-phase, rated 600 volts lightning arresters where shown on the PLANS. Lightning arresters shall be U.L. listed and certified, valve type, and shall be designed and manufactured in accordance with the latest revision of ANSI/IEEE C62.11.

2. Provide 3-phase surge capacitors where shown on the PLANS. Surge capacitors shall be U.L. listed and certified, and non-PCB type.

2.06 INSTRUMENT TRANSFORMERS

A. General: 1. All instrument transformers specified shall be installed and connected at the

factory.

B. Instrument current transformers (C.T.’s): 1. Provide current transformers where required by the PLANS. Connect as

shown on the PLANS. 2. Current transformers shall be the window type and shall have an ANSI 60 Hz

Metering Accuracy Class of 0.3 measured at burden of B0.1, at minimum. 3. Install a shorting terminal block for each current transformer (C.T.). Prewire all

terminals of each C.T. to its respective shorting terminal block. Shorting terminal blocks shall be as manufactured by “G.E.”, or approved equal.

C. Instrument Potential Transformers (P.T.’s): 1. Provide potential transformers where required by the PLANS. Connect as

shown on the PLANS. 2. Potential transformers shall have the following characteristics:

a. Primary voltage: 480 volts AC b. Secondary voltage: 120 volts AC c. Accuracy rating: 0.6 Y at burden of 1.2X d. Thermal Burden: 150 VA at 30 degrees C ambient e. Frequency: 60 Hz

3. Install with primary and secondary disconnect devices, grounding device, and accessories in conformance with IEEE and NEMA standards.

4. Provide current limiting type primary fuses.

2.07 METERING AND POWER MONITORING UNIT "PMU" FOR SWITCHBOARD

A. Where required by the PLANS, furnish and install a Power Metering Unit (PMU). The PMUs shall be as manufactured by General Electric - MULTILIN Model EPM 9450 (Transducer Module) complete with three line LED combination display and keypad Model PL900040N, Ethernet port and all required interconnect cabling, and harsh environment UL 746C recognized conformal coating on all printed circuit assemblies as also shown on the PLANS No Equal. Units shall be connected as shown on the PLANS.

2.08 METAL ENCLOSED OVERHEAD BUS DUCT

A. Furnish and install metal enclosed bus duct were required by the PLANS. The overhead bus duct shall have the following characteristics: 1. All buses shall be tin plated copper. 2. All buses shall be insulated with manufacturer’s standard insulation.


3. Buses shall be fully rated and the rating shall be based on 55 degrees C maximum temperature rise in a 40 degree C ambient. The bus continuous current rating shall be the same as the SWBD main bus, as also shown on the PLANS.

4. The minimum RMS symmetrical short circuit current rating of the buses shall be as indicated on the one-line diagram drawings.

5. Dedicated continuous ground bus shall be furnished for the entire length of the bus duct. The ground bus shall be rated for 50 percent of the main power (phase) bus rating, at minimum.

6. The bus duct shall have the “sandwich” type configuration with no air gap between bus bars.

B. Bus duct enclosure shall have the following characteristics: 1. Totally enclosed, non-ventilated, suitable for indoor use. 2. Fabricated from aluminum or steel per manufacturer’s standard. 3. Finish shall be primed and painted using the manufacturer’s standard finishing

process. Finish shall be applied at the manufacturing plant. Color shall be manufacturer’s standard.

C. Provide with all necessary joints, fittings, covers, adapters, hardware, etc., as required for a complete and functional bus duct installation. This shall include, but not be limited to: 1. Elbows, flanges, TEE fittings, 2. Flexible connectors, 3. All necessary covers for openings, 4. Thermal expansion fitting when bus duct crosses a building expansion joint.

Refer to the PLANS for locations of building expansion joints.

PART 3 EXECUTION



B. The Owner may elect to witness the factory tests as outlined above. The manufacturer shall provide at least three (3) week notice prior to the date the tests are to be performed.

3.02 FIELD INSTALLATION

A. Install per manufacturer’s instructions and recommendations. Install all required safety labels.

B. Perform manufacturer’s field services as previously specified.


C. Coordinate sizing of the wireway/plenum/pullbox enclosures with the SWBD manufacturer.


A. The following minimum test and checks shall be made before energizing the SWBDs and associated bus duct system. These tests shall be performed by a Factory Trained Field Technician (non sales type): 1. Thoroughly inspect the SWBD and bus duct system. 2. Test for proper phasing of power connections. Additionally, check phasing

across the SWBDs and connecting overhead bus duct/tie feeders (as applicable) using phasing sticks.

3. Set, adjust, and test all protective relays based on the results of the coordination study, refer to sub-section 1.08, this Section of the Specifications.

4. Megger terminals and buses for grounds, test per manufacturer’s recommendations.

5. Verify ratios of all CT’s, and proper operation of all metering. 6. Verify SWBD enclosure space heater circuits are operational. 7. Test key interlock system for proper functionality. 8. Check tightness of accessible bolted bus joints using calibrated torque wrench

per manufacturer's recommended torque values.

B. Submit documentation of all tests outlined above.

C. Submit manufacturer’s certification report per sub-section 1.12, this Section of the Specifications.

3.04 EQUIPMENT PROTECTION AND RESTORATION

A. Clean and vacuum clean all interior of the equipment.


C. Remove all current transformer shunts after completing secondary circuit.

D. Energize the space heaters within the SWBD and energize during storage and installation for humidity control.

3.05 TRAINING

A. Provide training sessions for owner’s representatives for One (1) FULL normal workday at the job-site location and/or at a location determined by the OWNER. If training is conducted in less than the time required by these specifications, the remaining time shall be utilized at the discretion of the OWNER.

B. The training session shall be conducted by the SWBD manufacturer’s non-sales-type technical representative, who performed the field installation and start-up/setting/adjustment services.


installed within the SWBDs.


2. Factory contact persons phone numbers, persons names, ordering procedures and procedures to follow to obtain meaningful results from the factory.

D. Training session may be concurrent with the training session for the 480 Volt Motor Control Centers specified in Section 16120 “480 Volt Motor Control Centers”, Subsection 3.05.


A. No separate measurement or payment for work performed under this section. Include cost of same in Contract price bid for work of which this is a component part.

END OF SECTION


SECTION 16150

RACEWAYS, FITTINGS AND SUPPORTS

PART 1 GENERAL

1.01 SUMMARY

A. This section specifies raceways, fittings, and supports for all cables, conductors and electrical equipment. The Contractor shall furnish and install complete raceway systems in accordance with the following specifications and as also shown on the PLANS.

B. Refer to the conduit/wire schedule shown on the PLANS for a listing of proposed raceways and other requirements. The conduit/wire schedule shown on the PLANS is not inclusive of all equipment required by this Contract. Refer to Part 2 of this section for additional requirements.



B. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors. Suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work.


1.03 REFERENCES

A. The publications listed below form a part of this specification to the extent referenced. The Publications are references in the text by designation only.

B. This section contains references to codes and standards. They are a part of this section as specified. In case of conflict between the requirements of this section and the listed standards, the requirements of this section shall prevail. All raceways, fitting and supports are to be U.L. listed and certified and shall conform to ANSI and NEMA standards.

1.04 SUBMITTALS

A. The Contractor shall submit manufacturer's catalog data for all material provided under this section and in accordance with the requirements of Section 01330 and 01730 of the Specifications. The Contractor shall submit certified notification from the Manufacturer that the rigid aluminum conduit system and all related materials, as described within this specification, is 99.0 percent copper-free. 1. Submit certifications of training associated with proper installation the PVC

coated rigid galvanized conduit and Fiberglass conduit.


2. Material Safety Data sheets for all sealants, solvents, etc.

PART 2 PRODUCT

2.01 EXPOSED CONDUIT SYSTEM INDOOR, AND EXPOSED OUTDOOR ABOVE GROUND LEVEL

A. General: All components shall be 99.0 percent copper free rigid aluminum.

B. Rigid Metal Conduit System 1. Conduit run above ground shall be rigid aluminum in all areas unless

specifically specified otherwise hereinafter in subsection 3.02, this Section of the Specifications.

2. Rigid Aluminum Conduit shall meet the following requirements a. U.L. listed b. Comply with ANSI C80.5 and U.L.6.

3. Bending Requirements: Furnish factory bends. 90-degree bends of conduit sizes equal to or greater than 4-inches in diameter shall have a minimum bending radius of 48-inches unless otherwise noted on the PLANS. 90-degree factory bends of conduit sizes less than 4-inches in diameter, shall be per manufacturers standard unless otherwise noted on the PLANS.

4. Minimum conduit size for all work shall be 3/4 inches. 5. Manufacturer: VAW of America Inc., or approved equal.

C. Conduit Hubs: 1. Provide grounding type with integral threaded insulated throat, and with

solderless grounding lugs, complete with rubber gasket. 2. Manufacturer: by “Myers”, or approved equal.

D. Grounding Bushings: 1. Provide with integral threaded insulated throat, and with solderless grounding

lugs 2. Manufacturer: “O.Z. Gedney” type ABLG with specified options, or approved

equal.

E. Conduit Bodies 1. Conduit body covers shall be of the bolt-on type and shall have Type 316-

Stainless Steel screws/hardware. 2. Manufacturer: “Crouse-Hinds” Form-7, or approved equal..

F. Conduit Unions: Threaded, as manufactured by “Crouse-Hinds” type UNF or UNY, or approved equal

G. Conduit Reducers: 1. Threaded. 2. Shall be used for final conduit system connection to equipment where shown

on the PLANS 3. Manufacturer: “Crouse-Hinds” type RE and type REA, or approved equal.


H. Cord and Cable Fittings: 1. Provide threaded gland nut, straight threaded body, and also a neoprene

sealing cable bushing. 2. Furnished with a Type 316 Stainless Steel wire mesh grip 3. Shall be used only where specifically shown on the PLANS. 4. Manufacturer: “Crouse-Hinds” type CGB, complete with all specified

accessories, or approved equal.

I. Expansion Fittings: 1. Furnished with oversized sleeve and insulated bushing 2. Furnished with tinned copper braided bonding jumper 3. Manufacturer: O.Z./Gedney Type EXPB-A, or approved equal

J. Sealing Fittings: 1. Furnish with drain 2. Manufacturer: Crouse Hinds, Type EYD, or approved equal 3. Exception: Sealing hubs shall be accepted for use where sealing fittings are

required on vertical conduits that enter the bottom of pad mounted equipment (e.g. switchboards, MCCs, instrumentation and control cabinets, etc.). a. Manufacturer: Crouse Hinds, Type ES, or approved equal

4. Sealing Compound: a. Where conduit seals are installed in compliance with NEC Class-I and

Class-II requirements, the sealing compound shall be as manufactured by “Crouse-Hinds” type Chico-AP, or approved equal.

b. Where conduit seals are not required for NEC Class-I and Class-II installations but are shown to be installed on the PLANS to block the migration of corrosive gases into the conduit system and conduit bodies, the conduit seals Sealing Compound shall be Scotchcast Reenterable Electrical Insulating Resin 2123 as manufactured by “3M”, or approved equal.

c. Coordinate application with the Owner. d. For vertical seals use mineral wool packing material to form a dam in the

annular space around the conductors and hold the sealing compound in place while it cures. Packing material shall be as manufactured by “Crouse-Hinds” type Chico-X, or approved equal.

K. Miscellaneous Requirements: 1. Conduit nipples shall have two independent sets of threads.

2.02 UNDERGROUND CONDUIT IN DUCT BANK SYSTEM

A. General: 1. Type: All components shall be non-metallic, except where noted herein and

specifically shown otherwise on the PLANS. Refer to the PLANS. 2. Bending Requirements: Furnish factory bends. 90-degree factory bends of

conduit sizes equal to or greater than 4-inches in diameter shall have a minimum bending radius of 48-inches. Also, all 90-degree, 45-degree, and 30-degree conduit bends shall be factory made bends.

3. Minimum conduit size for all work shall be 1 inch.


B. Rigid Nonmetallic Conduit System 1. All components shall be schedule 40 PVC, heavy wall, U.L. rated, No. 651,

conforming to NEMA standard TC-2-75 and listed in conformity with Article 352 of the latest edition of the National Electrical Code (NEC).

2. Solvent weld: Shall be a type approved by the conduit manufacturer. 3. Manufacturer: Conduit shall be as manufactured by “Carlon”, or approved

equal.

C. PVC Coated Rigid Galvanized Steel Conduit System 1. Material: Steel per UL 6 and ANSI C80.1, hot-dipped galvanized inside and

out after the threads are cut. 2. Exterior Coatings:

a. After galvanizing, the conduit/fittings shall be uniformly and consistently coated with a gray PVC coating of minimal 40 mil thickness. Exception: The threads shall be coated with urethane in lieu of PVC.

b. The PVC coating adhesion performance shall be ETL verified to the Intertek ETL SEMKO, High Temperature H2O PVC Coating Adhesion, Test Procedure for 200 hours.

3. Interior Coating: a. After galvanizing, the interior of conduit and fittings shall be uniformly and

consistently coated with a urethane coating of nominal 2 mil thickness. 4. Accessories: Threads shall be furnished with plastic thread protector caps. 5. Manufacturer: Robroy Industries, Perma-Cote, Plasti-Bond REDH2OT, or

approved equal.

D. Reinforced Thermosetting Resin Conduit (RTRC) Conduit System 1. General:

a. May be used only where specifically permitted by subsection 3.02.C.8, this Section of the Specifications.

b. Shall comply with NEC Article 355. 2. Material:

a. Fiberglass, Reinforced Thermosetting Resin Conduit. Resin system shall be epoxy based, with no fillers, using an anhydride curing agent. The fiberglass shall consist of continuous E-glass Grade “A” roving. Conduit shall be low-halogen per UL 2515.

b. Manufactured using the single circuit filament winding process. Oven cured. Nominal winding angle of 54.75 degrees.

c. Carbon black shall be used as ultra violet inhibitor. d. Internal walls shall be smooth with all fibers embedded in epoxy.

3. Certifications: NEMA TC14, UL 2420 and 2515. 4. Suitable for installation exposed outdoors and encased in concrete 5. Fittings:

a. The following fittings shall be provided. Example part numbers shown hereinafter apply to the raceway system manufacturer specified hereinafter. All part numbers required for this project are not shown. Contractor to coordinate necessary part numbers with the manufacturer for a complete installation.

b. 90 degree bends with factory installed 2 deep socket PVC coupling and 1 fiberglass coupling bonded to elbow: 1) For conduit sized 1” – 1 ½”, provide type IPS. Example part number

for 1”: 10C-XW-90-2DF


2) For conduit sized 2” – 6”, use type ID. Example part number for 2”: 20D-XW-90-2DF

c. Sleeve couplings: 1) For conduit sized 1” – 1 ½”, use type IPS. Example part number for

1”: 10C-XW-42 2) For conduit sized 2” – 6”, use type ID. Example part number for 2”:

20D-XW-42 d. Female Terminal Adapters:

1) For conduit sized 1” – 1 ½”, use type IPS. Example part number for 1”: 10C-XW-32

2) For conduit sized 2” – 6”, use type ID. Example part number for 2”: 20D-XW-32

e. Straight Socket Conduit: 1) For conduit sized 1” – 1 ½”, use type IPS. Example part number for

1”: 10C-XW-10S 2) For conduit sized 2” – 6”, use type ID. Example part number for 2”:

20D-XW-20-S 6. Mix Epoxy Adhesive:

a. For ambient temperatures 40 - 70 degree F, provide type CM-2040-SFG b. For ambient temperatures 70 degree F and above, provide type CM-2070-

SFG. 7. Mix Epoxy Adhesive Mixing Tip and Gun:

a. Mixing Tip: CM-MT b. Mixing Gun: CM-AG

8. Accessories: Provide with adhesive couplings, spigots, adapters, and other adhesive fittings as required to connect to the other specified raceways as shown on the PLANS.

9. Manufacturer: Champion Fiberglass “Haz Duct XW”, no equal.

2.03 LIQUID TIGHT FLEXIBLE CONDUIT

A. Sizes: - Greater than or equal to ¾ inch and smaller than or equal to 2 inch Flexible Conduit: 1. Conduit Type: Non-metallic type liquid tight conduit, formed from PVC plastic 2. Conduit Installation Temperature Range: –20 degrees Celsius to + 60

degrees Celsius (suitable for use outdoors and indoors) 3. Conduit Manufacturer: ELECTRI-FLEX series NM type B-PVC, or approved

equal. 4. Fittings Type: Non-metallic PVC fittings 5. Fittings Manufacturer: CARFLEX, or approved equal.

B. Sizes:- Greater than 2 inch Flexible Conduit: 1. Conduit Type: PVC-COATED metallic liquid tight conduit, formed from PVC

plastic 2. Conduit Temperature Range: –20 degrees Celsius to + 60 degrees Celsius

(suitable for use outdoors and indoors) 3. Conduit Manufacturer: SEALTITE, or approved equal. 4. Fittings Type: 99.0 percent Copper-Free-Aluminum 5. Fittings Manufacturer: Appleton, Crouse-Hinds, or approved equal.


C. Minimum liquid-tight flexible conduit size for all work shall be ¾-inch unless specifically noted otherwise on the PLANS. Exception: ½” non-metallic conduit may be used for the final conduit connection to device with ½” threaded opening with prior Owner approval.

2.04 MISCELLANEOUS

A. Polyurethane foam duct sealant: FST-250 and FST-MINI Duct Sealant as manufactured by “Polywater”, or approved equal

B. Pipe Tape: 20 mil, 3M company No.51, or approved equal

C. Conduit Sleeves 1. Conduit sleeves shall be schedule 80 PVC, heavy wall, U.L. rated, No. 651,

conforming to NEMA standard TC-2-75 and listed in conformity with Article 352 of the National Electrical Code (NEC).

D. Conduit Hole Seals 1. Hole seals shall be stainless steel, U.L. listed as NEMA 4X oil-tight, complete

with oil-resistant gasketing, backplate, stud and wing nut. Hole seals shall be manufactured by Hoffman, Rittal, Cooper B-Line, or approved equal.

2.05 ELECTRICAL EQUIPMENT AND RACEWAY SYSTEM SUPPORT CHANNELS

A. General requirements for all support channels: 1. Channels located in all areas:

a. Type: Type 316-Stainless Steel b. Manufacturer: “Unistrut Corporation” series P-1000ST and P-1001ST, or

approved equal.

B. All fastening hardware, fittings, supports, post bases, conduit clamps, beam clamps channel nuts, threaded rod, framing system, etc. shall be as follows: 1. Items located in all areas:

a. Type 316 stainless steel 2. Manufacturer: “Unistrut Corporation”, or approved equal. 3. Additionally, the following designations correspond to the following “Unistrut

Corporation” series numbers as used in the details shown on the PLANS: a. Items located in all areas:

1) Beam clamps: “Unistrut Corporation” series P-2785ST and P-2786ST, or approved equal.

2) Swivel fittings: “Unistrut Corporation” series M-2137ST, or approved equal.

3) Post bases: “Unistrut Corporation” series P-2072AST and series P-2073AST, or approved equal.

4) Hanger clevis fittings: “Unistrut Corporation” series P-2682ST, or approved equal.

C. Expansion anchors shall be installed per the manufacturer’s recommendations and shall be as follows: 1. Anchors located in all areas:

a. Type 316-Stainless Steel. Anchors shall also be per Section 05051 “Anchorages”.


2. Also refer to the PLANS.

2.06 MANHOLES AND HANDHOLES

A. Refer to the PLANS and Specifications for manhole requirements.

B. Furnish and install handholes as shown on the PLANS and as specified herein.

C. Provide all cable pulling eyes, cable support system components and accessories indicated on the PLANS and as otherwise required. Arrange support systems so that each cable can be securely anchored.

2.07 CABLE SUPPORT SYSTEM IN UNDERGROUND ELECTRICAL MANHOLES AND HANDHOLES

A. General Requirements for support channels: 1. Type: Type 316-Stainless Steel 2. Manufacturer: “Unistrut Corporation” series P-1000ST and P-1001ST, or

approved equal.

B. All fastening hardware, fittings, supports, post bases, conduit clamps, beam clamps channel nuts, threaded rod, framing system, etc. shall be fabricated with Type 316 stainless steel, as manufactured by “Unistrut Corporation”, or approved equal. Additionally, the following designations correspond to the following “Unistrut Corporation” series numbers as used in the details shown on the PLANS: 1. Porcelain Clamps and Saddles-“Unistrut Corporation P1787A through P1795B

Porcelain Cable Clamps”, for both Electric and Communications and Instrumentation and Control.

2. Surface Mounted Vertical Channels (Columns)-“Unistrut P-1000ST Type 316 stainless steel channels and accompanying Unistrut post bases”.

3. Surface Mounted Horizontal Channels (side mounted channels)-“Unistrut P-1001ST Type 316 stainless steel channels and accompanying Unistrut post bases as well as wall mounted vertical channels”.

4. Brackets-“Unistrut” P-2515 ST of 15 inch length for Electric, and P-2542 ST of 15 inch length for Telephone and Communications. All parts given shall be Type 316 stainless steel.

5. Beam Clamps – “Unistrut” P-2785 ST”. All parts given shall be Type 316 stainless steel.

PART 3 EXECUTION

3.01 GENERAL

A. Install electrical equipment and conduit raceway system in accordance with the recommendations of the manufacturer, the requirements of the latest edition of the National Electrical Code, and the PLANS. All cables/wiring shall be installed in a raceway system.

B. Contractor shall be trained and certified by the PVC coated rigid galvanized steel conduit manufacturer in the proper installation of the PVC coated rigid galvanized conduit.


C. Contractor shall be trained and certified by the Fiberglass conduit manufacturer in the proper installation of the Fiberglass conduit.

3.02 CONDUIT SYSTEM

A. General: 1. Run conduits continuous from outlet to outlet, from outlets to cabinets, pull or

junction boxes, etc. 2. Install all conduits as a complete system before wiring is pulled in. Conduits

shall be reamed, thoroughly cleaned of debris, and swabbed immediately before wire is pulled.

3. Furnish and install expansion fitting for each conduit across structural expansion joints. Coordinate locations of expansion joints with the PLANS. Additionally, furnish and install additional appropriate fittings such as conduit unions, adapters, etc. as required for a complete installation.

4. Conduit shall contain no more than the equivalent of three (3) 90-degree bends between outlets or pull points.

5. Maintain a minimum 6-inch clearance between conduit and piping and a minimum 12-inch clearance between conduit and heat sources.

6. Protect all coated conduit from accidental coating damage during storage and installation. Repair all damaged conduits in accordance with manufacturer’s recommendations at no additional cost to the OWNER.

7. Furnish and install temporary conduit closures during construction activities to prevent foreign matter from entering raceways.

8. Furnish and install conduit measuring tape in each empty spare conduit as manufactured by Ideal Industries Incorporated or approved equal.

B. Exposed Conduit System Indoor, and Exposed Outdoor Above Ground Level: 1. Rigid conduit joints shall be cut square, threaded, reamed smooth and drawn

up tight. Make field bends or offsets with an approved bender or hickey or hub type conduit fittings.

2. Run conduit parallel or at right angles to building lines and such to avoid moisture traps.

3. Arrange conduits to maintain headroom and present a neat appearance. 4. Support conduit using support channels as shown on the PLANS and as

specified herein. 5. Coat all conduit threads with Penetrox or Noalox prior to assembly. 6. Secure conduit runs firmly to specified support channels by conduit straps or

by hangers, as required, and as shown on the PLANS.

C. Underground Conduit in Duct Bank System 1. Install all underground conduit in concrete encased and steel reinforced duct

banks. 2. Concrete shall be Class ‘A’ per Section 403S “Concrete for Structures”. A red

admixture shall be added to the concrete a rate of 12 pounds per cubic yard of concrete and per the requirements of Section 403S. Red admixture shall meet the requirements of ASTM C-979-82. Red admixture shall be as manufactured by ChemSystems, Inc. series HBS #120 Conduit Red, or approved equal. Also, refer to conduit/duct bank reinforcement and concrete encasement details shown on the PLANS.


3. Reinforcing Steel shall be per Section 406S “Reinforcing Steel” unless noted otherwise on the PLANS. Also, refer to conduit/duct bank reinforcement and concrete encasement details shown on the PLANS.

4. Install detectable underground warning tapes at 12-inches below finished grade along the entire length of each duct bank. Each tape shall be a minimum of 6-inches wide, 4 mil thick, laminated, and contain a aluminum foil core backing. The tape shall be detectable using a non-ferrous locator. The tape color shall be red and shall be labeled with the words “CAUTION BURIED ELECTRIC LINE BELOW” in black lettering. For duct banks less than 24-inches wide, install one length of tape aligned along the centerline of the duct bank. For duct banks 24-inches wide and larger, install two lengths of tape, with each length aligned with each edge of the duct bank along the width of the duct bank. Warning tape is not required along the length of the specific portion of a duct bank that is installed underneath a building concrete floor slab.

5. Provide a minimum of 3-inches separation between conduits installed in concrete construction except at panelboards, pull or junction boxes and/or other locations where the conduits are grouped. Furnish and install plastic spacers as shown on the PLANS.

6. Underground system conduits shall be installed with a minimum depth below finished grade of 24” to top of concrete envelope of duct bank and shall slope 3-inches per 100 feet from high points toward pull boxes and handholes/manholes, at minimum. Increase the minimum duct bank depths below finished grade as shown on the PLANS. Additionally, underground duct bank system shall be routed per the PLANS and coordinated with the depths of Civil/Structural foundations, beams, etc. No conduit shall be routed through grade beam slab of a building floor slab.

7. All underground conduit joints shall be watertight in accordance with the manufacturer’s recommendations.

8. Transition from underground (underground work in duct bank) to above ground conduit as shown on the PLANS.

9. Where a duct bank penetrates a concrete structure, dowel between the duct bank and the structure at the point of penetration and tie the steel reinforcing rebar system of the underground duct bank system to the concrete structure and steel reinforcing rebar system of the concrete structure. Refer to the Civil/Structural Specifications and PLANS for additional requirements.

10. Where PVC coated rigid galvanized steel conduit is shown on the PLANS, Contractor may employ RTRC conduit in lieu of the PVC coated rigid galvanized steel conduit.

11. Where factory bends/elbows (11-1/4°, 22-1/2°, 30°, 45°, and 90°), as specified in Part 2.2 A 2 of this Specification, are not manufactured and field bends become necessary, field bends may be performed using a heat box type electric PVC conduit heater. The use of open flame to heat the PVC conduit is NOT permitted. Utilize a PVC conduit plug set to plug the ends of the conduit throughout the heating process and trap the air inside the conduit to help keep the PVC conduit from collapsing while forming the bend.


D. Conduit Penetrations: 1. Install sleeves for conduit penetrations of walls and floors unless shown

otherwise on the PLANS. Install sleeves during erection of concrete and masonry walls. Exception: Sleeves are not required for conduits stub-ups through floor slab from underground duct bank.

2. Where aluminum conduit penetrates a wall/floor-slab and/or walls/floors of dissimilar material (other than Stainless Steel) or is in contact with dissimilar material, wrap the aluminum conduit with Pipe Tape using a 50 percent overlap throughout the entire distance/length of the penetration and an additional 6-inches of distance beyond either side of the penetration/contacted region.

3. Install pitch pans on conduits which penetrate through roofs. 4. Also refer to the conduit penetration details shown on the PLANS.

E. Miscellaneous: 1. Seal empty spare conduits (at above ground stub-ups) with threaded insert

plug sized to the trade size of the conduits. a. Threaded insert plug shall have a square head and shall be constructed

from copper-free Aluminum material. b. Threaded insert plug shall be Type CUPX by Hubbell-Killark, Type PLG

by Crouse-Hinds, or approved equal. 2. Seal and pack/fill ends of each conduit with polyurethane foam duct sealant. 3. In all sealing fittings, utilize sealing compound to seal around and between

each conductor and associated sealing fitting body.

F. Requirements for cables inside of Manholes, Handholes, etc.: 1. Arrange cables so that there is a minimum of crossing. Provide slack in each

cable. 2. Secure cables in handholes/manholes on support channel system as specified

herein and as shown on the PLANS.

G. Connections to Equipment: 1. Liquid tight flexible conduit shall be used for connections to motors, field

instruments, etc., and any equipment subject to vibration, and where shown on the PLANS. Length of conduit shall not exceed 36-inches, unless specifically noted otherwise on the PLANS or approved by the Owner.

3.03 INSTALLATION OF SUPPORT CHANNELS

A. Utilize support channels and mounting hardware as previously specified to install raceways, and any other surface mounted electrical, instrumentation and control equipment. Refer to details shown on the PLANS. Use 316 stainless steel split ring lock washers with mounting hardware when installing support channels.

3.04 HOUSEKEEPING CONCRETE PAD FOR EQUIPMENT

A. Provide housekeeping concrete pad for all outdoor equipment whether it is free-standing or surface mounted. All housekeeping pad edges shall be chamfered. Outdoor electrical equipment pads shall be as detailed on the PLANS.

B. Provide housekeeping concrete pad for indoor all free-standing equipment. Indoor electrical equipment pads shall be as detailed on the PLANS.



A. No separate measurement or payment for work performed under this section. Include cost of same in Contract price bid for work of which this is a component part.

END OF SECTION


SECTION 16200

WIRING (600 VOLTS AND BELOW)

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install the field wiring as specified herein and as shown on the PLANS.

B. Furnish and install all wiring required to make the electrical system completely and satisfactorily operable. Comply with the National Electrical Code and all applicable federal, state, and local codes, regulations and ordinances.

C. The requirements of this section also applies in whole to the installation of the fiber-optic cables and Ethernet copper cables. Fiber optic cables are specified in Section 17600 “Distributed Control System” of the Specifications.




C. The PLANS designate the type, number, and size of field wiring.


1.03 SUBMITTALS

A. Submit shop drawings in accordance with Section 01330 of the Contract Specifications.

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Contract Specifications. O&M Manuals shall include copies of the approved shop drawings, factory and on-site/field test data.

PART 2 PRODUCTS

2.01 GENERAL REQUIREMENTS

A. All wire and cable on this project shall be new, unused, in good condition and shall be delivered in standard coils, packages or reels. Submit wire samples when requested by the OWNER. Final acceptance of wire shall be made by the OWNER or its representative.


2.02 SINGLE CONDUCTOR - GENERAL ELECTRICAL POWER SYSTEM AND AUXILIARY ELECTRICAL SYSTEM WIRING

A. All wire shall be 98% conductivity copper, stranded, single conductor Type XHHW-2. This wire shall have moisture resistant insulation and clean stripping characteristics. Wire shall be marked at minimum distance of every ten feet (10') with the size, type and voltage of the wires as well as the manufacturer's name and measurement markers. All neutral and ground wires shall be insulated and identified and marked.

B. The pigmentation of the wire insulation shall insulation shall conform to the color table listed below: Phase 277/480 Volts 120/208 Volts AC 24 Volts DC

A Brown Red -----------

B Yellow Black -----------

C Purple Blue -----------

Neutral Gray White -----------

Ground Green Green Green

Motor Space Heater (H) ----------- Black -----------

DC (+) ----------- ----------- Blue

DC (-) ----------- ----------- Brown

C. Any interlock wiring installed in one device with power from another device shall be properly marked.

D. The minimum wire size shall be No.10 for all wiring unless shown otherwise on the PLANS.

E. Departures from the sizes shown shall be made only in those cases in which the National Electric Code requires the use of larger conductors.

F. General Electrical Power System and Auxiliary Electrical System Wiring shall be as manufactured by General Cable Company, The Okonite Company, or approved equal.

2.03 SIGNAL AND COMMUNICATION WIRING

A. 4-20 Milliamp Signal Wiring and RS-485 Communication Wiring: 1. Number of Pairs: One 2. Wire Size: #16 AWG 3. Type of Conductors: Stranded copper conductors, twisted 4. Individual Conductor Insulation: PVC 5. Individual Conductor Insulation Color: Positive (+) is Black, Negative (-) is

White. 6. Drain Wire: Tinned copper 7. Overall Shield: Aluminum-mylar shield. 8. Overall Jacket: PVC


9. Overall Jacket Color: Black. 10. Manufacturer: Samuel Moore and Company, Dekoron Division, Cat. No. 1852

or approved equal.

B. Multi-Conductor RTD Temperature Signal Wiring: 1. Number of Triads: One 2. Wire Size: #16 AWG 3. Type of Conductors: Stranded copper conductors, twisted 4. Individual Conductor Insulation: PVC 5. Individual Conductor Insulation Color: Positive (+) is Black, Negative (-) is

White, Sense (S) is Red. 6. Drain Wire: Tinned copper 7. Overall Shield: Aluminum-mylar shield. 8. Overall Jacket: PVC 9. Overall Jacket Color: Black. 10. Manufacturer: Samuel Moore and Company, Dekoron Division, Cat. No. 1862

or approved equal.

C. Ethernet Data Communication Wiring: 1. Number of Pairs: Four 2. Wire Size: #23 AWG 3. Type of Conductors: solid copper conductors, twisted 4. Individual Conductor Insulation: 300 volt polyolefin 5. Individual Conductor Insulation Color: White/Blue Stripe, Blue, White/Orange

Stripe, Orange, White/Green Stripe, Green, White/Brown Stripe, Brown 6. Drain Wire: No. 24 AWG Tinned copper 7. Overall Shield: Aluminum-mylar shield. 8. Overall Jacket: PVC, include ripcord 9. Overall Jacket Color: Blue. 10. Maximum Attenuation at 100 MHz: 18.9 dB per 100 meters of cable length 11. Maximum Attenuation at 250 MHz: 31.2 dB per 100 meters of cable length 12. Manufacturer: Belden, Catalog No. 7851A, or approved equal. . 13. Agency Compliance: ANSI/TIA/EIA-568 B.2-1 Category 6

D. Fiber Optic Cable: 1. Refer to Section 17600 Distributed Control System.

2.04 SINGLE CONDUCTOR CONTROL WIRING

A. Single conductor control wiring shall be 98% conductivity copper, stranded, single conductor Type XHHW-2. This wire shall have moisture resistant insulation and clean stripping characteristics. Wire shall be marked at minimum distance of every ten feet (10') with the size, type and voltage of the wires as well as the manufacturer's name and measurement markers.

B. Conductors shall have a minimum size of #14 AWG, unless shown otherwise on the PLANS. The color of the wire shall be RED.

C. Single Conductor Control Wiring shall be as manufactured by General Cable Company, The Okonite Company, or approved equal.


2.05 MULTI-CONDUCTOR CONTROL WIRING

A. General: Multi-Conductor control system cables shall be shielded and shall be rated 600 volts. Cables shall be suitable and rated for installation for AC or DC service in wet or dry locations at conductor temperatures of 90 degrees C. Cable shall be suitable and rated for installation in conduit system, cable tray system, and directly buried in the ground/earth where electrostatic shielding is required.

B. Features: As minimum, the Multi-Conductor shielded control cables shall have the following features: 1. Passes the IEEE 383 and IEEE 1202 flame tests as well as ICEA T-29-520

(210,000 BTU/hour) flame test 2. Conductors: Each individual conductor in each multi-conductor cable shall be

copper per ASTM B-3. Each conductor shall have the following additional features: a. Stranding: Class B stranding per ASTM B-8 b. Insulation: Meet or exceed the requirements of ICEA S-73-532 c. Conductor Identification: Color coded using base colors and tracers

according to the following:

Conductor Size

Number of Conductors in a cable

Conductor Insulation Thickness

Cable Maximum

Overall Diameter

Color Code

Cond. No.

Base Color

Tracer

1 Black ---- 2 White ---- 3 Red ----

#12 Seven 30 0.74 4 Green ---- AWG (7) mils inches 5 Orange ----

6 Blue ---- 7 White Black 1 Black ---- 2 White ---- 3 Red ---- 4 Green ---- 5 Orange ----

#12 Twelve 30 0.96 6 Blue ---- AWG (12) mils inches 7 White Black

8 Red Black 9 Green Black 10 Orange Black 11 Blue Black 12 Black White 1 Black ---- 2 White ---- 3 Red ---- 4 Green ---- 5 Orange ---- 6 Blue ---- 7 White Black 8 Red Black 9 Green Black


Conductor Size

Number of Conductors in a cable

Conductor Insulation Thickness

Cable Maximum

Overall Diameter

Color Code

Cond. No.

Base Color

Tracer

#12 Nineteen 30 1.09 10 Orange Black AWG (19) mils inches 11 Blue Black

12 Black White 13 Red White 14 Green White 15 Blue White 16 Black Red 17 White Red

18 Orange Red 19 Blue Red

3. Size of each conductor and quantity of conductors: There shall be three (3) kinds of multi-conductor control cables: Seven (7) conductor (#12 AWG) cables, Twelve (12) conductor (#12 AWG) cables, and Nineteen (19) conductor (#12 AWG) cables. Sizes and Quantities shall be as shown on the Conduit/Wire Schedule shown on the Drawings.

4. Overall Cable Shield: 100 percent shield consisting of 5-mil corrugated copper tape, longitudinally applied.

5. Overall outer jacket: Each multi-conductor cable shall be covered with overall black thermoset chlorinated polyethylene flame retardant outer jacket. Minimum jacket thickness is 60 mils.

6. Number of conductors in a cable: Number of conductors shall be as shown on the Conduit/Wire Schedule shown on the Drawings.

7. Manufacturer: Okonite FMR-LCS-Okolon TS-CPE, or approved equal.

2.06 CONTROL CABINET/PANEL WIRING

A. Refer to Section 17200 Instrumentation and Control Cabinets and Associated Equipment

2.07 WIRE TAGGING

A. Wire Tags: 1. Rating: Flame-Retardant, 2. Style: Heavy-Duty Industrial Grade 3. Type: Heat Shrinkable type. 4. Character Height: 1/8 inch. 5. Maximum Length: 2 inches. 6. Text Type: Typed with indelible marking process. Handwritten shall not be

accepted. 7. Color: White.

a. Exception: Use Yellow for instrumentation/control circuits as described in Section 17200.

8. Manufacturer: “Raychem type Heavy-Duty Industrial Grade ShrinkMark Heat-Shrinkable Marking Sleeves”, or approved equal. Utilize "Raychem" Portable-Marking-System” complete with wire tag cartridges, or approved equal.


2.08 MISCELLANEOUS

A. Wire Pulling Lubricant: Ideal ClearGlide, or approved equal

B. Vertical cable supports (in conduit): O.Z. Gedney Type “S”, or approved equal.

C. Weatherproof Twist-on Wire Connectors: 1. 600V rated 2. Zinc plated steel spring insert with a thermoplastic polyester insulating housing 3. Pre-filled (factory-filled) with 100% Silicone-Based Sealant for maximum

protection against Moisture and Corrosion. 4. Manufacturer: IDEAL Model 61, 62, or 63 WeatherProof Wire-Nut Wire

Connectors, or approved equal.

D. Multi-Cable Connector Blocks: 1. Use only for power wiring termination for motors rated 600V and below 2. 600V rated 3. Insulated with UV rated chemical resistant plastisol compound that will not

support combustion 4. Suitable for use with fine stranded extra-flexible wiring 5. Suitable for use with aluminum and copper conductors 6. U. L. 486A Listed 7. Pre-filled with an oxide inhibitor. 8. Manufacturer: “Polaris Connectors” Series Polaris Grey, or approved equal.

E. Waterproof Streetlight Splice Kits 1. Ratings:

a. Voltage: 600 volts b. Usage: Capable of being submerged under water continuously

2. Construction: a. Connector Body:

1) Multiple port set screw terminal bus. 2) Dual rated for use with copper and/or aluminum conductors

b. Insulation: Thermoplastic rubber insulated 3. Manufacturer: “Ideal Industries, Inc.” Buchanan Streetlight Kits, or approved

equal by RAYCHEM.

F. Pin Terminal Adapters: 1. Dual rated for aluminum and copper conductors 2. Compression type barrel with solid pin and manufactured using all-aluminum

construction 3. Barrel shall be pre-filled at the factory with oxide inhibitor 4. Supplied with insulating cover 5. Manufacturer: Type AYP/AYPO by Burndy, Type ACM/ACO by Ilsco, or

approved equal.

G. Corrosion Resistant and Moisture Repelling Electrical Coating/Spray: 1. Color: Clear. Coordinate spray color with the Owner. Furnish and install the

color requested by the Owner at No Additional Cost to the Owner. 2. Type: Corrosion resistant and moisture repellant fast drying spray coating

sealant


3. Manufacturer: “3M” 1601 Clear-Color Fast Drying Sealer and Insulator, or approved equal.

H. Arc and fireproofing Tape: 1. Capable of withstanding temperatures to 23,000 deg. F (13,000 deg. K) for 70-

cycles. 2. Not less than 0.76mm thick 3. Capable of cover 100% elongation. 4. Non-corrosive to metallic cable sheaths and compatible with synthetic cable

jackets. 5. Self-extinguishing and shall not support combustion. 6. The tape shall not deteriorate when subjected to water, salt water, gases and

sewage. 7. Manufacturer: “3M” Scotch 77, or approved equal.

PART 3 EXECUTION

3.01 INSTALLATION

A. Before wire is pulled into any conduit, thoroughly swab the conduit to remove all foreign material and to permit the wire to be pulled into a clean, dry conduit. Use wire pulling lubricant in pulling any wire. Pull all conductors into their respective conduits by hand except where written permission of the OWNER is secured to the contrary.

B. Furnish and install the previously specified vertical cable supports in conduit were required by the NEC.

C. No wire splices shall be accepted except as permitted below: 1. SPLICING OF 208/120 VOLT LIGHTING AND RECEPTACLE CIRCUITING

INDOORS AND OUTDOORS ABOVE GRADE: a. General: Perform all splicing in splice/junction boxes dedicated for this

purpose. b. For splices where wiring is:

1) #10 AWG and smaller: Use Weatherproof Twist-on Wire Connectors as Specified in 2.07.C, this Section of the Specifications.

2) Larger than #10 AWG: Use the Multi-Cable Connector Blocks as Specified in 2.07.D, this Section of the Specifications.

2. SPLICING OF 208/120 VOLT LIGHTING AND RECEPTACLE CIRCUITING INSIDE OF THE UNDERGROUND JUNCTION BOXES/UNDERGROUND HANDHOLES (POINTS OF SPLICE BELOW FINISHED GRADE): a. General: Perform all splicing in underground junction boxes/underground

handholes dedicated for this purpose. b. Utilize Waterproof Streetlight Splice Kits.

D. For wiring termination to motors rated 600 volt and below, use the Multi-Cable Connector Blocks as Specified in 2.07.D, this Section of the Specifications.

E. For wiring terminations where the conductor size exceeds the rated wire capacity of mechanical connectors or circuit breakers, use the Pin Terminal Adapters as Specified in 2.07.E, this Section of the Specifications.


F. All wiring connections must be insulated with 600 volt insulation system

G. Tagging: 1. Tag all power, Instrumentation and Controls, Fiber Optic Cables, and all other

types of auxiliary electrical wiring and cables at both ends with the specified heat shrinkable tags and heat shrink tags.

2. Tag per Subsection 3.03 of this Section of the Specifications and per the OWNER’s cable and wire tagging standards.

3. Tag each wire in a Multi-Conductor cable in addition to the overall cable itself. 4. Group wiring routed in pullboxes that are routed in common conduits and tag

each wiring group inside each pullbox with nameplates as follows: a. Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose


b. Color: White-Black-White. c. Lettering: 1/4 inch height, minimum, engraved through the face layer to

the melamine middle layer. d. Accessories: Provide holes for mechanical fastening.

5. Secure each phenolic tag (where required) with a minimum of two nylon cable ties, one at each end of the tag.

H. Ground shielded instrument cables at one point only, i.e.; at the final destination in the associated instrument and control cabinets.

I. Terminate stranded wiring by use of lugs, clamps or pressure type terminals.

J. After all wiring connections have been made, the Contractor shall apply the Corrosion Resistant and Moisture Repelling Electrical Coating/Spray to all wiring connections. Coordinate application with the Owner prior to application, the Owner has the discretion to limit application. For bidding purposes, the minimum extent of spray application is further clarified as follows: 1. Spray shall be applied for all terminations of the following types of connections

at a minimum: a. termination points, terminals, terminal blocks, ground bar, neutral bar/bus, b. lugs of circuit breakers, buses, doors, etc. c. exposed/stripped ends of each conductor, etc. d. bolt-on connections, split-bolt connections, ring lugs, etc. e. compression connectors, connector blocks, etc. f. all other connection types not listed above

2. Spray shall be applied for all terminations at the following types of equipment at a minimum: a. Local and main control panels, field instruments, junction boxes, field

control stations, control relays, signal isolators, selector switches, pushbuttons, etc.,

b. Panelboards, transformers, switchboards, motor control centers, variable frequency drives, motor starters, contactors, disconnect switches, enclosed circuit breakers, light switches, light fixtures, etc.

c. Motor termination enclosures, valve actuators, cathodic protection system, package control panels of process equipment, etc.


d. Security system devices, cameras, roadway gate operators, etc. e. Convenience receptacles, SCADA receptacles, etc. f. All other types of equipment not listed above.

3.02 TESTS

A. Perform all tests as outlined in Section 16800 and all other tests which are necessary to determine that the electrical wiring system is in satisfactory operating condition. Wiring shall be tested end-to-end after it is pulled in the conduit system.

3.03 WIRE TAGGING METHODOLOGY

A. Single Conductor Wire Tagging Scheme: 1. All single conductor control and power wiring shall be tagged utilizing the

source and destination method. In general, as minimum each tag shall be comprised of various fields which are: a. Device Identifiers, b. Terminal Numbers and, c. Equipment Identification name

2. The following is the format that shall be used for each control power single conductor wire tag: XXXX - XX (XXXX-

XXXX-XXXX

/ XXXX - XX)

Device Identifier

Terminal Number

Equipment Identification

Name

Device Identifier

Terminal Number

a. The tag information to the left refers to the point of termination. Tag information in parenthesis refers to the point of origination. Note: For wiring within the boundaries of a piece of equipment, The Equipment identification name shall not be required, only the Device Identifier and the Terminal Number from the point of origination. Examples to this exception would be, wiring from one terminal strip to another within the same control panel, etc.

3. The following provides a brief description to each of the fields required within a single wire tag:

FIELD DESCRIPTION

Device Identifier: A four (4) alphanumeric character field that shall uniquely identify a device within a piece of equipment. Examples are: TB1, for Terminal Block Number 1, and CR02 for Control Relay #02, etc.

Terminal Number: A two (2) alphanumeric character field that shall identify which specific point on the Device the wire must be terminated to. Refer to manufacturer’s labeling or record drawings for Device Terminal Numbers.

Equipment A twelve (12) alphanumeric character field that shall be the same as the physical Equipment Identification


FIELD DESCRIPTION

Identification Name: Nameplate attached to the equipment.

B. Single Conductor Wire Tagging Scheme in a Multiconductor Cable: 1. All single conductor control and instrument wiring (in Multiconductor

Instrument or Control Cables) shall be tagged utilizing the source and destination method. In general, each tag shall be comprised of various fields which are 1) Device Identifiers, 2) Terminal Numbers, and 3) Equipment Identification Name, as minimum.

2. The following is the format that shall be used for each single conductor wire tag in a multiconductor cable (Instrumentation or Control wiring Cables):

XXXX - XX (XXXX / XX)

Device Identifier

Terminal Number

Cable ID Conductor Number

a. The tag information to the left refers to the point of termination. Tag information in parenthesis refers to the point of origination.

3. The following provides a brief description to each of the fields required within a single tag (in a Multiconductor Cable):

FIELD DESCRIPTION

Device Identifier: A four (4) alphanumeric character field that shall uniquely identify a device within a piece of equipment. Examples are: TB1, for Terminal Block Number 1, and CR02 for Control Relay #02, etc.

Terminal Number: A two (2) alphanumeric character field that shall identify which specific point on the Device the wire must be terminated to. Refer to manufacturer’s labeling or record drawings for Device Terminal Numbers.

Cable Identification (Cable ID):

A five (5) alphanumeric character field that shall

uniquely identify a cable within the facility. The

first character shall identify the cable type as

follows:

C - for Control Cables

I - for Instrumentation Cables

P - for Power Cables

The remaining four (4) alphanumeric characters shall make-up a unique number for a given cable type within the facility.


C. Overall Cable Tag of a Multiconductor Cable: 1. In addition to tagging each single conductor in a multiconductor cable (as

described in 3.03 B, above), the overall jacket of each multiconductor cable shall also be tagged to uniquely identify each cable within the facility. In general, each cable tag shall be comprised of various fields which are 1) Cable Identification (Cable ID), and 2) Equipment Identification Name, as minimum.

2. The following is the format that shall be used for overall cable tag of each multiconductor cable:

XXXX (XXXX-XXXX-XXXX / XXXX-XXXX-XXXX)

Cable ID Source Equipment Identification Name.

Destination Equipment Identification Name

a. The tag information to the left refers to the actual cable Identification (name). Tag information in parenthesis refers to the Identification Name of the Equipment at point of origination (source), followed by the Identification Name of the Equipment at the point of termination (Destination Point).

3. The following provides a brief description to each of the fields required within a cable tag:

FIELD DESCRIPTION

- Cable Identification (Cable ID):

A five (5) alphanumeric character field that shall uniquely identify a cable within the facility. The first character shall identify the cable type as follows:

C - for Control Cables

I - for Instrumentation Cables

P - for Power Cables

The remaining four (4) alphanumeric characters shall make-up a unique number for a given cable type within the facility.

- Source Equipment Identification Name:

A twelve (12) alphanumeric character field that shall be the same as the physical Equipment Identification Nameplate attached to the source (origination) equipment.

- Destination Equipment Identification Name:

A twelve (12) alphanumeric character field that shall be the same as the physical Equipment Identification Nameplate attached to the destination equipment (equipment at point of termination).

4. All cable tags (except in Manholes, handholes, above ground cable closets, and in cable tray system), shall be of 3-ply engraved plastic (phenolic) with background color, letter sizes, etc. as follows:


Cable Type Tag Color Color of Lettering Letter Height

600 volt Power Cable Orange White 3/16” (min.)

600 volt Control Cable Orange White 3/16” (min.)

Instrumentation Cable Black White 3/16” (min.)



END OF SECTION


SECTION 16250

BOXES AND CABINETS

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install all cabinets, junction boxes, pull boxes and outlet boxes as shown on the PLANS, required by the Specifications or N.E.C., or as otherwise necessary for a satisfactory operating system.





1.03 SUBMITTALS

A. Submit shop drawings in accordance with the Section 01330 of the Specifications.

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Specifications. O&M Manuals shall include copies of the approved shop drawings, factory and on-site/field test data.

PART 2 PRODUCTS

2.01 JUNCTION AND PULL BOXES

A. Lighting and power, signal, telephone, voice communication, instrumentation and controls, and any other junction and pull boxes hereinafter specified or shown on the PLANS shall be as provided as follows: 1. Outdoor boxes shall be NEMA-4X Type 316-Stainless Steel Boxes. Boxes

shall be equipped with hinged doors complete with 1/4 (quarter) turn door latches.

2. Indoor boxes in non-environmentally controlled rooms shall be as follows: a. All areas:

1) Smaller than or equal to 12” wide x 12” high: 99.0% copper-free rigid Aluminum NEMA-4X corrosion resistant and water tight boxes.

2) Larger than 12” side x 12” high: NEMA-4X Type 316-stainless steel Boxes.


b. Boxes shall be equipped with hinged doors complete with 1/4 (quarter) turn door latches.

3. Indoor boxes in environmentally controlled rooms shall be as follows: a. NEMA 12 with ANSI No. 61 Gray finish b. Boxes shall be equipped with hinged doors complete with 1/4 (quarter)

turn door latches.

B. Boxes or cabinets shall be not less than 6-inches deep and their minimum size determined by the requirements of, and in compliance with the National Electrical Code (NEC).

C. Each type of box and cabinet on the project shall be manufactured by a single manufacturer.

D. Manufacturer: 1. Hoffman Concept Series, Rittal, Millbank, or approved equal.

2.02 DEVICE BOXES FOR CONVENIENCE/SPECIAL PURPOSE RECEPTACLES AND LIGHT SWITCHES

A. Boxes for convenience/special-purpose receptacles shall be as specified in Section 16300 “Wiring Devices”.

B. Boxes for Light Switches shall be as specified in Section 16300 “Wiring Devices”.

2.03 OUTLET BOXES

A. Outlet boxes for pendant mounted light fixtures shall be as specified in Section 16300 “Wiring Devices”.

2.04 NAMEPLATES

A. General: 1. Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose

paper base engraving stock per ASTM D-709, Type I. Nameplates shall be ASTM Grade ES-1, ES-2, or ES-3 as applicable for the face and lettering colors specified hereinafter. Flexible or acrylic tags will be not be accepted

2. Color: White-Black-White 3. Lettering: 1/4 inch height, minimum, engraved through the face layer to the

melamine middle layer 4. Accessories: Provide holes for mechanical fastening. Provide adhesive

backplane where required in Part 3, Execution.


PART 3 EXECUTION

3.01 APPLICATION

A. General: 1. Pullboxes shall be used only to reduce the number of bends for conduit,

supports, taps, troughs and similar applications. No splicing shall be performed in pullboxes.

2. Junction boxes shall only be used where shown on the PLANS. Any other use of junction boxes other than for receptacle and lighting circuit wiring, is not permitted.

3.02 INSTALLATION

A. Set box square and true with building surfaces. Secure boxes firmly to support channels. Coordinate final location of boxes with other trades to avoid any conflicts.

B. Utilize specified support channels, then secure/mount boxes and cabinets to the support channels. All mounting hardware shall be Type 316-stainless steel. Equipment support channels shall be per the requirements of Section 16150 “Raceways, Fittings, and Supports”. Additionally, refer to details shown on the PLANS. Use 316 stainless steel split ring lock washers with mounting hardware when installing support channels.

C. Tagging: 1. Tag each box with the name as it appears on the PLANS using the specified

namplates. Exception: Use nameplates specified in Section 16300 “Wiring Devices” for manual motor starters located in environmentally controlled rooms, for light switches, and for receptacles.

2. Attach identification nameplates with two stainless steel screws.

D. Seal/Plug all unused conduit openings in boxes and cabinets with conduit hole seal per the requirements of Section 16150 “Raceways, Fittings, and Supports”.

E. Furnish and install labels as required by the NEC.



END OF SECTION


SECTION 16300

WIRING DEVICES

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install all necessary wiring devices at the locations indicated on the PLANS and as specified herein.





1.03 SUBMITTALS

A. Submit shop drawings in accordance with Section 01330 of the Contract Specifications. Include manufacturer’s catalog data/notification certifying Aluminum Device Boxes, as specified hereinafter, to be 99.0% copper-free.


PART 2 PRODUCTS

2.01 LIGHT SWITCHES

A. Light switches installed INDOORS in environmentally and climate controlled electrical rooms, control rooms and offices shall be provided complete with light switch, box and coverplate with the following features. 1. Light switch:

a. Specification grade, 20 amp, 120/277 volts b. Provide the number of poles as required by the PLANS. c. Provide maintained action type operation, unless momentary action is

specifically required by the PLANS. d. Ivory color switch handle operator. e. Manufacturer: Pass and Seymour No. PS20AC, or approved equal.

2. Box: Provide as hereinafter specified. 3. Coverplate: Provide as hereinafter specified.


B. Light switches installed OUTDOORS or INDOORS in process/mechanical areas that are not environmentally and climate controlled shall be provided complete with light switch, box and coverplate with the following features: 1. Light switch:

a. General use snap switch rated 20 amp, 120/277 volts b. Factory-Sealed-Switches where each switch is enclosed in a unique

sealing well with double flanges that mate with the light switch cover and box assembly.

c. Raintight, corrosion resistant, and rated for use in wet locations and in Class-I Division-2 hazardous areas (as classified by NEC).

d. Manufacturer: Crouse-Hinds EDS Series, Killark, or approved equal. 2. Box: Provide as hereinafter specified. 3. Coverplate: Provide as hereinafter specified.

2.02 120 VOLTS AC, COVENIENCE RECEPTACLES

A. 120 Volts AC convenience receptacles installed INDOORS in environmentally and climate controlled electrical rooms, control rooms and offices shall be provided complete with receptacle, box and coverplate with the following features: 1. Receptacle

a. Specification grade b. Duplex, 3-wire, polarized grounding type, rated 20 amp, 125 volt, 60 Hertz c. Ivory color d. Manufacturer: Hubbell No. HBL5362I, Bryant, Pass and Seymour, or

approved equal. 2. Ground Fault Interrupter Receptacle:

a. Provide where G.F.I receptacles are indicated on the PLANS b. Specification grade, weather-resistant type, c. Duplex, 3-wire, polarized grounding type, rated 20 amp, 125 volt, 60

Hertz. d. Red indicator light e. Test and Reset pushbutton f. Ivory color. g. Manufacturer: Pass & Seymour Cat. No. 2095TRWR, or approved equal.


B. 120 Volts AC convenience receptacles installed OUTDOORS or INDOORS in process/mechanical areas that are not environmentally and climate controlled shall be provided complete with receptacle, box and coverplate with the following features: 1. Receptacle

a. Specification grade, factory-sealed, pin and sleeve receptacles. b. 2-wires, 3-poles, dead-front, twist-lock, rated 20 amperes, 120 volts. c. Type 12 nylon (KRYDON) water proof and corrosion resistant enclosure,

rated for use in wet locations and in Class-I Division-2 hazardous areas (as classified by NEC).

d. Brass receptacle blades/contacts e. 316 Stainless Steel hardware f. Mechanically interlocked plug and receptacle where plug cannot be

engaged or disengaged under load.


g. Internal switch that shall activate only after the Plug is inserted into the receptacle and twisted. Switch shall be horsepower and AIC-rated.

h. Receptacle furnished complete with manufacturers matching device box (back-box). Device box shall be waterproof and corrosion resistant KRYDON enclosure and NEMA-4X rated as well as suitable for use in Class-I Division-2 hazardous areas (as classified by NEC). Device box shall be furnished with minimum hub sizes and quantity of hubs as required to comply with the circuiting and conduit/wire size requirements shown on the PLANS).

i. The receptacle shall be furnished with fully gasketed watertight, dustight, and corrosion resistant TWIST-ON cover.

j. The receptacle, plug and device box assembly shall be bare the following CERTIFICATIONS: 1) Class-I, Division 2, Groups A, B, C & D product, 2) U.L. 3) P66 and NEMA-4X, and C.E.

k. Manufacturer: Crouse-Hinds Series IEC-309 Hazardous Area Receptacles/Plugs and Interlocks, Factory-Sealed, TYPE GHG Pin and Sleeve receptacles complete with device boxes and specified accessories.

2. Furnish and install a total count of Three (3) Sets of completely assembled matching CORD and PLUG assembly for the 120 volt AC 20 ampere rated Receptacles. Each set of the CORD and PLUG assemblies shall be furnished complete with matching and pre-made cord and plug assembly. The cord and plug assembly (of each set) shall consist of matching Male plug, and 120 volt rated 20-ampere, 3-conductor extra-flexible 25-feet long power cord (each conductor shall be 100%-conductive-soft-copper conductors with 41-strands). Each conductor in the 3-conductor power cable shall be #12AWG rated for 20 amperes continuous current draw at 120 volts AC. The 3-conductor cable shall be Type SO-CORD. The total length of each 3-conductor power cord shall be 25-feet. One end of each of the flexible power cord assemblies shall be terminated to the matching Male plug of the associated Pin and Sleeve receptacle, the plug shall be 120 volts rated 20-ampere, 2-wires, 3-poles, watertight and corrosion resistant and rated for use in wet locations and in Class-I Division-2 hazardous areas (as classified by NEC), as manufactured by Crouse-Hinds Series IEC-309 Hazardous Area Plugs and Interlocks TYPE GHG Pin and Sleeve Twist-On plug. The other end of each conductor in the 3-conductor cord (of each of the flexible power cord assemblies) shall be terminated to 120 volts AC, rated 20-ampere, NEMA 5-20 Female cord receptacle with tin-plated-copper spade-connectors.

C. 120 Volts AC convenience receptacles installed OUTDOORS AND DEDICATED FOR INFLUENT COMPOSITE SAMPLER POWER shall be provided complete with receptacle, box and coverplate with the following features: 1. Receptacle

a. Specification grade b. Simplex, 3-wire, polarized grounding type, rated 20 amp, 125 volt, 60

Hertz c. Ivory color d. Manufacturer: Hubbell No. HBL5361I, Bryant, Pass and Seymour, or

approved equal.



2.03 DEVICE ENCLOSURES

A. General: Furnish and install the type of device enclosure complete with coverplate and necessary adapters as specified herein, fully coordinated with the operating environment and mounting configuration.

B. Sand Cast Aluminum, 99.0% copper-free, one piece construction, suitable for surface mounting

C. Single and Multi-Gang Weatherproof Outlet boxes, as required.

D. 3/4-inch threaded hubs, minimum box depth shall be 2-5/8”. Use 2-3/4” depth when “gang” arrangements of outlets are used.

E. Manufacturer: Crouse-Hinds Series FS or FD, Appleton, or approved equal. 1. Exception:

a. For light switches installed OUTDOORS or INDOORS in process/mechanical areas that are not environmentally and climate controlled manufacturer shall be Crouse-Hinds type EDSM and EDSC double-gang (as minimum) and multigang device boxes (Feed-through or dead-end configuration, as required), or approved equal by Appleton, Killark, or approved equal.

F. Coverplate: 1. For light switches installed INDOORS in environmentally and climate

controlled electrical rooms, control rooms and offices: a. 304 brushed stainless steel b. Manufacturer: Hubbell, Killark, or approved equal.

2. For light switches installed OUTDOORS or INDOORS in process/mechanical areas that are not environmentally and climate controlled: a. Sand Cast Aluminum, 99.0% copper-free, gasketed coverplate b. Front external operating handle (for snap switches) for on-off operation. c. Equipped with hole for lock d. Manufacturer: Crouse-Hinds series EDS or approved equal.

3. For receptacles installed INDOORS in environmentally and climate controlled electrical rooms, control rooms and offices: a. Die Cast Aluminum 99.0% copper-free, complete with rubber gasket b. Manufacturer: Crouse-Hinds WLRS (single cover), WLRD (duplex cover)

and WLGF-FS (GFCI duplex cover), or approved equal. 4. For receptacles installed OUTDOORS or INDOORS in process/mechanical

areas that are not environmentally and climate controlled: a. As specified above in Subsection 2.02 B.

5. For receptacles installed OUTDOORS AND DEDICATED FOR INFLUENT COMPOSITE SAMPLER POWER: a. Weather proof while-in-use type b. 99.0% copper-free die cast aluminum with silver powder-coated finish. c. NEMA-3R rating. d. Manufacturer: Thomas & Betts Red Dot® Catalog No. CKMUV or by Pass

& Seymour Catalog No. WIUCAST1, or approved equal.


2.04 DUPLEX SCADA RECEPTACLES

A. General: Shall be provided complete with receptacle, box, and coverplate with the following features: 1. Faceplates shall be available with multiple module spaces for both vertical and

horizontal applications. Each faceplate shall accept individual modules for both copper and fiber optic applications. Faceplates shall be flush mounted with a clean look and be available with labels. Faceplate color shall be white. For each faceplate, furnish and install a minimum of four (4) MINI-COM TX6A 10GIG UTP Jack Modules as manufactured by Panduit. Data outlet faceplate shall be manufactured by Panduit with Four Module Space, model CFPL4 with white color. Furnish and install data label with plastic cover as manufactured by Panduit. Provide label and clear plastic cover as manufactured by Panduit for all mini com modules. Label each non-blank mini com device data outlet on each face plate with indelible, permanent printing system with black color imprinted ¼” high capital lettering attached to faceplate and covered by plastic clear cover, as manufactured by Panduit. Submit proposed data labeling for review and approval by OWNER and ENGINEER prior to commencing data labeling. Clearly distinguish SCADA data outlets from other data outlets using color coded mini com data outlet color and faceplate icon color. Coordinate with OWNER for color preference of the data outlets and icons.

B. Box: Provide as hereinafter specified. Exception: The coverplate required by subsection 2.03, this Section of the Specifications, is not required for these receptacles.

2.05 OUTLET BOXES FOR PENDANT MOUNTED LIGHT FIXTURES

A. General: Furnish and install the type of outlet box complete with coverplate and necessary adapters as specified herein, fully coordinated with the operating environment and mounting configuration.

B. Sand Cast Aluminum, 99.0% copper-free, one piece construction, with mounting tabs/lugs, suitable for surface mounting

C. Suitable to support pendant mounted fixtures weighing up to 125 pounds.

D. Four threaded holes for cover attachment at minimum

E. 3/4-inch threaded hubs, minimum box depth shall be 3-1/8”.

F. Manufacturer: Crouse-Hinds Series GRFX, Appleton, or approved equal.

G. Swivel Coverplate: Ball type, 11 degree swing, Cast Aluminum 99.0% copper-free, complete with rubber gasket, as manufactured by Crouse-Hinds Series ARB662, or approved equal.

2.06 MISCELLANEOUS

A. All mounting hardware shall be Type 316-stainless steel.


PART 3 EXECUTION

3.01 INSTALLATION

A. Mounting: Device enclosures shall be surface mounted on conduit support channels per Section 16150 and as shown on the PLANS.

B. Mounting heights shall be as follows unless otherwise noted on the PLANS: 1. Light switches: 48 inches above finished floor to center of switch 2. Receptacles: 36 inches above finished floor to center of receptacle.

C. Tagging: 1. Tag all receptacles and switches 2. Tagging format: “ckt. PNLY-XX” where Y represents the panel number (i.e. for

“PNL-001”, Y is 1) and XX represents the circuit number. Add voltage if other than 120V.

3. Tag type: a. Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose


b. Color: White-Black-White. c. Lettering: Engraved through the face layer to the melamine middle layer. d. Accessories: adhesive backplane.

D. Provide 6-inches offset for receptacles or other wiring devices mounted on opposite sides of a wall.

E. Do not use switch boxes as junction boxes for switch and receptacle.

F. Set box square and true with building surfaces.

G. Maintain symmetry of all devices as closely as possible within the Architectural Section contained. For example, center a light fixture over a doorway, or a receptacle in a section of wall, if shown in that approximate position.

H. Verify location of receptacles and switches in finished rooms. In centering devices and locating device boxes, allow for overhead pipes, and mechanical equipment; etc., and correct any inaccuracy from failure to do so without extra expense to the OWNER.

I. Cap all outlet boxes not used under this Contract with blank outlet coverplates.

J. Seal/Plug all unused conduit openings in device/outlet boxes.




END OF SECTION


SECTION 16350

LIGHTING

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install lighting fixtures and outdoor lighting photocells as specified herein and as indicated on the PLANS. Lighting contactor panels are specified in Section 17200 of the Specifications, “Instrumentation and Control Cabinets and Associated Equipment”.

B. Refer to the lighting fixture schedule shown on the PLANS for a listing of proposed lighting fixtures and other requirements. The lighting fixture schedule shown on the PLANS is not inclusive of all equipment required by this Contract. Refer to Part 2 of this section for additional requirements.




C. The PLANS designate the number of lighting fixtures and other requirements for the proposed equipment specified under this Section.


1.03 SUBMITTALS

A. Submit shop drawings in accordance with Section 01330 of the Contract Specifications. Submit a lighting fixture brochure for each fixture indicating catalog number, pertinent physical characteristics, and complete photometric data.


1.04 SPARE PARTS

A. Provide quantities of spare parts as follows: 1. Spare LED lamp modules: Five percent spare LED lamp modules for each

fixture type specified, with minimum of 3 lamp modules of each type. 2. Spare LED Drivers: Five percent spare drivers for each fixture type specified,

with minimum of 6 drivers of each type.


3. Spare Ballasts: Five percent spare ballasts for each fixture type specified, with minimum of 6 drivers of each type.

4. Spare HID Lamps: 100 percent spare HID lamps for each lamp size and voltage specified

PART 2 PRODUCTS

2.01 GENERAL

A. General: 1. Furnish and install fixtures in accordance with the requirements of this

specification and the requirements of the PLANS. Fixtures shall bear the U.L. label and such labels shall apply to entire fixture as installed.

2. Deliver lamps to job site in original cartons. Lamps shall be as manufactured by General Electric, Sylvania, or approved equal.

2.02 LIGHT FIXTURES

A. General: Multiple types of light fixtures are required for this project and as described hereinafter. Refer to the PLANS for application of the specific light fixture types.

2.03 ACCESSORIES

A. Deliver all fixtures complete with suspension chains, accessories, canopies, hickeys, casings, sockets, holders, reflectors, ballast, diffusers, frames, recessing boxes, etc.

2.04 PROTECTION

A. Protect all fixtures, lenses and louvers from damage. Leave protective coverings on lenses and louvers until fixtures are installed. Replace all damaged lenses and louvers immediately prior to final inspection at no cost to the OWNER.

2.05 SUBSTITUTIONS

A. Comply with requirements of the Contract Specifications.

2.06 LIGHTING CONTACTOR PANEL

A. Lighting contactor panel(s) shall be furnished as specified in Section 17200 of the Specifications, “Instrumentation and Control Cabinets and Associated Equipment”.

PART 3 EXECUTION

3.01 INSTALLATION AND TESTING

A. Maintain perfect horizontal and vertical alignment of fixtures throughout.

B. Do not locate circuiting splices or taps within an arm, stem or chain.


C. Replace any damaged fixture or lens at no cost to the OWNER.

D. Support all pendant fixtures with swivel type hangers.

E. Install recessed luminaries to permit removal from below, to gain access to outlet or prewired fixture box.

F. Locate fixtures where shown on the PLANS and coordinate fixture location such to avoid interference with piping, fans, ducts, and other obstructions. Obtain approval of any location differing from the location shown on the PLANS.

G. Furnish and install outlet box as specified in Section 16300 “Wiring Devices” for photocell mounting. Orient and make wiring connections to photocell per photocell manufacturer’s recommendations.



END OF SECTION


SECTION 16450

600 VOLTS AND BELOW DRY TYPE TRANSFORMERS

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install dry type transformers as specified herein and as shown on the PLANS.




C. The PLANS designate the number, size and rating of transformers required.


1.03 - 1.05 (NOT USED)

1.06 SUBMITTALS

A. Submit shop drawings in accordance with Section 01330 of the Specifications. For each individual Transformer include: 1. Dimensioned/scaled plan view and elevation, 2. Ratings, product data sheets, including weight and nameplate data 3. Wiring connection diagram

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Specifications. O&M Manuals shall include copies of the approved shop drawings, factory and on-site/field test data.

1.07 (NOT USED)


A. Deliver, receive, unload and handle equipment by suitable methods. Inspect for damage before accepting shipment. Wrap in protective plastic wrapping and store in humidity controlled environment. Use heat lamps as necessary to prevent condensation.


1.09 - 1.10 (NOT USED)

1.11 ACCEPTABLE MANUFACTURER

A. General Use (Power & Lighting) Dry-Type Ventilated Isolation Transformers shall be Watchdog Premium Quality units manufactured by Sorgel (Square D) class 7430, or approved equal

B. General Use (Power & Lighting) Dry-Type Non-Ventilated Isolation Transformers in all areas shall be as manufactured by Square D class 7400, or approved equal.

C. Ultra-Isolator, Highly Shielded and Noise and Transient Voltage Suppressing Transformers IN ALL AREAS: shall be as manufactured by “Eaton” Power-Suppress T7 Series 30 Ultra-Isolation Transformers with “K” Factor 13 Rating (with electrostatic shielding) and all other specified accessories, or approved equal.

PART 2 PRODUCT

2.01 GENERAL AND BASIC REQUIREMENTS FOR ALL 600 VOLT AND BELOW DRY TYPE TRANSFORMERS

A. Type: 1. Manufacturer's premium quality dry type transformers. 2. Primary and secondary voltage ratings, and, KVA ratings to be as shown on

the PLANS. 3. All windings shall be copper. 4. Transformers shall be of ventilated type, with exception of transformers

located in the areas specified in Subsection 2.03, this section of the specifications.

B. Core and coils: 1. Continuous wound core impregnated with non-hygroscopic, thermosetting

varnish. 2. Core to be of high grade, non-aging silicon steel with high magnetic

permeability. 3. Core and coil bolted to base of enclosure but isolated from it by rubber

vibration absorbing mounts.

C. Additional Requirements: 1. Furnish with four (4) 2-1/2 percent full capacity primary taps, two (2) above

and two (2) below rated primary voltage. 2. Core is to be visibly grounded to enclosure by means of a flexible grounding

conductor sized per NEMA, IEEE and ANSI standards. 3. All transformers shall be U.L. listed and certified and carry the U.L. label. 4. Sound levels: Guaranteed not to exceed the following:

Transformer KVA Range Sound Level

15 to 50KVA 45dB

51 to 150KVA 50dB


Transformer KVA Range Sound Level

151 to 300KVA 55dB

2.02 GENERAL USE (POWER & LIGHTING) VENTILATED DRY TYPE ISOLATION TRANSFORMERS

A. General: 1. Furnish ventilated dry type isolation transformers inside the ELECTRICAL

BUILDING, where shown on the PLANS. 2. Transformers shall be suitable for indoor installation. Comply with all

requirements/specifications outlined in subsection 2.01, above (General and Basic Requirements for All 600 Volt and Below Dry Type Transformers).

3. Transformers shall meet NEMA TP-1 efficiency requirements.

B. Temperature Rise and Insulation System: 1. Temperature Rise: 80 degrees Celsius above a 40 degree Celsius. ambient 2. All insulating materials shall be in accordance with NEMA ST20 standards for

a 220 degree Celsius. U.L. component recognized insulation system.

C. Enclosure: Heavy gauge sheet steel with ventilation openings designed in accordance with U.L., NEMA and the N.E.C. Phosphatized, primed and finished with ANSI #61 gray baked enamel. Provide surface/wall mounting brackets where surface/wall mounting is shown on the PLANS.

2.03 GENERAL USE (POWER & LIGHTING) NON-VENTILATED DRY TYPE ISOLATION TRANSFORMERS

A. General: 1. Furnish non-ventilated dry type isolation transformers inside the BLOWER

BUILDING and inside the PUMP BUILDING, where shown on the PLANS. 2. Transformers shall be suitable for indoor installation. Comply with all

requirements/specifications outlined in subsection 2.01, above (General and Basic Requirements for All 600 Volt and Below Dry Type Transformers). Note: Requirements hereinafter specified take precedence over the requirements outlined in subsection 2.01 above.

B. Temperature Rise and Insulation System: 1. Transformer core and coils shall be totally encapsulated in epoxy resin. 2. Temperature Rise: 150 degrees Celsius above a 40 degree Celsius ambient. 3. All insulating materials shall be in accordance with NEMA ST20 standards for

a 220 degree Celsius. U.L. component recognized insulation system.

C. Enclosure: 1. Inside the BLOWER BUILDING, where shown on the PLANS:

a. Heavy gauge sheet steel, totally enclosed non-ventilated, designed in accordance with U.L., NEMA and the N.E.C. Phosphatized, primed and finished with ANSI #61 gray baked enamel.

2. Inside PUMP BUILDING, where shown on the PLANS: a. Type 316 Stainless Steel, totally enclosed non-ventilated, designed in

accordance with U.L., NEMA and the N.E.C.


3. Provide surface/wall mounting brackets where surface/wall mounting is shown on the PLANS.

2.04 CONTROL AND INSTRUMENT POWER ULTRA-ISOLATOR, HIGHLY SHIELDED AND NOISE SUPPRESSION TRANSFORMERS

A. General: 1. Transformers shall be of the dry type suitable for indoor installation. Comply

with all specifications requirements outlined in subsection 2.01, above (Basic and General Requirements for All Dry Type Transformers) in addition to the requirement specified in this subsection 2.03. Note: Requirements hereinafter specified take precedence over the requirements outlined in subsection 2.01 above

B. Ratings: 1. Input Voltage Range: Plus or minus 10 percent of nominal. 2. Isolation: All winding are to be electrically isolated from each other 3. Temperature Rise and Insulation System:

a. Temperature Rise: 115 degrees Celsius above a 40 degree Celsius. ambient.

b. All insulating materials shall be in accordance with NEMA ST20 standards for a 200 degree Celsius. U.L. component recognized insulation system.

4. Load Regulation: 3.5 percent or less from no load to full load at unity power factor.

5. Frequency Range: 57 Hz to 63 Hz. 6. Overload Capacity: 500 percent for one cycle with no adverse effects 7. Harmonic Distortion: 1 percent added to the output waveform, at maximum 8. Efficiency: 95 percent at all load levels, at minimum. 9. Maximum Audible Noise: Less than 50 dBA measured at a distance of 3-feet. 10. Common-Mode Noise Attenuation: 120 dB minimum 11. Shielding: 100 percent electrostatic shield wound between the primary and

secondary windings. Shield must be connected to a terminal inside the transformer enclosure.

12. “K” Factor Rating: 13, U. L. Listed.

C. Enclosure: Heavy gauge sheet steel with ventilation openings designed in accordance with U.L., NEMA and the N.E.C. Phosphatized, primed and finished with gray baked enamel.

2.05 NAMEPLATES




melamine middle layer. 4. Accessories: Provide holes for mechanical fastening.


PART 3 EXECUTION

3.01 INSTALLATION

A. Install at the locations shown on the PLANS in accordance with manufacturer’s recommendations and N.E.C. installation requirements.

B. Furnish and install equipment pads as shown on the PLANS for floor mounted transformers and surface/wall mounted brackets for surface/wall mounted transformers as required.

C. Install floor mounted transformers on 1” thick Korfund vibration isolating pads.

D. Make grounding connections as required by the N.E.C. and as shown on the PLANS.

E. Tagging: 1. Tag each transformer with the name as it appears on the PLANS using the

specified nameplates attached with stainless steel screws. Include the following additional information: a. name of the load served by the transformer, b. primary voltage rating, c. secondary voltage ratings, d. KVA rating, e. phase and wire, f. primary and secondary winding configuration, and g. transformer type.

3.02 TESTS AND INSPECTIONS

A. All test results (including factory test) shall be certified.



END OF SECTION


SECTION 16500

PANELBOARDS

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install panelboards and surge protective devices where indicated on the PLANS and as specified herein.



B. It is the CONTRACTOR’s responsibility for scheduling and coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work

C. The PLANS designate the type, size, ratings, and other requirements of the equipment specified in this Section.


1.03 - 1.05 (NOT USED)

1.06 SUBMITTALS

A. Submit Shop Drawings in accordance with Section 01330 of the Specifications. Include panelboard dimensions, ratings, branch circuit breaker schedules and main circuit breakers size. Submit protective device coordination curves and current limiting circuit breaker/fuse peak current let through curves, and transformer impedance, where applicable.

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Specifications. O&M Manuals shall include copies of the approved shop drawings, and on-site/field test data.


A. Panelboards to be U.L. labeled “U.L. 67”, “U.L 508” and meeting Fed. Spec. WP-115, Type 1, Class 1, latest revisions. Breakers to meet Fed. Spec. WC-375, latest revision.


1.08 DELIVERY, STORAGE, HANDLING, AND TOOLS

A. Deliver, receive, unload and handle equipment by suitable methods. Store in climate controlled (temperature and humidity, etc.) environment in original packaging, or, in protective plastic wrapping.

B. Provide breaker test set for Solid-State-Trip units for each type used.

1.09 ACCEPTABLE MANUFACTURERS

A. All Panelboards on the project shall be manufactured by a single Panelboard manufacturer.

B. 480 volts A.C., 3-phase, 3-wire Power Distribution Class Panelboards with main bus current rating of 300 ampere or greater, where indicated on the PLANS: 1. Square D Company Series I-LINE with specified accessories. Approved equal

Panelboards manufactured by Cutler-Hammer or Asea Brown Boveri are acceptable as equals.

2. These panelboards will be known as Type I panelboards hereinafter

C. 480 volts A.C., 3-phase, 3-wire Panelboards with main bus current rating lower than 300 ampere, where indicated on the PLANS: 1. Square D Company Series “NF” with specified accessories. Approved equal

Panelboards manufactured by Cutler-Hammer or Asea Brown Boveri are acceptable as equals.

2. These panelboards will be known as Type II panelboards hereinafter

D. 208/120 volts A.C., 3-phase, 4-wire Panelboards - Cutler-Hammer Corporation Type POW-R-Line 3a with specified accessories. Approved equal Panelboards manufactured by Square-D Company or Asea Brown Boveri are acceptable as equals.

E. 208/120 volts AC, 3-phase, 4-wire Distribution Class Panelboard with Integral Contactors (combination Contactor and distribution panelboard assembly) – Cutler-Hammer Corporation Type 4B with specified accessories. Approved equal Panelboards manufactured by Square-D Company or Asea Brown Boveri are acceptable as equals. Note: installation of ASCO-911 (or approved equal) Contactor inside combination distribution panelboard and contactor assembly will be acceptable.

1.10 SPECIAL MANUFACTURER’S SERVICES

A. Prepare an arc-flash study, harmonic study, and a coordination study, complete with short circuit calculations and coordination curves, etc. as required by and in compliance with Section 16140 of the Specifications, “Switchboards”, paragraph 1.08 “Special Manufacturer’s Services”.

B. Manufacturer's technical representative is to set, adjust and test all protective relays, etc. in the presence of a representative of the Owner. The settings will be based on coordination and short circuit studies performed per subsection 1.10 A., this Section of the Specifications. Provide the Owner with test report certified by the manufacturer. Include a record of all settings. Format and quantity of reports shall


be per the requirements of Section 01330 of the Specifications. The Manufacturer shall furnish the protective device of the appropriate characteristics that shall be the most suitable for the proper protection and coordination of the system at No Additional Cost to the Owner.

PART 2 PRODUCTS

2.01 GENERAL

A. Bussing Requirements 1. Main Bus

a. All buses shall be tin-plated copper, distributed phase sequence type, and shall extend the full length of the panelboard.

b. Refer to the PLANS for bus ratings. Ratings to be established by heat rise tests with maximum hot spot temperature on any connector or bus bar not to exceed 50 degrees Celsius rise above an ambient of 40 degrees Celsius.

c. Circuit numbering to be such that odd numbered circuits are on the left and even numbered on the right facing the front of the panel.

2. Ground Bus a. Each panelboard shall have a tin plated copper ground bus for connecting

equipment grounds. Ground bus shall not be connected to the neutral bus.

3. Isolated Ground Bus: a. In all 208/120 volts A.C., 3-phase, 4-wire Panelboards served from

shielded ultra-isolation transformers, furnish a second tin-plated isolated ground bar in addition to the equipment ground bar. The isolated ground bar shall be electrically isolated from the panelboard cabinet/enclosure by 600 volt isolators. Isolated ground bar shall have the same current rating as the phase-bussing (bus rating) of the panelboard.

B. Circuit Breakers 1. General:

a. Circuit breakers to be single pole, two pole or three pole as shown on the PLANS.

b. All breakers to be quick-make, quick-break thermal magnetic molded case bolt-on type, with inverse time thermal trip and instantaneous time magnetic trip. Multi-pole breakers to be common trip with a single trip handle. Provide overload tripping elements in each pole. A tripped condition to be indicated by the breaker assuming a neutral position between “ON” and “OFF”.

c. Circuit breakers to be equipped with individually insulated, braced and protected connectors. Affix large, permanent, individual circuit numbers to each breaker in a uniform position.

d. Circuit breakers for lighting circuit protection are not to be larger than 20 amperes.

e. Key interlocks shall be provided for circuit breakers where shown on the PLANS.

f. Padlock attachments shall be provided for circuit breakers where shown on the PLANS.


g. Provide lugs as required to facilitate the field wiring termination shown on the PLANS.

2. Circuit breaker interrupting ratings and type to be as follows: a. Main/Branch Circuit Breakers in Type I Panelboards, and Main Circuit

Breakers in Type II Panelboards and Lighting/Control Power Panelboards: 1) Minimum U.L listed Symmetrical Current Interrupting rating (A.I.C.

rating) at rated voltage shall be as shown and required by the PLANS.

2) Panelboards shall be provided with high interrupting capacity or current limiter type breakers where necessary to withstand the available short circuit or limit it to a value which the downstream breakers can withstand.

3) Provide current limiting circuit breakers where shown on the PLANS. 4) Provide electronic trip attachment were shown on the PLANS. Trip

unit shall be solid state type with field adjustable long time, short time, ground fault and pick up settings.

5) Provide as manufactured by Square D Company Type FC, or approved equal by Asea Brown Boveri, Cutler-Hammer Corporation.

b. Branch Circuit Breakers in Type II Panelboards: 1) Minimum U.L listed Symmetrical Current Interrupting (A.I.C rating) at

rated voltage shall be as shown and required by the PLANS for the panelboard main circuit breaker.

2) Provide as manufactured by Square D Company Type EDB, or approved equal by Asea Brown Boveri, Cutler-Hammer Corporation.

c. Branch Circuit Breakers in Lighting/Control Power Panelboards: 1) U.L listed Symmetrical Current Interrupting 10,000 A.I.C. symmetrical

at rated voltage. 2) Provide as manufactured by Square D Company Type QOB, or

approved equal by Asea Brown Boveri, Cutler-Hammer Corporation.

C. Miscellaneous Requirements 1. Integrated Equipment Rating: Each panelboard, as a complete unit, shall have

a rating equal to or greater than the integrated equipment rating shown on the PLANS.

2. Provide a minimum of 20 percent spares on all panelboards and/or as shown on panel schedules on the attached Appendix A.

2.02 COMBINATION CONTACTOR AND DISTRIBUTION PANEL

A. General: 1. Comply with the requirements of subsection 2.01, this Section of the

Specifications. Circuit breakers shall be furnished and installed per the requirements for Type I panelboards.

2. Panelboard shall have a contactor mounted integral to the panelboard.

B. Contactor Section of the Panelboard: 1. Voltage: 208/120 Volts A.C. 2. Current: 100 ampere at minimum, unless shown otherwise on the PLANS.

Regardless, rating shall not be less than the panelboard main bus.


3. Type: Totally enclosed, four pole, mechanically held, single throw normally open contacts. 100 percent rated for bulk load control of all types of ballast and tungsten lighting, motor loads, resistant loads, and transformer loads.

4. Integrated interrupting rating: 10,000 ampere at 208 Volts A.C., unless shown otherwise on the PLANS. Rating shall apply to the entire combination contactor/ panelboard assembly as a complete unit.

5. Controls: a. Coil Voltage: 120 Volts A.C. b. Auxiliary Contacts: Furnish and install contacts as required to meet the

requirements of the PLANS. Furnish and install one normally open (N.O.) and one normally closed (N.C.) contact over and above that required by the PLANS.

c. Furnish and install terminal blocks for connections to interlock field control wiring per manufacturer’s standard.

d. Furnish with heavy duty, NEMA Style, full size 30-millimeter selector switch with legend plate where selector switches are shown on the PLANS.

e. Refer to the PLANS for control wiring requirements.

2.03 CABINET

A. Adhere to the requirements of UL 50.

B. Panelboard assemblies installed indoors in ELECTRICAL ROOMS, CONTROL ROOMS and OFFICES that are environmentally and climate controlled: 1. Enclosure: NEMA-12, gasketed. 2. Doors: Provide door-in-door type arrangement 3. Finish: Primed and painted using the manufacturer’s standard finishing

process. Finish shall be applied at the manufacturing plant. Color shall be ANSI #61 Gray finish

C. Panelboard assemblies installed indoors in PROCESS/MECHANICAL ROOMS and STORAGE ROOMS that are not environmentally and climate controlled: 1. Enclosure: NEMA-4X, 316 stainless steel, gasketed. 2. Doors: Provide door-in-door type arrangement. Provide hinged doors

complete with door handles.

D. A circuit directory in a metal frame with clear plastic covering shall be provided on the inside of the door. A directory card shall be typed to identify the load served by each circuit. Spare breakers shall be noted in pencil, however.

E. The panelboard interior assembly to be dead front with panelboard front removed. Main lugs or main breaker to be barrier on five sides. The end of the bus structure opposite the mains to be barriered.

2.04 NAMEPLATES





melamine middle layer. 4. Accessories: Provide holes for mechanical fastening.

2.05 SURGE PROTECTIVE DEVICE

A. Furnish and install Surge Protective Devices (SPD) where required by the PLANS. Each SPD shall have the following features: 1. Number of phases and system configuration (delta, wye grounded) to match

and fully protect the bus to which the SPD is connected. 2. SPD shall be tested with the ANSI/IEEE Category C high exposure waveform

of 10 kA for 8 x 20 microseconds, at minimum. 3. Visual indication of SPD status. 4. Surge counter. 5. Provide dry contact failure status output contact. Contact shall be rated for

120 volts A.C. and shall satisfy the requirements of the PLANS. 6. UL 1449. 7. 10 year minimum warranty. 8. SPD surge current withstand ratings shall be as follows:

Panelboard Voltage Minimum Current Withstand rating (Ampere per phase)

Minimum Current Withstand rating (Ampere per mode)

480 volts AC 160kA 80kA

120/208 volts AC 80kA 40kA

B. Enclosure 1. SPD located indoors in environmentally controlled rooms: NEMA 12 2. SPD located outdoors or indoors in non-environmentally controlled rooms:

NEMA 4X, Type 316 stainless steel.

C. Manufacturer: Innovative Technologies Model PTX 120, Surge Suppression Inc. or approved equal.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install panelboards at the locations shown on the PLANS per the manufacturer’s instructions and recommendations.

B. Top of all panelboards shall be at no higher than 6 feet 0 inches above the finished floor elevation, unless specifically noted otherwise on the PLANS.

C. Tagging: 1. Tag equipment with the name as it appears on the PLANS using the specified

nameplates. Panelboard nameplate shall also include: voltage ratings, phase, wire, ampere rating, AIC and withstand current rating, size and type of the main circuit breaker OR Main Lug Assembly (as applicable).


2. Panelboards shall be provided with typed circuit schedule including circuit number, breaker rating and circuit description.

D. Balance phases as closely as possible and type in directory at the close of the job. Use erasable pencil to indicate “Spares” and “Spaces”.

E. For surface mounting, use support channel per the requirements of Section 16150 “Raceways, Fittings and Supports” and per the details shown on the PLANS. For floor mounting, provide equipment pad as shown on the PLANS. Also refer to the details shown on the PLANS.

F. Connect SPD per the requirements of the PLANS and in accordance with the SPD manufacturer’s recommendations.



END OF SECTION


SECTION 16524

480 VOLT AUTOMATIC TRANSFER SWITCHES

PART 1 GENERAL

1.01 SCOPE OF WORK

A. Furnish and install the 480 volt Automatic Transfer Switch (ATS) as specified herein and as shown on the PLANS.

B. Where specifically shown on the PLANS, furnish and install the Automatic Transfer and Bypass Isolation Switch as specified herein and as shown on the PLANS. The Automatic Transfer and Bypass Isolation Switch shall consists of two major elements that are furnished and installed pre-wired, factory interconnected, and mounted inside a single common enclosure as an assembly: 1. The automatic transfer switch (ATS) as specified hereinafter, 2. The bypass-isolation switch, hereinafter specified by Subsection 2.07, this

Section of the Specifications All other requirements of each ATS described hereinafter shall also apply to each Automatic Transfer and Bypass Isolation Switch.


A. The PLANS designate the size, rating, and other requirements of the ATS.

B. Related work as called for on the PLANS, as specified herein or in other Sections of the Specifications.

1.03 QUALIFICATIONS

A. The ATS shall be designed, constructed, and tested in accordance with the latest applicable requirements of NEMA, ANSI, U.L., and NEC standards.

B. All ATS’s on the project shall be manufactured by a single ATS manufacturer.

C. The ATS shall be as manufactured by “Automatic Switch Company-ASCO, Model 7000” or Russelectric Inc, No Equal.

1.04 SUBMITTALS

A. Submit Shop Drawings in accordance with Section 01330 of the Specifications. Submittals shall include: 1. Dimensioned/scaled top and bottom views, front elevations, and internal

component/device layouts 2. One-line and wiring diagrams, 3. Catalog cut sheets


B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Specifications. O&M Manuals shall include copies of the approved shop drawings. Also, as minimum the Operations and Maintenance Manuals shall include: 1. Copies of certified and approved shop drawings. 2. Detailed information on each component used, including:

a. Installation and operation manual. b. Renewal parts bulletin. c. As built drawings, including approved shop drawings. d. Test data. e. Detailed transfer switch setting parameters, DIP-switch settings, ranges,

options, operating setting and calibrating instructions, etc.


A. Protection 1. The CONTRACTOR, and hence the ATS supplier, shall be responsible for

safety of the ATS during storage, transporting and handling. 2. The ATS shall be environmentally protected and stored in climate controlled

(temperature and humidity, etc.) environment. 3. At all times the ATS shall be housed inside a moisture free, non-porous, extra

heavy duty plastic weatherproof housing. 4. Interior and exterior of the ATS shall be kept clean at all times. 5. Size, furnish and install temporary space heaters within the ATS and energize

during storage and installation for humidity control.









1.06 SPARE PARTS

A. One (1) quart of touch up paint.

PART 2 PRODUCT

2.01 AUTOMATIC TRANSFER SWITCHES REQUIREMENTS AND UNIT DESCRIPTION

A. General: 1. Automatic transfer switch shall be completely factory interconnected, pre-wired

and tested. 2. Automatic transfer switch mechanism shall be of the electrically operated,

double throw mechanically held type, actuated by a single solenoid operator momentarily energized to assure quiet operation.

3. Automatic transfer switch shall be inherently interlocked, mechanically in either normal or emergency position with no “OFF” position possible. Gravity or spring operated switches will not be acceptable. ATS shall be the “open transition” type of automatic transfer switch.

4. All main contacts shall be provided with silver alloy material for high conductivity under all conditions of service. The transfer switch shall be suitable for all classes of loads, including inductive loads, resistive loads, control loads, and electrical discharge and tungsten-filament loads.

5. Inspection of contacts shall be possible from the front of the switch. 6. A manual operating handle shall be provided. 7. The ATS shall have a U.L. listed minimum RMS symmetrical short circuit

current rating equal to or greater than the minimum RMS symmetrical short circuit current rating shown on the PLANS. The ATS contacts rating and number of poles shall be as shown on the PLANS (electrical one line diagrams).

8. The automatic transfer switch shall be furnished complete with the automatic transfer control system.

9. The automatic transfer switch ATS, automatic control transfer system, sensors, timers, etc. shall be mounted, as one unit, in a single enclosure as specified hereinafter. The ATS shall be mounted where shown on the PLANS.

2.02 ADDITIONAL REQUIREMENTS FOR THE AUTOMATIC TRANSFER AND BYPASS-ISOLATION SWITCH

A. Furnish and install the automatic transfer and bypass-isolation switch where specifically required by the PLANS. The following are additional requirements for each Automatic Transfer and Bypass-Isolation Switch over and above the requirements for each ATS: 1. The bypass-isolation switch shall provide manual bypass of the load to either

source and permit isolation of the automatic transfer switch from all source and load power conductors without interrupting power to the load. All main contacts shall be manually driven.

2. Separate bypass and isolation handles shall be utilized to provide clear distinction between the functions.

3. The bypass handle shall have three operating modes: "Bypass to Normal," "Automatic," and "Bypass to Emergency." In the “Bypass to Normal” mode, the “normal” source serves the load. In the "Automatic" mode, the ATS control


system selects the source to serve the load. Additionally, the bypass contacts shall be out of the power circuit so that they will not be subjected to fault currents to which the system may be subjected. In the “Bypass to Emergency” mode, the “emergency” source serves the load.

4. The isolation handle shall provide three operating modes: "Closed," "Test," and "Open." The “Closed” mode shall permit the normal operation of the ATS. The "Test" mode shall permit testing of the ATS with no interruption of power to the load. The "Open" mode shall completely isolate the automatic transfer switch from all source and load power conductors. When in the "Open" mode, it shall be possible to completely withdraw the automatic transfer switch for inspection or maintenance without the removal of power conductors.

5. When the isolation handle is in the "Test" or "Open" mode, the bypass switch shall function as a manual transfer switch and shall allow manual transfer of load to either power source (normal or emergency) regardless of the position (normal or emergency source selection) of the ATS or if the ATS is drawn-out.

2.03 AUTOMATIC TRANSFER SWITCH ATS CONTROL REQUIREMENTS

A. General: 1. The ATS shall automatically transfer power from one power source to another,

in the event of normal/primary power source failure, one primary feeder failure, etc. The ATS shall ensure continuity of the load circuit power supply for as long as one of the two primary feeders to the ATS is active. The ATS shall also include functionality to initiate transfer of power from one source to another based upon discrete commands received from the Owner’s Distributed Control System, as also shown on the PLANS.

B. Voltage and frequency sensing: 1. Provide field adjustable setpoints with the following Dropout and Pickup

ranges for the following parameters:

Parameter Source Dropout Range Pickup Range Undervoltage Normal and Emergency 70% – 98% 85% - 100%

Underfrequency Normal and Emergency 85% - 98% 90% - 100% Voltage Unbalance Normal and Emergency 5% - 20% 2% below dropout

C. Transfer time delays: 1. Provide the following field adjustable setpoints with the following ranges:

a. Time delay to override momentary normal power source outages to delay transfer switch: 0 to 6 seconds.

b. Transfer to backup power source time delay: 1 to 300 seconds. c. Time delay to re-transfer to normal power source (upon restoration): 0 to

30 minutes.

D. Manual transfer switch controls: 1. Combination Display and Keypad: Provide manufacturer’s standard four line,

20 character liquid crystal display (LCD) combination display and pushbutton keypad user interface module. The combination display and keypad module shall be an integral part of the ATS for viewing all available data and field adjustment of desired operational parameters. Mount the Combination Display and Keypad to the face of the ATS.


E. Accessories: 1. Provide a detailed instruction plate for convenient operation. 2. Auxiliary Contacts:

a. All contacts shall be rated for 10 ampere at 120 volts A.C. Wire to terminal blocks.

b. Provide contacts for the following: 1) ATS in normal position. 2) ATS in emergency (backup) position. 3) Normal source voltage is present. 4) Emergency (backup) source voltage is present. 5) Additional contacts where required by the PLANS.

3. Nameplates: a. Provide nameplates/legend plates for each pilot device and each

component/device/equipment installed on the face and inside the enclosure of the ATS.

b. Identification Nameplates: 1) Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated

cellulose paper base engraving stock per ASTM D-709, Type I. Nameplates shall be ASTM Grade ES-1, ES-2, or ES-3 as applicable for the face and lettering colors specified hereinafter. Flexible or acrylic tags will be not be accepted.

2) Color: White-Black-White. 3) Lettering: Nameplate shall be legible at a distance of six feet from

the nameplate. Lettering shall be engraved through the face layer to the melamine middle layer.

4) Accessories: Provide holes for mechanical fastening 5) Nameplates located on the face of the cabinet shall be secured with

two Stainless Steel screws.

2.04 ATS ENCLOSURE

A. The Automatic Transfer Switch ATS assembly (controls, contactors, sensors, relays, etc.) shall be mounted in a NEMA-12 gasketed enclosure. The ATS controller combination display and keypad and switch operators shall be mounted on the face of the enclosure door. Each door shall have a continuous piano hinge with key-lockable stainless steel handle (3-point latching mechanism).

PART 3 EXECUTION

3.01 FACTORY INSPECTION AND TESTS




A. Mount the ATS as shown on the PLANS. Top of ATS shall be no higher than 6 foot 0 inches above the finished floor elevation. For surface mounting, use support channel per the requirements of Section 16150 “Raceways, Fittings and Supports” and per the details shown on the PLANS. For floor mounting, provide equipment pad as shown on the PLANS. Also refer to the details shown on the PLANS.


A. The following minimum test and checks shall be made before energizing the Automatic Transfer ATS. These tests shall be performed by a Factory Trained Field Technician (non sales type): 1. Thoroughly inspect ATS. 2. Test for proper operation. 3. Calibrate, set and test control timers, relays according to settings provided and

required by this Specifications Section and as recommended by the manufacturer.

4. Submit documentation of all tests outlined above. Include all test documentation data in operation and maintenance manuals.

3.04 EQUIPMENT PROTECTION AND RESTORATION (BY CONTRACTOR)

A. Clean and vacuum clean all interior of the equipment.


3.05 TRAINING

A. Provide training sessions for OWNER’s representatives for Two (2) normal workday and Four (4) working hours each day, at the job-site location. If training is conducted in less than the time required by these Specifications, the remaining time shall be utilized at the discretion of the OWNER.

B. The training session shall be conducted by the ATS manufacturer’s non-sales-type technical representative.


installed within the ATS. 2. Factory contact persons phone numbers, persons names, ordering procedures

and procedures to follow to obtain meaningful results from the factory.



END OF SECTION


SECTION 16540

FIELD CONTROL STATIONS AND FIELD CONTROL PANELS

PART 1 GENERAL

1.01 SCOPE

A. Furnish and install field control stations and control panels as specified herein and as shown on the PLANS.


A. Related work as called for on the PLANS, as specified herein or in other Sections of the Specifications.

1.03 SUBMITTALS

A. Submit shop drawings, product data, and layout drawings for the products of this Section in accordance with Section 01330 of the Specifications.

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Contract Specifications. O&M Manuals shall include copies of the approved shop drawings.

PART 2 PRODUCTS

2.01 PUSHBUTTONS, SELECTOR SWITCHES, PILOT LIGHTS

A. General Requirements: 1. Rating: NEMA 4X, corrosion resistant, Heavy Duty 2. Size: NEMA Style full size 30-millimeter (30mm), 3. Contacts: Provide number of contacts to satisfy the requirements of the

PLANS. Contacts shall be as follows: a. Rated 5 ampere minimum at 120 volts A.C. b. Enclosed in a hermetically sealed chamber and suitable for use in Class I

and II, Division 2 hazardous locations. 4. Legend Plate: Provide per manufacturer’s standard with inscription as shown

on the PLANS. 5. Manufacturer: Allen Bradley Bulletin 800R, or approved equal.

B. Additional Requirements for Selector Switch/Pushbuttons: 1. Operator Color: Black, unless shown otherwise on the PLANS. 2. Selector Switch Action Type: Maintained action, unless shown otherwise on

the PLANS. 3. Pushbutton Action Type: Momentary action, unless shown otherwise on the

PLANS.


C. Additional Requirements for Pilot Lights: 1. Type: Transformer Type Light Emitting Diode (LED), 2. Voltage: 120 volts A.C. 3. Style: Push-to-test 4. Lens Color: Provide the colors as on the PLANS:

D. Additional requirements for Emergency Stop/Trip Push-Button Stations: 1. Action Type: Push-Pull maintained 2. Operator Type: Mushroom head 3. Operator Color: Red, unless shown otherwise on the PLANS 4. Each button shall be provided with a hinged polycarbonate corrosion resistant

locking cover. Cover shall be capable of closing without actuating the push button. Cover shall be C3 Controls Model LOAFC, or approved equal.

5. Padlock: Furnish and install padlock with 0.25 inch diameter padlock shackle. Coordinate the shackle diameter with the padlock attachment. Furnish and install padlock as manufactured by Master Lock, or approved equal.

2.02 MANUAL SPEED POTENTIOMETERS

A. Furnish and install where required by the PLANS. Additional manual speed potentiometer features are as follows: 1. Each potentiometer shall have a resistance per the requirements of the

variable speed controller manufacturer. 2. Potentiometer Action Type: Single turn variable resistance potentiometer 3. Operator Color: Black, unless shown otherwise on the PLANS 4. Manufacturer: ETI Systems, Model SP22E-SB-5K SEALED BODY

POTENTIOMETER.

2.03 MANUFACTURER FURNISHED DEVICES

A. Manufacturer furnished control devices that are not described in this Section of the Specifications are required to be installed inside of proposed control panels tagged “SST-CP-LMU1”, “SST-CP-LMU2” and “SST-CP-NP”. Install these devices as required by the PLANS. Refer to the PLANS. Refer also to Section 11225 of the Specifications “Portable Anoxic Submersible Mixers and Pumps” and Section 11312K of the Specifications “Submersible Medium Capacity Centrifugal Pumps”. 1. Wire manufacturer furnished control devices to terminal blocks inside the

control panel as required by the PLANS. Refer to the PLANS. Furnish and install Type II terminal blocks in compliance with Section 17200 of the Specifications “Instrumentation and Control Cabinets and Associated Equipment”.

2.04 FIELD CONTROL STATION ENCLOSURE:

A. Size: As required.

B. Rating: NEMA-4X.

C. Material: Type 316 Stainless Steel.

D. Doors and door latches: Boxes shall be equipped with hinged doors complete with 1/4 (quarter) turn door latches.


E. Backpanel: For control panels tagged “SST-CP-LMU1”, “SST-CP-LMU2” and “SST-CP-NP” furnish enclosure with a full and solid backpanel (one piece full subpanel). The backpanel shall extend the full height and width of the enclosure.

F. Manufacturer: Allen-Bradley, Hoffman, Rittal, Millbank, or approved equal.

2.05 LEGEND PLATES/NAMEPLATES FOR CONTROL STATIONS

A. General: 1. Provide nameplates/legend plates for each control station, and each pilot

device installed in a control station as shown on the PLANS and as previously specified.

B. Identification Nameplates: 1. General: Furnish and install identification nameplates for each field control

station as follows unless shown otherwise on the PLANS: a. Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose


b. Color: White-Black-White c. Lettering: 1/4-inch height minimum unless shown otherwise on the

PLANS, engraved through the face layer to the melamine middle layer. d. Accessories: Provide holes for mechanical fastening e. Attachment Means: Secured with two Stainless Steel screws.

PART 3 EXECUTION

3.01 INSTALLATION

A. Minimum mounting height shall be 3-foot 6-inches above finished floor unless shown otherwise on the PLANS. Secure stations firmly to support channels as specified in Section 16150 “Raceways, Fittings and Supports”.

3.02 FIELD TESTING

A. Perform field testing as required elsewhere.



END OF SECTION


SECTION 16550

GROUNDING

PART 1 GENERAL

1.01 SUMMARY

A. Provide grounding in accordance with the PLANS, these Specifications and the National Electrical Code “N.E.C.” Included within this section are furnishing and installing all the wire, connections, ground electrodes, and other devices associated with the grounding system associated with the aforementioned.


A. Related work as called for on the PLANS, as specified herein or in other Division 16 Sections of the Specifications.

1.03 - 1.05 (NOT USED)

1.06 SUBMITTALS

A. Submit shop drawings on all grounding system product and in accordance with Section 01330 of the Specifications. Include material safety data sheet for ground enhancement material.

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Specifications. O&M Manuals shall include copies of the approved shop drawings, and on-site/field test data.

PART 2 PRODUCTS

2.01 GENERAL

A. Ground electrodes shall be 24 inch depth by 24 inch wide high conductivity copper sheet plates with the plate thickness as shown on the PLANS as manufactured by Thermoweld, or approved equal. Multiple plate thicknesses are required for this project as shown on the PLANS. Each ground plate shall have two bare copper 250 kCMIL wire pigtails exothermically welded to the plate by the plate manufacturer. Exception: ground plates connected to test wells are not required to have pigtails. Refer to the PLANS for additional requirements.

B. Concrete encased ground electrodes for all new buildings or structures having a concrete foundation shall be encased in the concrete foundation a minimum of 20 feet and tied to the foundation’s steel reinforcing bar system. The concrete encased ground electrode shall be a minimum 3/4 inch diameter Type 316 stainless steel reinforcing bar per ASTM A955/A955M. The concrete encased ground electrode shall extend outside of the concrete foundation and turn up into a concrete encased electrode accessibility ground port enclosure as shown on the PLANS. Refer to the


PLANS for additional requirements. The enclosure shall comply with the requirements of Section 16250 of the Specifications “Boxes and Cabinets”.

C. Connections between ground electrode and grounding electrode conductors shall be made below grade using Burndy Thermoweld, Cadweld, or equal thermite reaction welding system. Exception: Connections between ground electrode and grounding electrode conductors made inside an accessible underground Grounding System Test Well, only where noted/detailed/shown on the PLANS, shall be permitted to be made with tin-plated Bolted Ground Lug connectors as manufactured by BURNDY Type GK, or approved equal.

D. Grounding electrode conductors/wire shall be green insulated stranded copper. Use bare copper for grounding grids only (as shown on the PLANS).

E. Equipment and/or static voltage and/or any other ground buses/bars (for any other type of use) called for on the PLANS and Specifications shall be tin-plated copper.

2.02 GROUND ENHANCEMENT MATERIAL

A. The Contractor shall encase the underground ground electrodes with the hereinafter specified Ground Enhancement Material.

B. Material: Low resistance non-corrosive carbon based backfill material, free of concrete and bentonite. Material shall not require periodic wetting or other Owner intervention in order to maintain its conductivity.

C. Application: Suitable for use as backfill material in rocky, sand, gravel, and other high resistance soil types to lower the ground resistance. Suitable for use in horizontal and vertical trench applications.

D. Manufacturer: Harger Model “Ultrafill”, Erico “Ground Enhancement Material (GEM)”, or approved equal.

PART 3 EXECUTION

3.01 GENERAL:

A. Connect each Ground Bus/bar directly to the Grounding Network conduit routed in the duct bank system in addition to the Grounding System around the manhole/handhole, as also shown on the PLANS.

B. Extend a dedicated equipment ground wire, minimum size No. 6 AWG green insulated wire, from each Ground Bus/bar to each individual conduit system grounding bushings, each cable clamp, each support channel, etc. housed inside the associated electrical manhole/handhole. Also, refer to the PLANS

C. Ground all electrical equipment, including lights and receptacles, etc., with a separate equipment ground wire installed in the conduit with the power conductors.

D. Install grounding system electrically and mechanically continuous throughout. System neutral shall be bonded only at the building service transformer.


E. Ground lighting transformer neutrals to their housing and bond the housing to the equipment grounding conductor.

F. Connect equipment grounding conductors to ground bars or busses provided at panelboards, motor control centers, disconnect switches, switchgears, etc., from which the equipment is served.

G. Where the equipment has no facility to attach an equipment ground wire, use a Burndy Quicklug or equal. Clean the metal surface under the lug to bright metal so that good contact can be made. Repaint metal surfaces after the lug and connecting ground wires are installed.

H. Make ground connections to equipment by using ground lugs or ground bars, where they are provided.

I. Use a thermite reaction welding system process as previously specified to make connections to ground rods; and, at any joint or connection which will be inaccessible after the construction. Exception: Connect to Grounding System Test Wells as previously specified and as also shown on the PLANS. Do not cover until each connection has been inspected by the Owner.

J. Furnish bonding jumpers as shown or as otherwise required by the National Electrical Code “N.E.C.” Use stranded copper wire.

K. Inside buildings and at above ground level and through concrete floor slabs, route the ground wire(s) in a conduit raceway system. Fill annular space between ground wire and conduit with Crouse Hinds, Nelson or Raychem watertight and flame-retardant sealant.

L. Connect ground wires entering outlet boxes in such a manner that removal of the receptacle will not interrupt the continuity of the grounding circuit. A grounding screw attached to the box, and used for no other purpose, may be used to accomplish this.

M. After ground wire connections have been made to equipment, to structures, in test wells and encased grounding electrode accessibility ground port enclosures, etc., the Contractor shall apply “3M” 1601 Clear-Color Fast Drying Sealer and Insulator, or approved equal corrosion resistant and moisture repelling electrical coating/spray to all exposed wiring and all wire connections, inclusive of mechanical and exothermic weld connections. Coordinate application with the Owner.

N. Test grounding in accordance with Section 16800. Maximum resistance to ground shall not exceed 2-ohms. At no additional cost to the owner, install additional ground rods over the number required by the PLANS, as necessary to accomplish the 2-ohms or less resistance.

O. Install a bonding jumper from the grounding lug of each Conduit-Grounding-Bushing to the ground bar or bus of each enclosure and/or equipment housing (such as pull boxes, junction boxes, panelboards, motor control centers, transformers, automatic transfer switches, instrument and control panels, etc.), as applicable. Instrument Grounds to be separate from power grounds. Instrument ground to be insulated up to the connection to the ground grid. Also refer to details shown on the Drawings.


Bonding jumper wire for Conduit system Grounding-Bushings shall be STRANDED bare copper wire with minimum of 19-strands. Minimum wire size shall be #10 AWG.

P. Where Grounding System bare copper underground conductors pass through a transition from soil to concrete/mud slab concrete/flowable fill concrete/etc., the conductors shall be wrapped with 20 mil polyvinyl chloride based Pipe Tape using a 50 percent overlap. Pipe tape coverage shall be installed at the point of the transition and an additional 12 inches of distance beyond either side of the point of transition/contacted region. Pipe Tape shall be 3M Company No.51, or approved equal.

Q. At the proposed Electrical Building, the Blower Building, the Primary Sludge/Scum Pump Station, and the Effluent Lift Station, in addition to the Grounding Network shown on the PLANS, furnish and install one (1) separate concrete encased electrode grounding system at each location to comply with City of Austin Amendment to the National Electrical Code Ordinance 20141211-199 Article 250.52(A)(3) and obtain City inspection prior to concrete placement of building grade beams or slab. Each said grounding system shall include 20 feet of 3/4 inch stainless steel rebar, routed horizontally and encased in a minimum of 4 inches of concrete, located above building foundation slab waterproofing and attached to the building foundation slab reinforcing steel bars. Additionally, each concrete encased electrode shall also extend vertically to finished grade and terminate at a concrete encased electrode accessibility ground port enclosure as shown on the PLANS. Label each enclosure cover “GROUND PORT” to comply with City of Austin Amendment to the National Electrical Code Ordinance 20141211-199 Article 250.68(A)(1).

R. In each proposed manhole/handhole as well as in each existing manhole/handhole where splicing to existing phase conductors is required: 1. Mount a 400 amperes rated, tin-plated copper Ground Bus/bar of minimum

length of 1-feet, unless shown otherwise on the PLANS. 2. Mount ground bus on 600 volts AC stand-off isolators/insulators, as

manufactured by Square-D Company or approved equal. 3. Furnish each Ground Bus/bar with a minimum of six (6) terminals (ground

lugs), unless shown otherwise on the PLANS. Each terminal (Grounding lug) shall be: a. Tin-plated copper, b. Cable of terminating wire from #10 AWG to #4 AWG

4. Connect each Ground Bus/bar directly to the Grounding Network conduit routed in the duct bank system in addition to the Grounding System around the manhole/handhole, as also shown on the PLANS.

5. Extend a dedicated equipment ground wire, minimum size No. 6 AWG green insulated wire, from each Ground Bus/bar to each individual conduit system grounding bushings, each cable clamp, each support channel, etc. housed inside the associated electrical manhole/handhole. Also, refer to the PLANS.

S. Ground Enhancement Material Installation: 1. All underground grounding electrodes shall be encased in an envelope of

grounding enhancement material extending beyond the extents of the grounding electrode a minimum of 4 inches in all directions.


2. Prior to installation, all ground enhancement material shall be mixed with water into a slurry in accordance with the ground enhancement material manufacturer’s installation instructions. Salt water shall not be mixed with the grounding enhancement material.

3. Refer to and comply with the installation details shown on the PLANS. Additionally, follow the ground enhancement manufacturer’s installation instructions.



END OF SECTION


SECTION 16600

DISCONNECT SWITCHES AND ENCLOSURES

PART 1 GENERAL

1.01 SUMMARY

A. Furnish and install disconnect switches, enclosed circuit breakers, and manual motor starters as shown on the PLANS and specified herein.




C. The PLANS designate the size, rating, and other requirements of the equipment specified under this Section.


1.03 SUBMITTALS

A. Submit Shop Drawings in accordance with Section 01330 of the Contract Specifications. Include enclosure dimensions, ratings, wiring connection diagram and fabrication drawings. Submit protective device coordination curves and current limiting circuit breaker/fuse peak current let through curves, where applicable.

B. Submit Operations and Maintenance Manuals (O&M) in accordance with Section 01730 of the Contract Specifications. O&M Manuals shall include copies of the approved shop drawings, and on-site/field test data.

PART 2 PRODUCTS

2.01 DISCONNECT SWITCHES

A. Construction: 1. U.L. Listed, Non-fused, Single Throw, Heavy Duty type. 2. Switchblades shall be fully visible in the "OFF" position when the door is open. 3. Dead-front construction with permanently attached arc suppressors. 4. Switches to have quick-make and quick-break operating mechanism and

handles with provision for padlocking in all three positions, with at least four padlocks. The locking provisions shall be such that the padlock directly interferes with the operating handle and is fully visible.


5. Switches shall have a dual cover interlock to prevent unauthorized opening of the switch door in an "ON" position from either source, or closing of the switch mechanism with the door open.

6. Furnish lugs to terminate the incoming/outgoing field wiring as shown on the PLANS. Refer to the PLANS. Additionally, provide a grounding lug for equipment ground wire connection. Lugs to be U.L. listed.

7. All current-carrying parts to be plated.

B. Ratings: 1. Voltage Rating: 600 Volts AC 2. Current Rating: Maximum continuous current capacity shown on the PLANS 3. Number of Phases: Three, unless shown otherwise on the PLANS 4. Minimum RMS symmetrical short circuit current rating: 10000 ampere at 208

volts A.C.

C. Enclosure: 1. NEMA-4X Type 316-Stainless Steel gasketed cabinets.

D. Manufacturer: 1. All Disconnect Switches on the project shall be manufactured by a single

Disconnect Switch manufacturer. 2. Square D Company Class 3110, Asea Brown Boveri, Cutler-Hammer

Corporation, or approved equal.

2.02 ENCLOSED CIRCUIT BREAKERS

A. Construction: 1. Molded case type, NEMA rated, and U.L. Listed. 2. Circuit breakers shall have an overcenter, toggle handle-operated, trip free

mechanism with quick make, quick break action independent of the speed of the toggle handle operation. Breakers shall be thermal magnetic molded case type having inverse time thermal trip and instantaneous time magnetic trip. The design shall provide common tripping of all poles.

3. Circuit breaker shall have handles with provision for padlocking in the ”OFF” position. The locking provisions shall be such that the padlock directly interferes with the operating handle and is fully visible. Circuit breakers shall have a dual enclosure interlock to prevent unauthorized opening of the enclosure door when the circuit breaker is in the "ON" position, or closing of the circuit breaker mechanism with the door open.

4. Furnish lugs to terminate the incoming/outgoing field wiring as shown on the PLANS. Refer to the PLANS. Additionally, provide a grounding lug for equipment ground wire connection. Lugs shall be U.L. listed.

B. Enclosures: NEMA-4X type 316 Stainless Steel gasketed cabinet

C. Circuit Breaker Ratings: 1. Voltage Ratings: 600 volts AC 2. Number of Phases: Three, unless shown otherwise on the PLANS. 3. Current Rating: Maximum continuous current carrying capacity shown on the

PLANS 4. Minimum RMS symmetrical short circuit current rating: Equal to or greater

than that of bus serving the circuit breaker at rated bus voltage A. C.


5. Breakers shall operate continuously when operating/running current is equal to 80% of the long time trip setting (or frame rating, as applicable) of the breakers.


7. Furnish current limiting type circuit breakers when specifically required by the one-line drawings shown on the PLANS.

8. Provide electronic trip attachment where specifically shown on the PLANS. Trip unit shall be solid state type with adjustable long time, short time, instantaneous, ground fault and pick up settings as manufactured by “Square D” Micrologic LSIG Series B Trip Unit and Internal Ground Fault Protection, or approved equal.

D. Manufacturer: Circuit breakers shall be Square D Company Type FCL, Asea Brown Boveri, Cutler-Hammer Corporation, or approved equal.

2.03 IDENTIFICATION

A. General: 1. Furnish and install identification nameplates for each piece of equipment as

follows: a. Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose


b. Color: White-Black-White c. Lettering: 1/4 inch height, minimum, engraved through the face layer to

the melamine middle layer. d. Accessories: Provide holes for mechanical fastening e. Attachment Means: Secured with two Stainless Steel screws.

2. Exception: Identify manual motor starters mounted in environmentally controlled rooms as specified in Section 16300 “Wiring Devices”.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install where the top of each enclosure is no higher than 6-feet-6-inches above the finished floor elevation, unless otherwise noted on the PLANS.

B. Surface mount on support channels per the requirements Section 16150 “Raceways, Fittings and Supports” and the details shown on the PLANS. Also refer to details shown on the PLANS.

C. Tag equipment with the name as it appears on the PLANS using the specified nameplates.




END OF SECTION


SECTION 16800

CALIBRATION, TESTING AND SETTINGS

PART 1 GENERAL

1.01 SUMMARY

A. Provide all equipment and labor required for calibration, setting and testing as described herein or otherwise required. All tests shall be witnessed by the OWNER or the OWNER’s designated representative. Give written notification of the tests at least seven days prior to the desired date to perform the tests. Repair or replace all defective material, equipment or workmanship disclosed as a result of these tests at no cost to OWNER.

B. All work, including installation, connection, calibration, testing, and adjustment, shall be accomplished by qualified, experienced personnel working under continuous, competent supervision. The completed installation shall display competent work, reflecting adherence to prevailing industrial standards and methods.

C. Tests: The Contractor shall make all tests required by these specifications, or other authorities having jurisdictions. All such tests shall be performed in the presence of the OWNER or the OWNER’s designated representative. The Contractor shall furnish all necessary testing equipment and pay all costs of tests, including all replacement parts and labor necessary due to damage resulting from damaged equipment or from test and correction of faulty installation.

1.02 SUBMITTALS

A. Submittals shall include copies of the test results/reports. Submittals shall be per the quantity and format requirements of Section 01330 and 01730 of the Specifications. Include the following at minimum: 1. Test results, inclusive of catalog number/drawing cross-reference, where

applicable, and any other data entered on the field test report 2. Testing Plans 3. All test instrument data sheets and calibration certificates

1.03 TEST PLAN AND TEST RESULTS

A. Performance: Testing shall be performed in compliance with the approved Test Plan. The Test Plan shall be submitted in accordance with the outline given below. Provide the OWNER with typewritten results of all tests, including a description of the equipment tested, the date and time of day tested, names of witnesses, weather conditions; and test values and results.


B. Test plan: At minimum, Submit a Test Plan for each of the Sections listed in Division 16 of these specifications. Test Plan shall be submitted at least two (2) weeks prior to the desired date and time of the test. Test Plan shall clearly identify the following, as applicable: 1. Desired date and time to perform the test 2. Name of Entity/individual that shall perform the test 3. Test procedures and recording data sheets 4. Name, description, catalog number, calibration date, and calibration entity’s

name of each of the test instruments to be used in executing the test 5. Expected duration of the test 6. Request for type, time and duration of any shutdown that may be required

during the test.

C. Test Results: Submit Test Results for each of the Sections listed in Division 16 of these specifications. Test Results shall be submitted no later than at least two (2) weeks after the last date of the respective test. Test Results shall be typewritten and shall include the following, as minimum: 1. All data and information provided in the Test Plan 2. Name of Entities and individuals that attended and witnessed the test 3. Weather Conditions 4. Tabulated test values and results 5. Corrective measures taken and/or to be taken toward defective material,

equipment or workmanship disclosed as a result of these tests. Also include Re-Test dates and procedures for defective material, equipment or workmanship disclosed from the previous test.

1.04 TEST EQUIPMENT

A. Each test instrument shall have been certified by an established calibration laboratory within the six (6) months prior to its use in testing and calibration procedures. Calibration shall be traceable to the National Institute of Standards and Technology (NIST).

PART 2 PRODUCTS

A. No products are required by this Section of the Specifications.

PART 3 EXECUTION

3.01 INSULATION RESISTANCE (MEGGER) TESTS:

A. Use a minimum 500 volt megohmeter.

B. Take each reading for at least one minute.


C. Include the following tests:

Equipment Minimum Resistance

115 and 230 volt motors 5.0 Megohms

460 volt motors 7.0 Megohms

600 volt transformer winding 100.0 Megohms

600 volt wiring up to 1000 ft. 25.0 Megohms

Coordinate minimum values shown with equipment manufacturer’s recommendations.

D. Test all transformer windings as follows: 1. Primary to ground 2. Secondary to ground 3. Primary to secondary

E. Record and submit all Megger readings to the OWNER/ENGINEER for review and record keeping purposes. Neatly type all readings and organize in a Database table form. Incremental megger readings shall also be recorded and included in the table.

3.02 GROUND TEST

A. Ground System testing shall be performed by an independent professional testing company specialized in, and well equipped to perform, ground resistance testing.

B. Ground testing shall assure resistance to ground values listed in the Grounding Specification. All tests must be witnessed by the Owner or the Owner's designated representative.

C. At a minimum, test each of the following separately, with ground under test isolated from other grounds: 1. Each process area/building grounding network, i.e., Electrical Building, blower

Building, etc. Furnish and install additional grounding/ground electrodes if the resistance to ground measures more than the values stipulated in the Grounding Section of the Specifications. This shall be executed at no additional cost to the Owner.

2. Each manhole, 3. Each handhole,

D. Finally, after all tests of each individual process area/building, manhole, handhole, etc., are performed as previously specified, perform a final test after all of the individual process areas/buildings, manholes, handholes, etc. grounding networks are interconnected as also shown on the PLANS.


3.03 MOTORS

A. Test the insulation resistance (megger test) of all motors installed under this Contract inclusive of process mechanical drive motors and the Heating and Ventilation System drive motors such as exhaust fans, fan and coil units drive motors, etc. Test all motors in accordance to with subsection 3.01 above.

B. Dry out any wet insulation by use of space heaters or other approved methods.

C. Check coupling alignment, shaft end play, lubrication, and other mechanical checks as required. Follow manufacturer’s instructions.

D. Check for proper motor rotation.

3.04 RECEPTACLES

A. Test all receptacles for proper connections and grounding. Use an approved plug-in tester equal to Woodhead 1750 or Hubbell 5200.

3.05 CONTROL CIRCUITS

A. Check all circuits for continuity, proper connection, and proper operations.

B. Set all time delay relays and timers for the desired operations. Record the settings, indicating the relay or timer, its location, and the setting used. Verify all settings with a stopwatch.

3.06 CONTINUITY TESTS

A. Perform continuity test on all low voltage conductors (600 volt, and below, wiring system). Continuity test must be performed after wiring is pulled in the conduit system and/or underground electrical system (as applicable). Continuity test must be performed on each conductor between its source and final destination (point of termination to load/device/etc.). Utilize Ohmmeter for this test. Ohmmeter must be set to lowest ohm setting (highest resolution).



END OF SECTION


SECTION 17100

PROCESS INSTRUMENTATION AND CONTROL SYSTEMS (PICS)

PART 1 GENERAL

1.01 SUMMARY

A. Provide all labor, materials, and equipment to design, furnish, install, calibrate, test, adjust, and place in operation the facility complete monitoring and control system as specified herein and as shown on the PLANS. The PLANS and Specifications show and specify those features required to illustrate and describe functional requirements of the monitoring and control system.

B. A single Instrument and Control System Contractor (ICS) shall furnish all services and equipment defined herein and in other Specification sections as listed below under Related Work. The Instrument and Control System Contractor is referred to herein and after (in Division 17 of the Specifications) as the ICS, ICS supplier/firm, or Contractor. The ICS shall have the qualifications as described in subsection 2.0, “Quality Assurance”, this Section of the Specifications.

C. The ICS shall also: 1. Terminate and tag all field wiring associated with the process instrumentation

and control system shown on the PLANS and specified herein and in other Specification sections listed below under Related Work.

2. Tag Instrumentation and control wiring/cable per the requirements and methodology/scheme outlined in specifications Section 16200 “Wiring (600 volt and Below) paragraph 3.03 “Wire Tagging Methodology”.

3. Calibrate, set and test the PICS equipment, components, cables, hardware, and software.

4. For equipment and ancillaries required under PICS Subsystem sections: a. Required submittals. b. Equipment and ancillaries. c. Instructions, details, and recommendations to, and coordination with, all

other installation entities for Certificate of Proper Installation. d. Certifying readiness for operation. e. Starting up. f. Testing. g. Training h. Use of testing/calibration equipment to facilitate calibration/testing of field

sensors and instruments. Equipment shall include, but not be limited to: 1) Test pressure pump for field calibration/testing of pressure

transmitters. 2) Signal generator/multi-function meter for field calibration/testing of

resistance temperature detector (RTD) monitoring devices 3) Temperature/heat generator for field calibration/testing of

temperature transmitters. 4) Shaker table for vibration transmitters, etc.


5. Provide special additional services during installation, including: a. Verifying that the following are furnished and installed:

1) Correct type size, and number of signal wires with their raceways. 2) Correct electrical power circuits and raceways. 3) Correct size, type, and number of PICS related pipes, valves, fittings,

and tubes. 4) Correct size, type, materials, and connections of process mechanical

piping for in-line primary elements b. For equipment not provided by the ICS, but directly connected to the

PICS: 1) Obtain manufacturer’s information regarding installation, interface,

function, and adjustment for equipment from the Contractor. 2) Coordinate with Contractor to allow required interface and operation

with the PICS. 3) Verify that installation, interfacing signal terminations, calibration, and

adjustments have been completed in accordance with the manufacturer’s recommendations.

4) Test to demonstrate the required interface and operation with the PICS.

5) Examples of equipment in this category include, but are not limited to the following: a) OWNER’s Top-End Computer System b) Motorized Valve Operators c) Motor Control Centers d) Process/Mechanical Equipment

6. Provide equipment, software, and services for the installation of the DCS configuration system at the ENGINEER’s Austin, Texas office.

7. Assist OWNER/ENGINEER, as specified in applicable DCS subsystem specifications sections, in the PAT testing of the Applications Software which shall be developed by OWNER/ENGINEER for the DCS and Laptop Computer (as applicable).

D. As also shown on the PLANS, the proposed Distributed Control System at the Side Stream Treatment Plant Electrical Building is networked with the proposed Blower packaged control system and the OWNER’s existing plant Top-End computer system by means of equipment located in the Maintenance Building of the Hornsby Bend Biosolids Management Plant. Refer to the PLANS. Effort is required of the ICS to establish functional and complete communication network links between the proposed equipment of this project and the Owner’s existing DCS equipment in order to achieve proper and complete system operation. This effort shall include, but not be limited to: 1. Furnish and install proposed communication equipment and associated

cabling in the OWNER’s existing Maintenance Building Distributed Control Panel(s)/Rack(s). Refer to the PLANS.

2. Coordination with all responsible parties, i.e. OWNER, manufacturers, etc., to facilitate proper communication equipment selection, cable termination connector quantities/types, patch panel locations in controls panels to address minimum cable bending radius, etc., as required

3. System startup testing, diagnosing, and resolving communication system issues, etc.


E. Extensive field verification is required for all modifications to existing control panels. The ICS shall include effort associated with field verifying spatial dimensions inside the existing control panels for proposed equipment, wiring terminations, loop power supply sizes, loads on existing instrument loops, points of connections to existing equipment, etc. as required to support the proposed modification effort associated with this project. The ICS shall field locate proposed equipment to be installed inside the existing control panel as also shown on the PLANS. The proposed location shall be coordinated with the arrangement of the existing control panel internal and externally mounted components.

F. The OWNER’s existing distributed control system is vital to the OWNER’s treatment plant process system. Therefore, required interruptions to the OWNER’s existing distributed control system shall be minimized and coordinated with the OWNER. Should an outage to a facility be required, the Contractor shall request such an outage in writing no less than ninety-six (96) hours in advance. Contractor's written request shall identify the desired date, time, duration, and purpose of the requested day unless he/she obtains a written approval from the owner authorizing the outage. The OWNER reserves the right to modify or reject any request such an outage. Modification or rejection of the contractors request be the OWNER shall not be considered reason for delays in the construction schedule. Unless otherwise noted, the duration of the outage shall be limited to four (4) hours or less. The OWNER reserves the right to limit the duration of the outage to less than 4 hours. Modification of the outage duration by the OWNER shall not be considered reason for delays in the construction schedule.

G. The OWNER’s existing distributed control system equipment and its associated interconnect wiring, power supplies, fuses, etc., is in perfect working condition. Should the existing equipment, its associated interconnect wiring, power supplies, fuses, etc., as applicable, be damaged or become otherwise unusable during the construction course of this project, the ICS shall determine the problem, correct it, and furnish and install all necessary wiring/hardware/etc., to match existing and make all final connections such that all affected equipment operates as previously operated to the OWNER’s satisfaction at No Additional Cost to the OWNER.

H. The ICS shall also include effort required to facilitate the construction sequencing requirements of this project. This shall include the temporary installation of proposed equipment as shown on the PLANS and all associated wire termination, tagging, testing, etc. required to make the equipment operational and fully functional. Effort shall also be included to relocate the temporarily installed equipment to their permanent location as well as all associated re-termination, re-tagging, re-testing, etc., to make this equipment operational and fully functional. This shall include coordination with the existing field conditions, proposed motor starters and existing control system to maintain continuous facility operation. Refer to the PLANS for additional requirements.





C. Division-16 ELECTRICAL SPECIFICATIONS

D. Division-17: INSTRUMENTATION AND CONTROL SPECIFICATIONS

E. All other division of the Specifications related to the installation of the process mechanical equipment, etc. that are related to the operation of the instrumentation and control system.

F. Related work as called for on the PLANS, as specified herein or in other Sections of the Specifications.

1.03 SUBMITTALS

A. General: Do not design, manufacture, or ship any PICS equipment until all related submittals have been reviewed and approved by the ENGINEER. Submit shop drawings and product data in complete functional packages; i.e., submit all shop drawings and product data for a given loop or subsystem together as a functional package. Piecemeal submittals not organized by systems or incomplete submittals for a given loop or subsystem will not be accepted.

B. Administrative Submittals: 1. Schedule of Values

a. Purpose: Project Schedule of Values to provide a basis for Partial Payment for Work completed.

b. Content: Summary of major milestones and associated Partial Payments for Work provided under PICS Subsystems.

2. PICS Progress schedule a. Purpose: Supplement the overall Project Progress Schedule to:

1) Coordinate activities between the Contractor and the ICS 2) Coordinate interactions with the OWNER/ENGINEER for

coordination meetings, submittal reviews, etc. 3) Clarify required work sequences and major milestone prerequisites.

b. Provide multiple submittals of the project schedule throughout the duration of the Project as required.

3. OWNER Training Plan: Submit description/schedule of OWNER Training to be provided.

4. Statements of Qualification: Submit for PICS firm, site representative, start-up and testing team member.

C. Submit shop drawings in accordance with Section 01330 of the Specifications and as specified below: 1. Detailed product data, catalog cut sheets, cabinet exterior and interior front

elevations, bill of materials, and spare parts list 2. Point-to-Point Wiring Diagrams: Prepare Point-to-Point Instrument Loop

Wiring Diagrams, ladder diagrams (control schematics), cabinet wiring, and other field wiring diagrams in accordance to the format shown on the PLANS. Drawings shall be neat, and legible, and on 11 inch x 17 inch sized sheets. Drawings to include all relevant information for equipment connected to the


PICS, regardless if the equipment is provided by the ICS or not, i.e., include motor control centers, manufacturer packaged equipment, etc. Contractor shall also submit for approval a complete schedule of all wire tag numbers sorted by area and equipment/instrument/field device.

3. Although typical control schematics/instrument loops are presented on the PLANS for some equipment, the Contractor shall generate specific equipment control schematic drawings/instrument loops (i.e., individual control schematic/instrument loop drawings dedicated for each specific equipment) based upon the typical control schematic/instrument loop drawings, the device identification/tag replacement schedules shown on the PLANS, and the additional requirements described herein. The Contractor generated specific equipment control schematics/instrument loops shall follow the same overall presentation format as the typical equipment control schematics/instrument loops presented on the PLANS. The specific equipment control schematics/instrument loop drawings complete with all specific equipment/device tags (as a minimum, also refer to the additional requirements described herein) shall be generated by the Contractor and included with the project submittals (i.e., prior to equipment purchase) and the “As-Built” drawings. Any Contractor generated control schematic/instrument loop shown as applicable to multiple equipment shall not be accepted.

4. Contractor may submit wire tag samples for all types of interconnect and field wiring from the proposed/existing cabinets/panels with associated point-to-point wiring diagrams in a separate submittal for approval prior to submitting the complete wire tag schedule for review. After approval of the sample wire tags, a wire tag table showing all provided wire tags shall be submitted for review with the associated point-to-point wiring diagrams. Refer to Specification 17100 Subsection 1.03.C.5 for additional wire tag table requirements. Refer to Specification 16200 Subsection 3.03 for wiring tagging methodology.

5. Wire Tags: Contractor shall also submit for approval a complete schedule of all wire tag numbers sorted by area and equipment/instrument/field device. It is anticipated that all wire numbers cannot be accommodated on the loop diagrams, ladder diagrams, control schematics, etc. format shown on the PLANS. As a minimum, to facilitate the depiction of the wire numbers on the loop diagrams, ladder diagrams, control schematics, etc., the Contractor shall generate and include uniquely identified alpha-numeric wire codes on the loop diagrams, ladder diagrams, control schematics, etc. The wire codes shall cross-reference tables of wire numbers shown on additional drawings that shall be generated by the Contractor. At minimum, the Contractor shall generate the wire codes and the cross-reference tables which depict the wire numbers associated with each wire code and shall group the cross-reference tables by specific equipment (e.g. Sludge Pump No. 4, Sludge Pump No. 5, Sludge Pump No. 6, etc.). As a minimum, the Contractor shall generate drawings to depict the wire code and wire tag cross-reference tables and these drawings shall also be grouped by specific equipment (e.g. Sludge Pump No. 4, Sludge Pump No. 5, Sludge Pump No. 6, etc.). Additional requirements concerning the cross-reference table headings, table organization, wire code generation, formatting, etc., shall be provided by the Owner during the Pre-Submittal Conference specified hereinafter (refer to subsection 1.03G in this Section of the Specifications) and the Contractor shall incorporate these requirements at no additional cost to the Owner. Contractor shall submit wire


tag samples for all types of interconnect and field wiring from the proposed/existing cabinets/panels with associated point-to-point wiring diagrams in a separate submittal for approval prior to submitting the complete wire tag schedule for review.

D. Testing Related Submittals: 1. Submit factory and field calibration reports 2. Submit the following for each of type of test (ORT and PAT) required under

Division 17 of the Specifications: a. Preliminary Test Procedures: Outlines of proposed tests, forms, and

checklists. b. Final Test Procedures: Proposed test procedures, forms, and checklists. c. Test Documentation: Copy of signed off test procedures when tests are

completed.

E. Training Related Submittals: 1. Submit the following for each type of training required under Division 17 of the

Specifications: a. Training plan, course topics, subjects to be addressed in the training b. Schedule c. Training agenda for each course d. Instructor qualifications e. Listing of available training courses and outline of course topics and

agendas

F. Submit Operation and Maintenance manuals in accordance with Section 01330 and 01730 of the Specifications and as specified below: 1. Include approved shop drawing data in the Operation and Maintenance

manuals with the following modifications to the shop drawing exhibits: a. Reflect “As-Built” conditions. b. Prints of exhibits, wiring diagrams, etc. shall be half size (11 inch by 17

inch). 2. Procedures for operating and shut-down 3. Included approved Testing Related Submittals with final “As-Built” conditions. 4. Safety instructions. 5. Calibration instructions and factory test results of each instrument. 6. Maintenance and repair instructions. 7. Recommended spare parts list. 8. Name, address and phone number of instrumentation control system supplier's

local representative. 9. Additionally, comply with the requirements of the Contract Documents.

G. Pre-submittal conference 1. General:

a. Review the manner in which the contract requirements will be met prior to preparation of submittals. The Contractor, Engineer, OWNER, and ICS shall attend. Schedule, conduct, and arrange the conference within 90 calendar days after receipt of written notice to proceed work is given by the OWNER.


b. The ICS shall present the following at the conference: 1) List of equipment and materials required and the brand that shall be

used for each item 2) Sample submittals from similar projects including the types of

drawings/data/lists specified herein

1.04 SPECIAL CONDITIONS

A. All components used in the instrument and control systems shall be new (not used) and the current model produced by the manufacturer.

B. All equipment of a common type shall be the product of a single manufacturer.

PART 2 QUALITY ASSURANCE

2.01 ACCEPTABLE PROCESS INSTRUMENTATION AND CONTROL SYSTEM (PICS)

A. Provide a complete, workable, and installed-in-place Process Instrument and Control System, hereinafter referred to as the PICS, as specified herein. The PICS shall be designed, installed, and started up by the single ICS firm.

B. Acceptable ICS firm shall have the following minimum qualifications: 1. ICS Firm: Minimum of 5 years experience in providing, integrating, installing,

testing, and start-up similar systems as those required for this project 2. ICS Firm Site Representative: Minimum of 8 years experience installing

similar systems as those required for this project 3. ICS Firm Start-up and Testing Team Members: Minimum of 3 years

experience in testing systems similar to those required for this project.

C. PICS meetings to be scheduled in accordance with the Contract Documents.

2.02 SYSTEM COORDINATION AND QUALITY

A. Coordinate installation of instrumentation with mechanical and electrical systems.

B. Coordinate subsystems to provide a complete operational and functional instrumentation system to the satisfaction of the OWNER and ENGINEER.

C. Equipment, instruments, components, and materials for PICS components shall be new (not used) and of the current model.

D. Instrument and Control Components Furnished By Others: Certain items of instrumentation and controls shall be furnished by various equipment manufacturers. Coordinate the purchase orders of the items such that the resulting system will function properly.

2.03 DESIGN CRITERIA

A. Design, construct, and install all PICS components in compliance with the applicable provisions of the following standards, codes, and regulations: 1. American National Standards Institute (ANSI) Standards.


2. American Institute of Steel Construction (AISC) Standards. 3. American Society for Testing and Materials (ASTM) Standards. 4. American Waterworks Association (AWWA) Standards. 5. Joint Industrial Council (JIC) Standards. 6. National Electric Code (NEC) 7. National Electrical Manufacturer's Association (NEMA) Standards. 8. Local and State Building Codes. 9. Occupational Safety and Health Administration (OSHA) Regulations. 10. Scientific Apparatus Manufacturer's Association (SAMA) Standards. 11. Instrument Society of American Standards (ISA). 12. National Fire Protection Association (NFPA) 13. Institute of Electrical and Electronics Engineers (IEEE).

2.04 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Delivery: Enclose cabinets and subassemblies in heavy polyethylene envelopes to protect them from dust and moisture. Place corrosive-inhibitive vapor capsules in shipping containers, and related equipment as recommended by the capsule manufacturer.

B. Storage: All materials and equipment shall be environmentally protected and stored in climate controlled (temperature and humidity, etc.) environment. The Instrument Control Panels and the field control and instrument/monitoring panels shall not be moved from climate controlled storage room to the project site until one (1) of the following conditions have been met: 1. The construction of each electrical/control room is completed, and, the air-

conditioning and heating system of the facility and, where applicable, the gaseous air scrubbing equipment of the facility is in an operating condition satisfactory to the OWNER and ENGINEER.

2. Upon delivery to the project site and prior to final installation, protect and store in accordance with the following: a. Environmentally protected and stored in climate controlled (temperature,

humidity, and non-corrosive class) environment at the job site. Size, furnish and install temporary gaseous air scrubbers, air conditioners, and additional environmental control equipment complete with branch circuiting conduit/wire as required to maintain in a controlled environment at the following conditions: 1) Ambient Dry Bulb Temperature:

a) Minimum: 68 degrees Fahrenheit. b) Maximum: 85 degrees Fahrenheit.

2) Ambient Relative Humidity: Maximum: 50%. 3) Ambient Corrosion Level: International Society of Automation Class:

G1 b. Every effort shall be made to provide all necessary electrical power

connections ready for immediate connection to equipment upon arrival of equipment on jobsite.

c. Upon arrival of equipment onto job site, a maximum of one day shall be allowed for equipment to be left without to allow proper transition of power of equipment, especially any 120 VAC powered equipment, to ensure all air conditioning, heating, and gaseous air scrubbing equipment are fully


operational with a maximum of a 10 minute down time during this transition of power.

d. Furnish and install replacement air scrubber media, air filters, etc., as required for proper operation of the environmental control equipment.

2.05 CALIBRATION INSTRUMENTS

A. Each instrument used for calibrating PICS equipment shall bear the seal of a reputable laboratory certifying that instrument has been calibrated within the previous twelve (12) months to a standard endorsed by the National Institute of Standards and Technology (NIST). At OWNER’s request, ICS shall submit calibration certification report.

2.06 START DATE OF THE PROCESS INSTRUMENTATION AND CONTROL SYSTEM AND ASSOCIATED SUBSYSTEM WARRANTY (PICS INCLUDING SUBSYSTEMS)

A. Start Date of the process instrumentation and control system and associated subsystem Warranty (PICS including Subsystems) shall commence the date in which the Warranty period commences for the overall project per the requirements of the Procurement Documents.

PART 3 SEQUENCING AND SCHEDULING

3.01 GENERAL

A. All work provided under this section shall be in accordance with the OWNER/ENGINEER-approved Schedule of Submittal Submissions and Schedule of Values.

B. Specification and Construction Implementation Plan requires phased installation of equipment and systems. Stage all PICS activities (submittals, fabrication, installation, testing, start-up, training, etc.) to support the construction sequencing requirements of the project.

C. Wherever language in this section refers to the PICS, the entire installed PICS, the entire PICS, or similar language, it shall be interpreted to apply to the individual phases of the work; except the requirements for the Performance Acceptance Test (PAT).

D. Key milestone dates associated with PICS activity shall be included in the overall project schedule. Include the following dates as a minimum: 1. ORT start and end date 2. PAT start and end date 3. Date Configuration System is delivered to the Engineer 4. Date Configuration System is expected to be retrieved from the Engineer. 5. Training dates


3.02 PREREQUISITE ACTIVITIES AND LEAD TIMES:

A. Start the following key Project activities when prerequisite activities and lead times listed below have been completed and satisfied: 1. Shop Drawings submittal prerequisite: Completion of the Pre-submittal

conference 2. Test Prerequisite:

a. All associated process and mechanical equipment, controlled and monitored by the instrumentation and control system, complete in place

b. Associated test plan submittal completed. For ORT and PAT, notice of test schedule required 4 weeks prior to the start of test

3. ORT Prerequisite: a. Approved ORT test procedures b. Approved ORT test forms c. 30 calendar days advance written notice to given to OWNER of impending

ORT. 4. PAT Prerequisite:

a. Six (6) months minimum elapsed time after delivery of Configuration System to Engineer’s office.

b. ORT successfully completed. c. Approved PAT test procedures d. 30 calendar days advance written notice to given to OWNER of impending

PAT. 5. O&M submittal prerequisite: PAT successfully completed.

B. Configuration System Delivery: Deliver the entire Configuration System to the Engineer’s office no later than 90 days after the completion of the Pre-Submittal Conference.

PART 4 PRODUCTS

4.01 GENERAL Refer to requirements of PICS Subsystem provided in Division-17 Specifications.


A. General: 1. Test all PICS elements, both hardware and specific software, to demonstrate

that PICS satisfies all requirements. 2. On-Site Tests Described Under PART 3 - EXECUTION:

a. Operational Readiness Test “ORT” b. Performance Acceptance Tests “PAT”.

3. Test Format: Cause and effect a. Person conducting test initiates an input (cause) b. Specific test requirement is satisfied if the correct result (effect) occurs

4. Procedures, Forms, and Checklists: a. Conduct all tests in accordance with, and documented on, ENGINEER

accepted procedures, forms, and checklists. b. Describe each test item to be performed. c. Have space after each test item description for sign off by appropriate

party after satisfactory completion.


5. Required Test Documentation: Test procedures, forms, and checklists. All signed by OWNER/ENGINEER and Contractor.

6. Conducting Tests: a. All special testing materials and equipment. b. Wherever possible, perform tests using actual process variables,

equipment, and data. c. If it is not practical to test with real process variables, equipment, and

data, provide suitable means of simulation. d. Define simulation techniques in test procedures e. For PICS Subsystems for which OWNER provides applications software,

provide sufficient temporary software configuring to allow for ORT testing of these subsystems.

7. OWNER/ENGINEER will actively participate in many of the tests. 8. OWNER/ENGINEER reserves the right to test or retest all specified functions

whether or not explicitly stated in the Test Procedures. 9. OWNER’s/ENGINEER’s decision will be final regarding acceptability and

completeness of all testing.

B. Maintenance of Configuration System (as defined in Section 17600 “Distributed Control System): 1. Provide for maintenance of the Configuration System at the ENGINEER’s

office. Repair or replace failed equipment within two days of notice by ENGINEER.

C. Provide field support during OWNER/Engineer testing of installed applications software

PART 5 EXECUTION

5.01 EXAMINATION

A. Equipment furnished by Supplier or any other subcontractor and installed by the ICS/Contractor, requires Supplier to observe and advise on installation to extent required to certify that equipment has been properly installed and will perform as required.

B. For equipment not provided by the ICS, but that directly interfaces with the PICS, verify the following conditions: 1. Proper installation. 2. Calibration and adjustment of all instrumentation and control devices. 3. Correct control action. 4. Switch settings. 5. Opening and closing speeds and travel stops. 6. Input and output signals.

5.02 INSTALLATION

A. Material and Equipment Installation: 1. Follow manufacturer’s installation instructions, unless otherwise indicated or

directed by the OWNER/ENGINEER


2. Retain a copy of the manufacturer’s instructions at the project site, available for review at all times.

B. Wiring: 1. All wiring connected to PICS components and assemblies shall be in

accordance to the requirements of Division 16 and 17 of the Specifications.


A. General: All requirements listed in Subsection Source Quality Control, above, also apply to this Subsection, Field Quality Control.

B. Onsite Supervision: 1. The ICS Project Site Representative shall supervise and coordinate all onsite

PICS activities. 2. The ICS Project Site Representative shall be On-Site during total period

required to complete all On-Site PICS activities.

C. Startup and Testing Team: 1. Thoroughly check installation, termination, and adjustment for all PICS

Subsystems and their components. 2. Completed On-Site tests. 3. Provide and conduct startup services 4. Complete onsite training.

D. Sequence of Work: Provide individual ORTs and PATs for individual process equipment where required to support the staged construction and startup of the facility. Coordinate the construction sequencing requirements with the OWNER.

E. Specialty Equipment: For certain components or systems provided under this Section but not manufactured by the ICS, provide services of qualified manufacturer’s representative during installation, start-up, testing (both ORT and PAT) and OWNER’s training. For example: RTD calibrator, vibration shaker table (which may be furnished/operated by vibration sensor manufacturer representative), pressure calibrator, etc, shall be provided as required.

F. Operational Readiness Test (ORT): 1. Prior to start of the Performance Acceptance Test “PAT”, the ICS firm shall

inspect, test the PICS equipment and systems, document the resulting tests performed, implement all corrective actions necessary, perform all associated re-testing, and document that the PICS is installed and ready for operation. Subsequent to the ICS documentation that the PICS is installed and ready for operation, perform jointly with the OWNER an ORT on the associated PICS equipment to demonstrate that it is fully operable as required by the Contract Documents.

2. For PICS subsystems where the PLC application software is provided by the OWNER, provide sufficient temporary software configuring to allow testing of these subsystems.

3. Loop/Component Inspections and Tests: a. Check PICS for proper installation, calibration, and adjustment on a loop-

by-loop, and component-by-component basis.


b. Develop and provide forms as required to document ORT. All forms generated shall have provisions for signature by PICS representative.

c. Develop and provide test form hereinafter called the “Loop Status Report” to organize, track inspection, adjustment, and calibration of each loop. Loop Status Report shall include the following as a minimum: 1) Project name 2) Loop number 3) Tag number for each component 4) Checkoff/signoffs for each component:

a) Tag/identification b) Installation c) Wiring termination d) Tubing termination e) Calibration/adjustment

5) Checkoffs/signoffs for each loop: a) Panel interface termination b) PLC I/O interface terminations

6) PLC I/O Signals are Operational: Received/sent, processed, adjusted

7) Total loop operational 8) Space for comments.

d. Develop and provide test form hereinafter called the “Component Calibration Sheet” to organize, track inspection, adjustment, and calibration of each component (except hand switches, pilot lights, gauges, and similar items) and each PLCs I/O Module. The Component Calibration Sheet shall include the following as a minimum: 1) Project Name 2) Loop Number 3) Component tag number or I/O module number 4) Manufacturer name 5) Model number/serial number 6) Summary of functional requirements. For example:

a) Indicators b) Transmitters/converters, input and output ranges c) Computing elements’ functions d) Controllers, action (direct/reverse) and control modes (P&ID) e) Switching elements, unit range, differential (fixed/adjustable),

reset (auto/manual) f) PLC I/O modules: input or output

7) Calibrations, for example, but not limited to: a) Analog devices: Actual inputs and output at 0, 10, 50, and 100

percent of span, rising and falling b) Discrete Devices: Actual trip points and rest points c) Controllers: Mode settings (P&ID) d) PLC I/O Modules: Actual inputs or outputs of 0, 10, 50, and 100

percent of span, rising and falling. 8) Space for comments

e. Maintain loop status reports, valve adjustment sheets, and component calibration sheets at the project site and make them available to the OWNER at all times.


f. These inspections and tests, inclusive of the above described forms, will be spot checked by the OWNER.

g. The ICS shall implement all corrective measures needed and perform re-test on any modified sub-system/component.

h. The Contractor shall claim and validate a thorough ORT was performed successfully and all resulting corrective action measures taken were performed successfully and re-tested successfully. Upon successful completion of the ORT, the Contractor shall submit letter notification to the OWNER stating that the ORT has been successfully completed. The letter notification shall further state that the ICS is ready to begin the Performance Acceptance Test. Submit all forms upon completion of ORT as required by the OWNER.

G. Performance Acceptance Tests “PAT”: 1. Once the ORT has been successfully completed, perform jointly with the

OWNER a PAT on the associated PICS to demonstrate that it is operating as required by the Contract Documents. The PAT will employ the OWNER’s PLC application software developed for the project.

2. Minimum duration of the PAT shall be a cumulative total of forty-five (45) calendar days. The cumulative total quantity of calendar days shall be consumed in association and in synch with the overall construction sequence for the project. Any Holidays that occur during the PAT shall result in a corresponding number of days being added to the duration of the PAT. The PAT encompasses startup and testing period of the instrumentation and control system for the associated process and mechanical equipment that are controlled and monitored by the instrumentation and control system. The PAT shall be conducted using application software developed by the Engineer. The ICS shall test functions installed and the hard-wired system and the entire associated instrumentation and control system including validating the operation and monitoring and control functions of the all instruments, all control devices, all instrument and control components, control functions, alarm function, monitoring function, calibration ranges, control/alarm setpoint operations, etc. OWNER/Engineer shall test software functions. The ICS shall also test the DCS.

3. Demonstrate each required function on a paragraph-by-paragraph, loop-by-loop, and site-by-site basis based upon the operating description used by the OWNER for PLC application software development.

4. Non-loop specific tests shall be the same as previously required except that the entire installed PICS shall be tested using actual process variables and all functions demonstrated.

5. Perform local and manual tests for each loop before proceeding to remote and automatic modes

6. Where possible, verify test results using visual confirmation of process equipment and actual process variable. Unless otherwise directed, exercise and observe devices supplied by Others, as needed to verify correct signals to and from such devices and to confirm overall system functionality. Test verification by means of disconnecting wires or measuring signal levels is acceptable only where direct operation of plant equipment is not possible.

7. Make updated versions of documentation required for PAT available to the OWNER at the project site, both before and during tests.


8. Develop and provide PAT test forms that include the following, at minimum: a. Project name b. Lists the requirements of the loop c. Briefly describes the test d. Cites the expected results and the actual results e. Provides space for checkoff by witnesses.

9. Make one copy of all O&M manuals available to the OWNER at the site both before and during testing.

10. The ICS shall implement all corrective measures needed and perform re-test on any modified system.



END OF SECTION


SECTION 17101

SPECIFIC CONTROL STRATEGIES

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Descriptions:

a. Specific control requirements and functional descriptions for individual process equipment and systems.

B. Related sections: 1. Section 01300 – Submittals.

1.02 REFERENCES


1.03 DEFINITIONS

A. As specified in Section 17050

1.04 DESCRIPTIONS

A. Influent Flow Meters: 1. References:

a. 00N05 2. Equipment Tagging:

a. Thickening Centrate Influent Flow Meter: SST-FE-9101 b. Dewatering Filtrate Influent Flow Meter: SST-FE-9102

3. Abstract: a. Sludge Thickening Centrate Flow Meter:

1) The flow meter indicates the instantaneous flow from the Thickener Lift Station to the SSTP and totalizes the flow. Data is indicated locally and on SCADA.

2) Flow signal is sent to the sampler so that samples are paced on the incoming flow rate.

3) Flow signal is sent to the RAS Pumps by means of SCADA so that the return flow rate can be paced on the incoming flow rate.

b. Digested Sludge Dewatering Filtrate Flow Meter. 1) The flow meter indicates the instantaneous flow from the Digested

Sludge Dewatering Lift Station and totalizes the flow. Data is indicated locally and on SCADA.

2) Flow signal is sent to the sampler so that samples are paced on the incoming flow rate.

4. OIU control: a. None.

5. SCADA control: a. None.


6. SCADA and OIU Indicators and alarms: a. None.

7. Failure modes: a. None.

B. Influent Composite Samplers: 1. References:


a. Thickening Centrate Influent Sampler: SST-SAM-9101 b. Dewatering Filtrate Influent Sampler: SST-SAM-9102

3. Abstract: a. Each sampler is paced from its respective influent flow meter. The

sampler is able to set the sample rate on time or rate of flow. Sampler is capable of discrete sample or 24-hour composite sample.

4. OIU control: a. None.

5. SCADA control: a. None.

6. SCADA and OIU Indicators and alarms: a. None.


C. Primary Clarifier: 1. References:

a. 00N05 b. 11395A.

2. Equipment Tagging: a. Primary Clarifier Mechanism: SST-SE-001 b. Solenoid Valve: SST-SV-001

3. Abstract: a. The Primary Clarifier removes the heavier solids from the influent flow by

providing a quiescent zone so that the solids settle to the bottom of the basin and scum is allowed to float to the surface.

b. Settled sludge is moved to the center of the clarifier by the clarifier mechanism scraper where it is withdrawn via the Primary Sludge Pump(s).

c. Scum is moved to the perimeter scum baffle and swept up on the Scum Beach and trough where it is discharged into the Primary Scum Vault. Spray nozzles are used to flush the scum from the Scum trough into the vault. The spray water solenoid valve is activated by the Clarifier Scum Arm position indicator.

d. Clarifier mechanism is monitored for high torque, high-high torque, and high temperature.

4. OIU control: a. Start/Stop

5. SCADA control: a. Start/Stop

6. SCADA and OIU Indicators and alarms: a. Alarm on high torque. b. Alarm and shutdown on high-high torque.


7. Failure modes: a. As indicated on the Drawings and Section 11395A.

D. Primary Scum Vault: 1. References:


a. Solenoid Valve: SST-SV-002 b. Transducer Level Sensor: SST-LE-9201 c. Float Level Sensor: SST-LSLL-9202

3. Abstract: a. The scum from the Primary Clarifier is drained into the Primary Scum

Vault. The vault stores the scum until a sufficient amount is collected for pumping. A level sensor monitors the level and sends a signal to SCADA. When the level reaches the set point level and the pumps are called to start, the spray nozzles over the vault are begun by opening the solenoid valve on the water line. Nozzles operate for an adjustable time prior to the pumps starting and stop when the pump stops. A low level float is provided to shut down the pump if the level transducer fails to shut stop the pump on low level. An alarm is sent upon activation of the low level float.

4. OIU control: a. No OIU control.

5. SCADA control: a. As indicated on the Drawings and Specifications.

6. SCADA and OIU Indicators and alarms: a. As indicated on the Drawings and Specifications.

7. Failure modes: a. As indicated on the Drawings and Specifications.

E. Primary Sludge/Scum Pumps: 1. References:

a. 00N06 b. Section 11312Q.

2. Equipment Tagging: a. Pump 1: SST-SLP-001 b. Pump 2: SST-SLP-002 c. Pump 3: SST-SCP-001 d. Flow Meter: SST-FE-9203

3. Abstract: a. Three pumps are provided. Any of the pumps may be used to pump either

primary sludge or scum. A panel at each pump is provided with a selector switch to manually select the service. Selection of service can only be made at the pump station. Because of the piping configuration, if pump SST-SLP-001 is selected for pumping sludge then scum cannot be pumped. If pump SST-SLP-003 is selected for pumping scum then sludge cannot be pumped. Valves on the suction piping must be manually adjusted to match the selected service for each pump. Sludge and scum are combined in the discharge header and pumped to the headworks of the Hornsby Bend Biosolids Treatment Plant.

b. The pump selected for sludge service will be controlled by an adjustable timer in SCADA for starting and for run duration.


c. The pump selected for scum service will be controlled by the level transducer by means of SCADA in the Primary Scum Vault. Pump will start on the selected high level set point and will stop at the low level set point.

d. A flow meter will measure the combined sludge and scum flow. Instantaneous flow rate and totalized flow are indicated locally and on SCADA.

4. OIU control: a. Start/Stop for each pump

5. SCADA control: a. Start/Stop for each pump.



F. Anoxic Zone: 1. References:

a. 00N07 b. Sections 11332B.

2. Equipment Tagging: a. Mixer 1: SST-LMU-001 b. Mixer 2: SST-LMU-002

3. Abstract: a. The anoxic zone is for alkalinity recovery and nitrogen control. There is no

aeration in the zone. Two mixers are provided to keep the floc in suspension. The mixers can be started or stopped either manually or by SCADA. A local LOCAL-OFF-REMOTE panel is provided at each mixer. When operating, the mixers run continuously.

b. With the selector switch in the LOCAL position, the mixer can be started and stopped with the START-STOP switch.

c. With the selector switch in the REMOTE position, the mixer can be started and stopped through SCADA.

4. OIU control: a. Start/Stop for each mixer.

5. SCADA control: a. Start/Stop for each mixer.

6. SCADA and OIU Indicators and alarms: a. As indicated on the Drawings.

7. Failure modes: a. As indicated on the Drawings.

G. Aeration Zone: 1. References:

a. 00N07 b. Sections 11332B.

2. Equipment Tagging: a. Air Inlet Valve: SST-BFV-001


3. Abstract: a. Fine bubble diffusers provide air for mixing and oxygen for the biological

floc. Two dissolved oxygen probes are provided to monitor the dissolved oxygen in the Aeration Basin. The measured dissolved oxygen is indicated locally and on SCADA.

b. The signal from the dissolved oxygen probe at the north end of the basin is used to modulate the air inlet valve by means of SCADA. The valve modulates to maintain the dissolved oxygen at the selected set point.

c. A flow meter is provide to indicate the volume of air that is flowing to the Aeration Basin. Both instantaneous flow and totalized flow are indicated locally and on SCADA.

d. The basin is divided into four (4) aeration zones. Generally, the valves are adjusted to maintain a visual mixing pattern over the entire Basin with slightly move agitation in the first zone since it will have the highest oxygen demand.

4. OIU control: a. As indicated on the Drawings.

5. SCADA control: a. Open/Close.

6. SCADA and OIU Indicators and alarms: 7. As indicated on the Drawings. 8. Failure modes:

a. None.

H. Blowers: 1. References:

a. 00N07 b. Section 11376E.

2. Equipment Tagging: a. Blower 1: SST-PAB-001 b. Blower 2: SST-PAB-002 c. Blower 3: SST-PAB-003 d. Flow Meter: SST-FE-9304

3. Abstract: a. Three blowers are provided. The blowers provide the air for the Aeration

Basin. The output of the blowers is controlled by the pressure in the discharge pipe. The inlet damper adjusts the air intake to meet the pressure requirements. A vendor master control panel starts and stops the blowers and controls the blower output.

b. The blowers can be started and stopped manually. When run manually the automatic control of the output pressure and Aeration Basin DO control are not functional.

4. OIU control: a. Refer to manufacturers packaged control system.

5. SCADA control: a. Refer to manufacturers packaged control system.

6. SCADA and OIU Indicators and alarms: a. Refer to manufacturers packaged control system.

7. Failure modes: a. Refer to manufacturers packaged control system.


I. Secondary Clarifiers: 1. References:

a. 00N08 b. Section 11353B

2. Equipment Tagging a. Secondary Clarifier No. 1: SST-SE-002 b. Secondary Clarifier No. 2: SST-SE-003 c. Solenoid Valve: SST-SV-003 d. Solenoid Valve: SST-SV-004

3. Abstract: a. The Secondary Clarifier removes the biological floc from the mixed liquor

by providing a quiescent zone so that the solids settle to the bottom of the basin and scum is allowed to float to the surface.

b. Settled sludge is moved to the center of the clarifier by the clarifier mechanism scraper where it is withdrawn via the Returned Activated Sludge (RAS) Pump(s).

c. Scum is moved to the perimeter scum baffle and swept up on the Scum Beach and trough where it is discharged into the Secondary Scum Vault. Spray nozzles are used to flush the scum from the Scum trough into the vault. The spray water solenoid valve is activated by the Clarifier Scum Arm position indicator.

d. Clarifier mechanism is monitored for high torque, high-high torque, and high temperature.

4. OIU control: a. Start/Stop.

5. SCADA control: a. Start/Stop.

6. SCADA and OIU Indicators and alarms: a. Alarm on high torque. b. Alarm and shutdown on high-high torque.

7. Failure modes: a. As indicated on the Drawings and Section 11353B.

J. Secondary Scum Vault: 1. References:


a. Solenoid Valve: SST-SV-005 b. Transducer Level Sensor: SST-LE-9501 c. Float Level Sensor: SST-LSLL-9502

3. Abstract: a. The scum from the Secondary Clarifiers is drained into the Secondary

Scum Vault. The vault stores the scum until a sufficient amount is collected for pumping. A level sensor monitors the level and sends a signal to SCADA. When the level reaches the set point level and the pumps are called to start, the spray nozzles over the vault are begun by opening the solenoid valve on the water line. Nozzles operate for an adjustable time prior to the pumps starting and stop when the pump stops. A low level float is provided to shut down the pump if the level transducer fails to shut stop the pump on low level. An alarm is sent upon activation of the low level float.



5. SCADA control: a. As indicated on the Drawings and Specifications.



K. Secondary Scum Pumps: 1. References:


2. Equipment Tagging: a. Pump 1: SST-SCP-002 b. Pump 2: SST-SCP-003

3. Abstract: a. Two pumps are provided to pump the scum to the headworks of the

Hornsby Bend Biosolids Treatment Plant. b. The pumps alternate the Lead position upon stopping. c. Pump will start by means of SCADA on the selected high level set point

and will stop at the low level set point. 4. OIU control:

a. Start/Stop for each pump. 5. SCADA control:

a. Start/Stop for each pump. 6. SCADA and OIU Indicators and alarms:

a. As indicated on the Drawings and Specifications. 7. Failure modes:

a. As indicated on the Drawings and Specifications.

L. RAS Pumps: 1. References:


2. Equipment Tagging: a. Pump 1: SST-SLP-003 b. Pump 2: SST-SLP-004 c. Flow Meter: SST-FE-9602

3. Abstract: a. Two pumps are provided. Typically, one pump is used to pull sludge from

one clarifier and the other pump is used to pull sludge from the other clarifier. However, the piping and valving are provided to allow one pump to pull sludge from both clarifiers at the same time. The Returned Activated Sludge flow is measured and the signal sent to SCADA.

b. With the selector switch in the REMOTE position the pump output, by means of SCADA, is paced by the signal from the Thickening Influent Meter and the selected ratio of recycle to influent flow. The signal from the flow meter adjusts the speed of the pumps to maintain the selected ratio.

c. The pumps can be started and stopped manually from the Local Control Panel by placing the switch in the LOCAL position and using the Start-Stop switch. In manual mode, there is no flow pacing feature.


d. A flow meter will measure the combined flow from the pumps. Instantaneous flow rate and totalized flow are indicated locally and on SCADA.

4. OIU control: a. Start/Stop for each pump.




M. WAS Pumps: 1. References:

a. 00N12 b. Section 11312J.

2. Equipment Tagging: a. Pump 1: SST-SLP-005 b. Pump 2: SST-SLP-006 c. Flow Meter: SST-FE-9603

3. Abstract: a. Two pumps are provided for pumping Waste Activated Sludge (WAS).

The piping and valves are provided so that either pump can pull suction from both clarifiers at the same time. Or, a pump may be dedicated to a secondary clarifier. The pumped WAS is pumped to the headworks of the Hornsby Bend Biosolids Treatment Plant.

b. With the selector switch in the REMOTE position, the pump(s) for WAS service will be controlled by an adjustable timer by means of SCADA for starting and for run duration. Controls are provided so that a selected amount of WAS can be wasted over a 24-hour period.

c. With the selector switch in the LOCAL position, the pump(s) can be started manually with the Start-Stop switch.

d. A flow meter is provided to indicate and totalize the WAS volume pumped. Instantaneous flow rate and totalized flow are indicated locally and on SCADA.

4. OIU control: a. Start/Stop for each pump.




N. Effluent Metering: 1. References:

a. 00N10 b. Section 17380

2. Equipment Tagging a. Effluent Meter: SST-FE-9401


3. Abstract: a. The SSTP effluent flow is measure using a 6-inch Parshall flume and an

ultrasonic level sensor. b. Instantaneous flow is indicated locally. The totalized flow is also indicated

locally. c. Both the instantaneous and totalized flow data is transmitted to SCADA.


5. SCADA control: a. No SCADA Control.

6. SCADA and OIU Indicators and alarms: a. Instantaneous flow rate b. Totalized flow volume.


O. Effluent Lift Station: 1. References:

a. 00N10 b. Section 11312K.

2. Equipment Tagging a. Pump 1: SST-NP-001 b. Pump 2: SST-NP-002 c. Pump 3: SST-NP-003

3. Abstract: a. Three pumps are provided. Each pump has local means for selecting

LOCAL or REMOTE operation. In the LOCAL position, start and stop pushbuttons are used to start and stop the pump manually. With the switch in the REMOTE position, the pump, by means of SCADA, is controlled by the ultrasonic level sensor. The effluent pumps operating position of Lead or Lag 1 or Lag 2 will be controlled by means of SCADA.

b. Each pump is monitored for high temperature and for moisture intrusion. An alarm from either will stop the pump and keep it from restarting.

c. High level alarm and low level alarm for the wet well are provided by separate float level sensors. Low level alarm will stop any pump that is running.

4. OIU control: a. Refer to Section XXXXX for OIU control.

5. SCADA control: a. As indicated on the Drawings.

6. SCADA and OIU Indicators and alarms: a. As indicated on the Drawings.

7. Failure modes: a. As indicated on the Drawings.



PART 3 EXECUTION Not Used.

END OF SECTION


SECTION 17200

INSTRUMENTATION AND CONTROL CABINETS AND ASSOCIATED EQUIPMENT

PART 1 GENERAL

1.01 SUMMARY

A. Furnish, install, and put into satisfactory service the Main Instrumentation/Control Panels, Local Control Panels, Distributed Control System Panels as specified herein and as shown on the PLANS.

B. The requirements of this Section of the Specifications applies to all of the various types of instrumentation and control cabinets/boxes as specified herein and shown on the PLANS.




1.03 SUBMITTALS

A. Submit the following in accordance with the Section 01330 and 01730 of the Specifications: 1. Shop drawings and product data. Include paint color selection chart for

selection of paint color by OWNER. 2. Operation and maintenance manuals.


A. Furnish the following spare parts in conformance with the specifications: 1. One set (minimum 3) of fuses for each type and size used. 2. One set (minimum 3) of Circuit Breaker Overcurrent Protection Devices for

each type and size used. 3. Twenty (20) terminal blocks of each color and type used. 4. Four (4) control relay assemblies of each type specified, complete with all

accessories. 5. Four (4) timing relay assemblies of each type specified, complete with all

accessories. 6. Two (2) complete Instrument Loop Current Isolators (I/I converters) for each

type used. 7. Two (2) complete 24VDC power supplies for each type used. 8. 25 percent spare push-buttons, selector switches, indication light assemblies

for each type used (minimum of 2 per type).


9. 50 percent of spare lenses and lamps for each type, color and size used (minimum of 4 per type)

10. 50 percent spare instrument loop surge suppressors.

PART 2 PRODUCTS

2.01 INSTRUMENT AND CONTROL CABINETS/PANELS/BOXES

A. General: 1. The various instrument and control cabinets/panels shall be constructed to the

approximate dimensions and instrument arrangement as shown on the PLANS. The ENGINEER will review alternate arrangements and recommendations.

2. Hinges and doors shall be capable of supporting weight of equipment mounted on doors.

3. Mounting channels and interior panels shall be provided in the cabinets for mounting terminals, relays, etc.

4. The cabinet shall be completely assembled and wired at the factory such that installation can be accomplished by connecting field wiring to terminal strips located in the panel.

5. Furnish and install both isolated and non-isolated ground bars for each cabinet. Furnish and install for each ground bus: a. Required number of terminals for proper wiring in addition to 20 percent

spare terminals for future connections b. Isolated Ground Bus Only: 600 volt mounting isolators. c. Certain microprocessor based control equipment will (PLCs, etc.) require

the connection of both distorted and undistorted (isolated) ground wires. Provide this wiring as required.

B. Freestanding Cabinets/Panels: 1. Type: Free Standing, modular design, completely enclosed 2. Configuration: Provide Single Bay and Double Bay as required. Use Double-

Bay where possible. Each Single Bay section shall have one door, each Double-Bay section shall have two doors, unless specifically shown otherwise on the PLANS. Provide sections with rear doors where specifically shown on the PLANS.

3. Enclosure Material: Steel 4. Framing Member Thickness: 12 gauge, minimum 5. Door/panel member Thickness: 14 gauge, minimum. 6. Rating: NEMA-12 gasketed 7. Finish: Prime and paint using manufacturer’s standard process. 8. Finish color: For Contract Bidding purposes, Foxboro beige with textured

finish. The final exterior cabinet components color shall be selected by the OWNER after Contract Bid Award.

9. Interior Panel Finish Color: All interior back and side panels shall be painted white.

10. Additional Requirements for each Door: a. Solid, Gasketed, and Hinged b. 3-point latching mechanism, door latch rods shall have rollers. c. Oil-tight key-locking handle. d. Reinforcing bars for inner device panels


e. Data pocket, f. Door stop kit g. Thermostatically controlled exhaust fan complete with filtered louver. Fan

rated for 120 volts A. C. Connect as shown on the PLANS. Refer to the PLANS. Exception: fans and louvers are not required for rear doors.

h. Air intake/exhaust louver. Refer to the PLANS. i. Electrically bonded to the frame using manufacturer’s grounding device

assembly and #8 AWG green insulated ground wire. 11. Comply with the requirements of the PLANS. 12. Miscellaneous Accessories:

a. Provide each section with 7.5-inch high solid plinth base. Include solid base access panel covers.

b. Provide 1-1/2 inches high removable heavy-duty fiberglass floor grating at the bottom of each section (above the plinth base). The floor grating shall meet OSHA safety standards for personnel traffic. Wiring routed underneath grating shall be neatly laced/arranged.

c. Include all back, joining, side, hinged swing-out, etc. panels, slide-out shelves, 19” rack mounting brackets, all associated mounting hardware to facilitate a complete installation and a totally enclosed overall cabinet. Also refer to the PLANS. All panels shall be full height unless specifically shown otherwise on the PLANS.

d. Removable lifting eyes e. Panel stabilizers and extra support brackets where conduit connects to

the enclosures. f. Cabinet manufacturer’s additional hardware and component accessories

shall also be provided that will result in a neat, safe, aesthetically pleasing installation.

g. Provide overall master nameplate for the cabinet, as hereinafter specified, with the exception that the text height shall be 3/8 inch.

13. The cabinets shall be as manufactured by “HOFFMAN” Model PROLINE Modular Industrial Enclosures complete with specified accessories, or approved equal by “RITTAL”

C. Wall/Rack Mounted Cabinets/Panels 1. Each enclosure shall be 316 stainless steel NEMA 4X. Enclosure shall be

equipped with hinged doors complete with 1/4 (quarter) turn door latches. Provide door latch handle.

2. Each enclosure door assembly shall be furnished with manufacturer's door stop kit that will hold the door open in any position between 0-130 degrees. Each door shall be electrically bonded to the frame of the associated enclosure with #8 AWG 600 volts insulated green ground wire. Utilize manufacturer's grounding device assembly. The inside of each door shall be equipped with the manufacturer's data-pocket for storing drawings and manuals.

3. Each enclosure shall be furnished with a full and solid backpanel (one piece full subpanel). The backpanel shall extend the full height and width of the cabinet/panel.

4. Cabinet/Panel manufacturer's additional hardware and component accessories shall also be provided that will result in a neat, safe, aesthetically pleasing installation. Adherence to this requirement is necessary in order to accomplish


a good craftsmanship-like system installation to the satisfaction of the Owner and Engineer.

5. Each enclosure shall be as manufactured by "Hoffman" model Concept series industrial enclosures complete with specified accessories, or approved equal by "Rittal".

6. The minimum anticipated panel size for each wall/rack mounted cabinet/panel is shown on the PLANS. The Contractor shall size each cabinet/panel per the requirements of the NEC. Contractor to determine exact as-built size required for the cabinet/panel to meet the contract documents (drawings and specifications) without any additional cost to the Owner (should the final size be larger than that which was anticipated by the PLANS). Additionally, the Contractor is to carefully review the electrical/control floor plan drawing and make any adjustments/equipment rearrangements necessary to meet National Electrical Code requirements and any other safety codes adopted by the City of Austin should the cabinet/panel size be any greater/larger than the minimum size required by the PLANS. Conduit/wiring, etc. adjustment caused by any equipment rearrangement, etc. shall also be provided at no additional cost to the Owner.

2.02 INSTRUMENT AND CONTROL WIRING

A. General wiring and control Power and alarm wiring: 1. Extra flexible, #14 AWG, tin plated copper conductor 600V insulation, SIS wire

manufactured by General Cable Company, The Okonite Company or approved equal. The pigmentation of the wire insulation shall conform to the color table listed below:

Wiring Function Wire Jacket Color

Wiring for 120 volts A.C. control/status/alarm Red

Wiring to actuate electro-mechanical relay coils only Gray

Wiring for 120 volts A.C. power wiring Gray

Wiring for 24 volts D.C. power supply wiring Blue = Positive

Brown = Negative

Wiring for 120 volts A.C. light fixtures and convenience receptacles

Black = Line

White = Neutral

Wiring to Discrete Input PLC modules Violet

Wiring to Discrete Output PLC modules Pink

B. 4-20 Milliamp Signal wiring: 1. Number of Pairs: One 2. Wire Size: #16 AWG 3. Type of Conductors: Stranded copper conductors, twisted 4. Individual Conductor Insulation: PVC


5. Individual Conductor Insulation Color: Positive (+) is Black, Negative (-) is White

6. Drain Wire: Tinned copper 7. Overall Shield: Aluminum-mylar shield. 8. Overall Jacket: PVC 9. Overall Jack Color: Black. 10. Manufacturer: Samuel Moore and Company, Dekoron Division, Cat. No. 1852

or approved equal.

C. Multi-Conductor RTD Temperature Signal Wiring: 1. Number of Triads: One 2. Wire Size: #16 AWG 3. Type of Conductors: Stranded copper conductors, twisted 4. Individual Conductor Insulation: PVC 5. Individual Conductor Insulation Color: Positive (+) is Black, Negative (-) is

White, Sense (S) is Red. 6. Drain Wire: Tinned copper 7. Overall Shield: Aluminum-mylar shield. 8. Overall Jacket: PVC 9. Overall Jack Color: Black. 10. Manufacturer: Samuel Moore and Company, Dekoron Division, Cat. No. 1862

or approved equal.

D. RS-232 ModBus Digital Data Communication System Wiring: 1. Number of Pairs: Two 2. Wire Size: #22 AWG 3. Type of Conductors: Tinned stranded copper conductors, twisted 4. Individual Conductor Insulation: 300 volt PVC 5. Individual Conductor Insulation Color: Red, Black, Green, and White. 6. Drain Wire: No. 24 AWG Tinned copper 7. Overall Shield: Aluminum-mylar shield. 8. Overall Jacket: PVC 9. Overall Jacket Color: Chrome. 10. Manufacturer: Belden, Catalog No. 8723, or approved equal.

E. Fiber Optic Cable: 1. Refer to Section 17600 Distributed Control System.

2.03 INSTRUMENTATION AND CONTROL CABINETS EQUIPMENT

A. Overcurrent Protection 1. General: Individually protect each device as shown on the PLANS. Furnish

and install protection using the devices shown on the PLANS and as specified hereinafter.

2. 120 volts AC circuit Protective Devices: a. Ratings: 120 volts A. C., one pole. Size per NEC. Note: Use 20 ampere

rating for control panel convenience receptacles. b. Certifications: U. L. Listed. c. Mounting: Din Rail Mountable d. Indications: Visible trip indicator e. Manufacturer: Allen-Bradley Series 1492-SP, Phoenix Contact, or

approved equal.


3. 24 volts DC circuit breakers: a. Ratings: 24 volts DC, one pole. Size per NEC. b. Certifications: U. L. Listed c. Mounting: DIN rail mountable d. Indications: Visible trip indicator e. Manufacturer: Allen-Bradley Series 1492-GH, Phoenix Contact, or

approved equal.

B. Convenience Receptacle: 1. Furnish and install where required by the PLANS. Additional receptacle

assembly features are as follows: a. Specification grade b. Duplex, 3-wire, polarized grounding type, rated 20 amp, 125 volt, 60 Hertz c. Ivory Color d. Manufacturer: Hubbell No. HBL5362I, Bryant, Pass and Seymour, or

approved equal. e. Coverplate: 304 brushed stainless steel, as manufactured by Hubbell,

Killark, or approved equal. f. Install in NEMA-1 enclosure inside of the control panel.

C. Lighting Fixture: 1. Furnish and install where required by the PLANS. Additional light fixture

features are as follows: a. Type: LED b. Voltage: 120 volts A.C c. Length: 14 inches d. Lumens per fixture: 400 lumens e. Although it may not be shown on the PLANS, furnish and install two light

fixtures per vertical section of control panel enclosure f. Motion sensors shall not be accepted. g. Furnish and install manufacturer’s extension cable to connect to fixture. h. Furnish and install door switch wired to switch the light based upon door

position

D. Pushbuttons, Selector Switches, Pilot Lights 1. General Requirements:

a. Rating: NEMA 4X corrosion resistant, Heavy Duty b. Size: NEMA Style full size 30-millimeter (30mm), c. Contacts: 10 ampere minimum at 120 volts A.C. Provide number of

contacts to satisfy the requirements of the PLANS. d. Legend Plate: Furnish and install per manufacturer’s standard with

inscription as shown on the PLANS. e. Manufacturer: Allen Bradley Bulletin 800H, or approved equal.

2. Additional Requirements for Selector Switch/ Pushbuttons: a. Operator Color: Furnish and install the color as shown on the PLANS,

black otherwise. b. Selector Switch Action Type: Maintained action, unless shown otherwise

on the PLANS. c. Pushbutton Action Type: Momentary action, unless shown otherwise on

the PLANS. 3. Additional Requirements for Pilot Lights:


a. Type: Transformer Type Light Emitting Diode (LED), b. Style: Push-to-test c. Lens Color: Furnish and install the colors as shown on the PLANS.

4. Additional requirements for Emergency Stop/Trip Push-Button Stations: a. Action Type: Push-Pull maintained b. Operator Type: Mushroom head c. Operator Color: Red, unless shown otherwise on the PLANS d. Padlock attachment: Furnish and install as manufactured by Allen-Bradley

Bulletin Push-Pull Padlocking Attachment Catalog Number 800T-N314, or approved equal.

e. Padlock: Furnish and install padlock with 0.25 inch diameter padlock shackle. Coordinate the shackle diameter with the padlock attachment. Furnish and install padlock as manufactured by Master Lock, or approved equal.

E. Control Relays: Control relays shall be furnished and installed as required by the schematic diagrams. All control relays shall be Type I relays unless specifically noted otherwise on the PLANS or as specified hereinafter. 1. Type I Control Relays:

a. Type: 300 volt “Ice-Cube” type b. Rated: Pilot-Duty C300 rated c. Coil Voltage: 120 volts A.C. d. Contact Rating: 10 ampere at 120 volts A.C. e. Number and Configuration of Contacts: three Form-C Contacts (3PDT) f. Position Indication: Integral LED pilot light g. Manual Operator: Integral to relay h. Mounting: DIN rail mountable socket i. Accessories: Socket, Retaining Clip, Relay Manufacturer’s Transient

Voltage Suppression Module. j. Manufacturer: “Allen-Bradley” Bulletin 700-HA33A1-3-4, complete with

700-HN203 socket, 700-HSV3 surge suppressor, and 700-HN151 retainer clip, or approved equal.

k. The following are additional requirements associated with Type I control relays: 1) Of the maximum of three Form-C type contacts that are available

from each Type I Control Relay, one of the Form-C contacts shall be dedicated as “spare” and wired to terminal blocks for future use by the OWNER. Multiple Type I relay coils shall not be connected in parallel in order to develop additional contacts as may be shown on the PLANS. Should the PLANS require greater than two contacts from a control relay, then furnish and install a Type II Control Relay in lieu of a Type I Control Relay.

2. Type II Control Relays: a. Type: 600 volt Heavy-Duty industrial type b. Rated: NEMA rated c. Coil Voltage: 120 volts A.C. d. Contact Rating: 10 ampere at 120 volts A.C. e. Number and Configuration of Contacts: 4 Normally Open and 4 Normally

Closed, at minimum. Furnish and install one additional normally open (N.O.) and one additional normally closed (N.C.) contact, over that required by the PLANS. Field configurable type contacts.


f. Position Indication: Visual mechanical unlatch-latch indicator g. Mounting: Provide universal mounting strip/plate for backpanel mounting. h. Accessories: Relay Manufacturer’s Transient Voltage Suppression

Module i. Manufacturer: Allen Bradley Bulletin 700-P, or approved equal.

3. Type III Control Relays: a. Type: 300 volt “Ice-Cube” type b. Coil Voltage: 24 volts D.C. (nominal voltage) c. Position Indication: Integral LED pilot light d. Manual Operator: Integral to relay e. Contact Rating: 10 ampere at 120 volts A.C. f. Number and Configuration of Contacts: four (4) Form-C Contacts (4PDT) g. Mounting: DIN rail mountable socket h. Accessories: LED indicator light, Push-to-Test button, socket and

retaining clip i. Miscellaneous: Used only where specifically noted on the DRAWINGS. j. Manufacturer: "Allen-Bradley", catalog 700-HF34Z24-3-4, complete with

relay socket base catalog number 700-HN139 and relay retaining clip 700-HN140, or approved equal.

F. Timing Relays: 1. Type: Solid state, multi-time, and multi-function type relay. Both timing ranges

and timing modes shall be field selectable. Each relay shall be capable of the following timing modes: On Delay, Off Delay, One Shot, Repeat Cycle, and Interval

2. Coil Voltage: 120 volts A. C. 3. Contact Rating: 10 amps, continuous, at 120 VAC. 4. Number and Configuration of Contacts: 2 Form C (2PDT) 5. Mounting: DIN rail mountable socket 6. Accessories: Socket, DIN rail mountable 7. Manufacturer: Square D Class 9050 model No. JCK70 complete with Type

NR61 Socket, or approved equal.

G. Speed Control Potentiometer Transmitters: 1. Input: 3-wire potentiometer ranging from 0-100 ohms through 0-10,000 ohms. 2. Output: 2-wire loop powered, 4-20mA signal proportional to the percent (%)

travel of the potentiometer (input signal). 3. Adjustments: Twenty-two turn potentiometers

a. Span: 0-100 percent adjustable over selected input range of 15%-100% of potentiometer value.

b. Calibration Capability: +/- 0.1% of full span (linearity and repeatability). 4. Ambient Temperature: -20°F to +180°F 5. Housing: High-density type, DIN-rail mount 6. Range: Verify with manufacturer of Potentiometers and/or manufacturer of the

Adjustable Speed Drive units (ASD) prior to ordering the transmitters. 7. Accessories:

a. Front accessible terminal blocks b. RFI filter terminal assembly

8. Identification: Tag by loop number and loop process identification. Refer also to the PLANS.


9. Manufacturer: MOORE Industries Model PTX with specified accessories, or approved equal.

H. Single Input, Dual Output Instrument Loop Current Isolators (I/I Converters) 1. Number and Type of Input Signals: One 4-20mA input signal 2. Number and Type of Output Signals: Two 4-20 mA isolated output signals.

Integral load trimmer. 3. Maximum Load: 1200 Ohms per output channel. 4. Power Requirements: External 24 VDC supply as also shown on the PLANS. 5. Accuracy: +/- 0.1% of full span 6. Housing: Corrosion resistant metal 7. Mounting: DIN rail mountable. 8. Noise Protection: Provide RFI /EMI protection such that less than +/- 0.1 % of

span error is incurred when tested against a reference signal of 30 volts per meter over the frequency range of 20 to 1000 MHz, inclusive.

9. Transmitter Excitation: Provide with field selectable transmitter excitation option which allows the isolator to supply 24VDC power to a 2-wire instrument connected to the isolator input.

10. Manufacturer: MOORE Industries Model ECT-DIN with TX, or approved equal.

I. Single Input, Single Output Instrument Loop Current Isolators (I/I Converters) 1. Number and Type of Input Signals: One 4-20mA 2. Number and Type of Output Signals: One 4-20mA. Integral load trimmer 3. Maximum Load: 1000 Ohms 4. Power Requirements: External 24 VDC supply as also shown on the PLANS. 5. Accuracy: +/- 0.1% of full span 6. Housing: Corrosion resistant metal 7. Mounting: DIN rail mountable 8. Noise Protection: Provide RFI/EMI protection such that less than +/- 0.1 % of

span error is incurred when tested against a reference signal of 30 volts per meter over the frequency range of 20 to 1000 MHz, inclusive.

9. Transmitter Excitation: Provide with field selectable transmitter excitation option which allows the isolator to supply 24VDC power to a 2-wire instrument connected to the isolator input.

10. Manufacturer: MOORE Industries Model ECT-DIN with TX option, or approved equal

J. Instrument Loop Surge Suppressors 1. General:

a. Application: Furnish field-mount instrument loop surge suppressor for instruments where shown on the PLANS. In conjunction with each field-mount surge suppressor, furnish a surge suppressor inside the instrumentation and control cabinet.

2. Surge Suppressors Inside the Instrumentation and Control Cabinet a. Operating Voltage: 28 Volts b. Maximum Operating Voltage: 30 Volts c. Maximum Operating Current: 200mA d. Clamping Action Turn-On: 31.4 Volts e. Maximum Clamping at 2kA (8x20 µsec): 46 volts f. Maximum Surge Voltage: 20kV


g. Maximum Surge Current (8x20 µsec): 2.5kA/line h. Current Leakage/Line at Operating Voltage: 5 µA i. Capacitance/Line at Rated Voltage: 500pF j. Response Time: <1 nanosecond k. Operating and Storage Temperature: -40°F to +185°F l. Mounting: Plug into MOORE Industries DIN instrument loop current

isolators m. Manufacturer: MOORE Industries DIN-Plug Surge Suppressor, part

number 205-863-01, or approved equal. 3. Field-Mount Surge Suppressor

a. Operating Voltage: 28 Volts b. Maximum Operating Voltage: 30 Volts c. Maximum Operating Current: 650mA d. Clamping Action Turn-On: 34.2 Volts e. Maximum Clamping at 3kA (8x20 µsec): 50 volts f. Maximum Surge Voltage: 20kV g. Maximum Surge Current (8x20 µsec): 2.5kA/line h. Current Leakage/Line at Operating Voltage: 5 µA i. Capacitance/Line at Rated Voltage: 1nF j. Response Time: <1 nanosecond k. Operating and Storage Temperature: -40°F to +185°F l. Enclosures:

1) Single surge suppressor in an enclosure. Refer to the PLANS. a) Explosion-proof enclosure with aluminum body and cover with a

chromatic conversion seal undercoat and a TGIC Polyester powdercoat.

b) Aluminum enclosure mounting bracket with black sulfuric acid anodized finish.

c) Manufacturer: MOORE Industries series BH enclosure, or approved equal.

2) Multiple surge suppressors in a common enclosure. Refer to the PLANS. a) Enclosure shall be as specified in this Section of the

Specifications, Subsection 2.01 C “Wall/Rack Mounted Cabinets/Panels”. (1) Exception: Enclosure door stop kit and data pocket are not

required. m. Manufacturer: MOORE Industries Field-Mount Surge Suppressor, part

number 205-863-12 with specified enclosures, or approved equal.

K. Instrument Control Panels/Cabinets Dual Input Single Output 24VDC Instrument Loop Power Supply: 1. Number of inputs and voltage: Two, 120 volts A.C. 2. Number of outputs and voltage: Two, 24 volts D.C. 3. Type: Dual Redundant primary-backup (secondary) arrangement 4. Topology: Two switching type power supplies connected in parallel via current

steering diodes with automatic switchover from the primary to the backup (secondary) power supply unit.

5. Input Power Regulation: 0.2% from 105 to 130 VAC. 6. Output Current, per unit: 15 ampere 7. Output Voltage Adjustment Range: 24 to 28 VDC, field adjustable


8. Output Voltage Ripple: 0.5% at full load, maximum 9. Output load regulation: 0.2% maximum from zero to full load. 10. Output Protection: Integral current limiting and over voltage 11. Common Alarm Contact Ratings: 5 ampere at 120 volts A.C. 12. Mounting: Provide rack/wall mounting configuration as shown on the PLANS 13. Accessories:

a. Draw-out handles mounted on the face of the power supply unit. b. Voltage level analog indicator, one per source (primary and redundant). c. Current level analog indicator, one per source (primary and redundant) d. Ventilated metal case.

14. Manufacturer: Acopian Switching Regulated Redundant Power Package, or approved equal.

L. Instrument Control Panels/Cabinets Single Input Single Output 24VDC Instrument Loop Power Supply: 1. Number of inputs and voltage: One, 120 volts A.C. 2. Number of outputs and voltage: One, 24 volts D.C. 3. Type: Suitable for use as a single stand-alone power supply as well as

parallel operation in conjunction with a second power supply and a redundancy/switchover module. Field selectable switch for single or parallel operation.

4. Topology: Switching type power supply. 5. Output Current, per unit: 10 ampere 6. Output Voltage Adjustment Range: 22 to 28.5 VDC, field adjustable 7. Output Voltage Ripple: 50 milliVolts at full load, measured peak-to-peak,

maximum 8. Output load regulation: 2% maximum from zero to full load. 9. Output Protection: Integral current limiting and over voltage 10. Common Alarm Contact Ratings: 2 ampere 11. Mounting: Provide DIN rail mounting configuration. 12. Accessories:

a. Ventilated metal case. 13. Manufacturer: Sola/Hevi-Duty Model SDN 10-24-100P, or approved equal.

M. Instrument Control Panels/Cabinets 24 VDC Power Supply Redundancy/Switchover Module: 1. Number of inputs and voltage: Two, 24 volts D.C. 2. Number of outputs and voltage: One, 24 volts D.C. 3. Type: Unit shall have the capability to immediately and automatically transfer

load from the primary to the backup (secondary) power supply unit, as also shown on the PLANS.

4. Topology: Switching type power supply. 5. Output Current, per unit: 40 ampere 6. Vout Alarm Contact Ratings: 2 ampere at 240 volts A.C. 7. Vin Alarm Contact Ratings (2 contacts, one for each input): 2 ampere at 240

volts A.C. 8. Mounting: Provide DIN rail mounting configuration. 9. Accessories:

a. Ventilated metal case b. Green light emitting diode (LED) to indicate output voltage exceeds 18

volts D.C.


10. Manufacturer: Sola/Hevi-Duty Model SDN 30/40RED, or approved equal.

N. Thermostat: 1. Type: Heavy Duty line voltage type, suitable for use in controlling heating and

cooling circuits. Shall have field adjustable temperature setpoint and also display the measured ambient temperature.

2. Measurement Range: a. Thermostat: 40 to 90 degrees Fahrenheit b. Thermometer: 50 to 90 degrees Fahrenheit

3. Sensing Element: Liquid filled with diaphragm and lever mechanism 4. Thermometer: Bi-metal type 5. Number and Type of Output Contacts: One Single Pole Double Throw

(SPDT), snap acting 6. Contact Ratings:

a. Heating Contact: 16 ampere at 120 Vac. b. Cooling Contact: 8 ampere at 120 Vac

7. Enclosure: Thermoplastic cover, suitable for vertical or horizontal mounting configuration

8. Accessories: a. Provide temperature adjustment knob b. Provide faceplate with each thermostat with temperature measured in

degrees Fahrenheit. Faceplate shall include cutout such that the measured ambient temperature is visible.

c. Mount each thermostat in a device enclosure on the enclosure backpanel in accordance with the manufacturer’s recommendations.

9. Manufacturer: Johnson Controls Model T26T Series Line Voltage Thermostat, or approved equal

O. Terminal Blocks: 1. General:

a. All terminal blocks shall be provided with manufacturer’s standard snap-in marker card and holder as manufactured by Allen-Bradley Bulletin No. 1492-SMN81, Phoenix Contact, or approved equal. Provide manufacturer’s standard typed adhesive terminal block tag for each terminal block.

b. Provide manufacturer’s standard insulating jumpers, DIN rail, barriers, end anchors, etc., and all related mounting hardware as required for a complete and functional installation. Coordinate models of terminal block accessories such as end anchors, jumpers, DIN rail, etc., with the terminal blocks as specified hereinafter for a complete and functional installation.

2. Type I Terminal Blocks: a. Rating: 600 volts A.C./D.C., 55 ampere b. Type: Single Layer c. Wire Range: No. 22 through No. 8 AWG d. Material: Nylon or polypropylene e. Quantity per Foot: 37 f. Color: As specified hereinafter. g. Manufacturer: Allen-Bradley Bulletin 1492-HM3, Phoenix Contact, or

approved equal. 3. Type II Terminal Blocks:

a. Rating: 300 volts A.C./D.C., 12 ampere


b. Type: Single Layer, fused terminal blocks c. Wire Range: No. 30 through No. 12 AWG d. Material: Nylon or polypropylene e. Quantity per Foot: 33 f. Fuse: Bussman ¼ inch x 1-1/4 inch. g. Miscellaneous: Provide with LED blown fuse indicator h. Manufacturer: Allen-Bradley Bulletin 1492-H5, Phoenix Contact, or

approved equal. 4. Terminal Block Colors: Provide terminal blocks with the colors as follows:

Terminal Block Function Terminal Block Color

Terminal Blocks for 120 volts A.C. control/status/alarm/ PLC monitoring

Red

Terminal Blocks for 120 volts A.C. power wiring Black

Terminal Blocks for Ground wiring Green

Terminal Blocks for 24 volts D.C. wiring White

P. Flexible spiral wrapping: Size as required. Provide as manufactured by Electrovert Spiraband, or approved equal.

Q. Plastic Wireway: Size as required. Also refer to the PLANS. Provide white color unless specified otherwise. Provide as manufactured by Panduit, or approved equal.

R. Multi-Outlet Power Strip: Furnish and install where shown on the PLANS. 1. Shelf Mounted: Provide white color unless specified otherwise. Multi-Outlet

Power Strip shall have six 15 ampere, 120 volt NEMA 5-15R receptacles, U. L. Listed, main circuit breaker and integral on/off switch and indicator light and integral 4 foot power cord. Furnish and install as manufactured by Kensington Model 50688 or approved equal.

2.04 PROGRAMMABLE LOGIC CONTROLLERS “PLCS”, AND ASSOCIATED EQUIPMENT

A. Refer to Specifications Section 17600, “Distributed Control System” of the Specifications.

2.05 INSTRUMENTATION AND CONTROL CABINETS UNINTERRUPTIBLE POWER SUPPLY (UPS)

A. Furnish and install a UPS inside the control panel enclosure where shown on the PLANS. Each UPS shall be as follows: 1. General:

a. Apparent Power: Provide for the maximum connected load and as shown on the PLANS.

b. Run Time (without input power): Minimum duration of fifteen (15) minutes in the event of permanent power loss to the UPS AC input with the UPS serving all connected load at full load.


c. Power Factor: greater than 0.9 d. Operating Temperature Range: 0 - 40 °C, with relative humidity of 20 -

90%. e. Storage Temperature Range: -20 - 40 °C, with relative humidity of 20 -

90% (without condensation). f. Provide additional features as shown on the PLANS.

2. Input: a. Input Voltage: 120 volts AC, 60 Hz. b. Connections: Integral AC power cord with ground.

3. Output: a. Wave form: Continuous, 120 volts AC, 60Hz. sine wave. b. Voltage distortion: 5% at full load, maximum. c. Filtering: Filtered with 0.3% IEEE surge let-through and zero clamping

response time, complying with UL 1449 requirements. d. Connections: Minimum of four 120VAC, (4) 15A output receptacles, at

minimum. Coordinate the receptacle configuration with that required by the external maintenance bypass switch.

4. Batteries: a. Type: Maintenance-free, fumeless, sealed, leak proof battery that is

accessible for replacement by the OWNER. The batteries shall be rated for use in Computer Rooms (by NFPA and all other Safety Codes).

b. Recharge Rate: Maximum of five (5) hours to charge to 95 percent capacity.

c. Provide battery extension cabinet where required to obtain a minimum duration runtime of fifteen (15) minutes for the connected load in the event of a power loss and where shown on the PLANS.

5. External Maintenance Bypass Switch: a. The UPS shall be provided with a manufacturer’s standard external

maintenance bypass switch. The external maintenance bypass switch shall be sized such to carry the full load current of the UPS inclusive of inrush current, at minimum. Also refer to the requirements shown on the PLANS. The maintenance bypass switch shall be installed in such a manner that the selector switch is accessible from the front of the control cabinet. Provide any additional accessories necessary to facilitate the installation of the maintenance bypass switch.

6. Features: a. The UPS shall consist of a field configurable bypass mode for automatic

or manual bypass to the AC input source. b. The UPS shall consist of automatic self test, executed on start up and at

regular intervals (minimum of once per 14 days), and fault detection LED annunciating self test failure.

c. The UPS shall consist of automatic voltage regulation to maintain its sine wave output in accordance to these specifications. The settings for the UPS AC input source voltage high and low values to initiate transfer to battery power shall be field adjustable.

7. Indications (LED type) and alphanumeric display: a. UPS On Status b. Fault c. On Battery d. Bypass e. Battery Replacement Needed


8. Audible Alarms: a. UPS failure b. Battery failure c. Power loss to the UPS

9. Push Buttons: a. Energizing UPS b. De-energizing UPS c. Manual UPS Self test initiation

10. Warranty: Two (2) year manufacturer’s warranty. 11. Accessories:

a. The UPS shall consist of a relay I/O module which provides 24VDC, 1A rated relay output contacts. At minimum, the card shall consist of a dry contact indicating UPS fault, a dry contact indicating requirement for Battery Replacement, and a dry contact indicating that the UPS is in Bypass. Wire the UPS fault alarm, the battery replacement alarm, and the UPS in bypass status in series to a 24VDC rated Type III control relay as specified in section 17200. An alarm contact from the 24VDC UPS fail relay shall be wired as a discrete input into the programmable logic controller to indicate a UPS common trouble/fail alarm. Also refer to PLANS for wiring to the UPS relay I/O module.

b. The UPS shall be provided with all necessary interconnecting cables, connectors, Windows compatible configuration software (if necessary), for a complete and functional installation.

12. Mounting: a. Provide for the mounting configuration as shown on the PLANS:

1) Type 1: Provide all 19 inch rack mounting brackets, miscellaneous mounting hardware necessary to facilitate the rack mounting of the UPS inside the Instrumentation and Control Cabinet.

2) Type 2: Provide all upright position mounting supports necessary to facilitate installation of the UPS tower on the floor of the Instrumentation and Control Cabinet.

b. Mount UPS within the control cabinet, without obstructing access to components within cabinet. Install UPS in accordance to manufacturer’s requirements and recommendations, including proper UPS power termination, ventilation, and cooling.

13. Manufacturer: Eaton Model 9PX Series UPS with external maintenance bypass switch Eaton HotSwap MBP Model EHBPL****R-PDU1U (where **** is based on UPS rating), and Relay Interface Card Eaton Model No. 9120, or approved equal.

2.06 IDENTIFICATION

A. Instrument and Control Devices Identification 1. General:

a. The device designations shall agree with those shown on the PLANS. b. Each device shall be provided with permanent type identifying nameplate. c. Nameplates:

1) Type: 3-ply, 1/8” thick, rigid thermoset phenolic resin laminated cellulose paper base engraving stock per ASTM D-709, Type I. Nameplates shall be ASTM Grade ES-1, ES-2, or ES-3 as applicable


for the face and lettering colors specified hereinafter. Flexible or acrylic tags will be not be accepted.

2) Color: White-Black-White, unless shown otherwise on the PLANS. 3) Lettering: 1/4 inch height minimum unless shown otherwise on the

PLANS, engraved through the face layer to the melamine middle layer.

4) Accessories: Provide holes for mechanical fastening. 2. Devices located on the face of, on the back, or inside of instrument control

cabinets/panels: a. Devices which penetrate the door shall be provided with two nameplates,

one located on face of the door and one located on the rear of the door. b. Nameplates located on the panels/cabinets face shall be secured with two

Type 316-Stainless Steel screws. 3. Field mounted control and instrument devices:

a. Securely hang nameplates from each instrument/control device by a flexible stainless steel snap-on type hanger/key-chain cord (neatly drill a hole through the top of the identification nameplate for this purpose).

B. Wire Tag: 1. Rating: Flame-Retardant, 2. Style: Heavy-Duty Industrial Grade 3. Type: Heat Shrinkable type. 4. Character Height: 1/8 inch. 5. Maximum Length: 2 inches. 6. Text Type: Typed with indelible marking process. Handwritten shall not be

accepted. 7. Color: Yellow. Exception: Use White for 120 volts A.C. power circuits to

instrument/devices, and branch circuit lighting and convenience receptacle circuits.

8. Manufacturer: “Raychem type Heavy-Duty Industrial Grade ShrinkMark Heat-Shrinkable Marking Sleeves”, or approved equal. Utilize "Raychem" Portable-Marking-System” complete with wire tag cartridges, or approved equal.

2.07 MISCELLANEOUS

A. Corrosion Resistant and Moisture Repelling Electrical Coating/Spray: 1. Color: Clear. Coordinate spray color with the Owner. Furnish and install the

color requested by the Owner at No Additional Cost to the Owner. 2. Type: Corrosion resistant and moisture repellant fast drying spray coating

sealant 3. Manufacturer: “3M” 1601 Clear-Color Fast Drying Sealer and Insulator, or

approved equal.

PART 3 EXECUTION

3.01 STORAGE

A. Storage: Refer to Section 17100.


3.02 PANEL ASSEMBLY

A. All panel assembly, internal wiring, device installation, tagging, etc. shall be accomplished by the ICS prior to shipment. All wiring shall be connected as shown on PLANS and all systems shall be thoroughly checked out prior to shipment of the panel to the site. Additional requirements are as described below.

B. Termination and Routing of Wiring: 1. Prior to being connected to any instrument or switch, all incoming wiring shall

be terminated to terminal blocks located on an interior panel. Although multiple types of terminal blocks are specified, not all types may be used for this project. Terminal block application shall be limited as follows: a. Type I Terminal Blocks: All proposed control panels/cabinets specified

herein. b. Type II Terminal Blocks: Used at the discretion of packaged control

system manufacturer as defined in Section 13390 for process/mechanical equipment with packaged control systems.

c. Type III Terminal Blocks: Used at the discretion of packaged control system manufacturer as defined in Section 13390 for process/mechanical equipment with packaged control systems.

2. Each blower unit shall have its individual control wiring terminal block/strip segregated and isolated from terminal block/strip of any other blower unit.

3. Each PLC shall have dedicated terminal strips for each analog input, analog output, discrete input, and discrete output module, with each point from each module wired out and terminated to terminal blocks i.e., all input/output module points, where shown active or as spare, shall be wired out and terminated to terminal blocks. Spare points shall be treated the same as any other active point and shall follow the same format described under wiring/terminal block tagging scheme/strategy/method. Also refer to and comply with the requirements of the PLANS.

4. Provide separate terminal blocks for power wiring, from control/discrete signal wiring, and from analog/instrument wiring. Additionally, segregate and isolate analog/instrument terminal strips from control/discrete signal wiring terminal strips from power wiring terminal strips.

5. Terminate shield wire of each shielded cable to a terminal point (block) on the terminal strip (i.e., treat as current carrying conductor), with each shield terminated to a dedicated terminal block. Extend No. 14 AWG insulated green ground wire from each shielded cable shield termination terminal point to the isolated main ground bar of the cabinet (shield/drain wire ground).

6. Wire spare contacts of each device (i.e., control relays, timing relays, selector switches, indicating/controlling instruments/devices, etc.) to terminal blocks for future use by the OWNER.

7. Tag each terminal block. All tags must be typed and neatly attached to the marking surface.

8. Tag each terminal strip/string of terminal blocks with nameplates as previously specified.

9. Terminal blocks shall have the colors previously specified according to the function of the terminal block.

10. Utilize manufacturer’s standard terminal block insulated side jumpers for making connections between adjacent terminal blocks.


11. Route all wiring from a device (instrument, relay contact, push button, etc.) through the terminal block to the other device (instrument, relay contact, push button, etc.) rather than directly from one device to the other.

12. All wiring shall be neatly bundled, laced together and routed as required throughout the cabinet. Enclose wiring routed against the back panel in plastic wireways where possible. Otherwise, group where possible and wrap with flexible wire wrapping or waxed twine. Wiring routed on doors shall be routed such that the door can be fully opened without stressing the wiring.

13. Wire entering the cabinets shall enter through the floor, the side and/or the top of the cabinets via conduits with bushings or hubs.

14. Also refer to and comply with the requirements of the PLANS.

C. Wire Tagging 1. Tag each wire at each end. 2. Tag each wire in multi-conductor cable in addition to the overall cable. 3. Heat shrink all wire tags. 4. Wire Tag Content:

a. Wiring of each equipment (such as Distribution Service Pump, Pump Discharge Control Valve, etc.) within the facility must be tagged different from any other equipment

b. Terminal block terminal designation must be included in the wire tag. c. To represent all of the text to be shown, multiple wire tags may be needed

at each end of the wire. Provide additional tags as necessary at no additional cost to the OWNER.

d. Provide per Section 16200 “Wiring (600 Volts and Below), subsection 3.03 “Wire Tagging Methodology”.

D. Special and additional installation requirements associated with fiber optic communication system: 1. The fiber cables entering each cabinet shall be coiled, allowing at least 8-feet

of additional cable. The coiled fiber shall be positioned vertically. The fiber bend radius upon entry and coiling must not be less than the minimum required for the cable.

2. The fiber optic cable shall be enclosed in a plastic, flex material. This flex material shall surround the cable for all routing of the cable.

E. After all wiring connections have been made, the Contractor shall apply the Corrosion Resistant and Moisture Repelling Electrical Coating/Spray to all wiring connections. Coordinate application with the Owner. The extent of spray application is further clarified as follows: 1. Spray shall be applied for all terminations of the following types of connections

at a minimum: a. termination points, terminals, terminal blocks, ground bar, neutral bar/bus, b. lugs of circuit breakers, buses, doors, etc. c. exposed/stripped ends of each conductor, etc. d. bolt-on connections, split-bolt connections, ring lugs, etc. e. compression connectors, connector blocks, etc. f. all other connection types not listed above

2. Spray shall be applied for all terminations at the following types of equipment at a minimum:


a. Local and main control panels, field instruments, junction boxes, field control stations, control relays, signal isolators, selector switches, pushbuttons, etc.,

b. Panelboards, transformers, motor control centers, manual motor starters, contactors, light switches, light fixtures, etc.

c. Motor termination enclosures, valve actuators, cathodic protection system, package control panels of process equipment, etc.

d. Security system devices, cameras, roadway gate operators, etc. e. Convenience receptacles, scada receptacles, etc. f. All other types of equipment not listed above.

3.03 FIELD INSTALLATION

A. Install the panels in the locations shown on the PLANS. Also refer to the installation details shown on the PLANS.

B. All wiring shall be connected as shown on PLANS and all systems shall be thoroughly checked out.

C. Install all equipment in accordance with the drawings and instructions furnished by the manufacturer.

D. Inspect each new instrument, control component, etc., before installation. Replace deficient items.

E. Touch-up and restore damaged surfaces to factory finish to match existing.

3.04 INSTALLATION REPORT

A. After installation, the manufacturer's representatives shall inspect the installation and prepare a report or reports to include the following: 1. A list of all deficiencies found. 2. Recommend corrective action for all deficiencies. 3. Certification that the item or system is properly installed, except as noted.

3.05 FIELD CALIBRATION AND TESTING

A. Calibrate instruments and prepare calibration reports. All calibration shall be performed by factory-trained technical personnel. Calibration shall be witnessed by OWNER.

B. The complete system shall be tested by an experienced factory-trained technical person. All system tests shall be witnessed by OWNER.

C. Perform the following tests using simulated inputs: 1. Check the overall system and each subsystem to see that they function as

specified based on simulated inputs at each sensor and at each set of field contacts monitored. This check shall include the testing of all automatic functions, sounding of alarms, shutdowns, etc.

2. Check the overall accuracy of each new and modified instrument loop to ensure that it is within acceptable tolerance.


D. If defects are found under simulated conditions, make corrections and retest.

E. After start-up, test the complete system under actual conditions to determine that all specified functions can be performed.

F. After completion of testing, submit a System Test Report. This report shall include: 1. Certification that the system is operating correctly and within tolerances. 2. Listing of calculated tolerances for each new and modified instrument loop.

3.06 OPERATION AND MAINTENANCE TRAINING

A. Start-up Training: Provide required instruction to the OWNER's personnel during start-up period.

B. Special Training School: Provide services of a factory-trained instructor or instructors for a period of not less than two (2) working days for the purpose of instructing the OWNER’s personnel in the correct operating and maintenance procedures for all the instrument and hard-wired control system components and the entire Instrumentation and Control System, and Communications System including the various instrument and control system cabinets/panels installed in this project. This is in addition to the training requirements defined in Section 17600 of the Specifications. The date of this school shall be scheduled with the OWNER, but will be after the entire instrument and control systems is in operation. Also, refer to the additional training requirements defined in Section 17600 of the Specifications.



END OF SECTION

March 1, 2019 – CONFORMED 17302–1 9080B11

SECTION 17302

FLOW MEASUREMENT: MAGNETIC FLOWMETERS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Full-body magnetic flowmeters.

B. Related sections: 1. Section 01330 - Submittal Procedures. 2. Section 17100 – Process Instrumentation and Control Systems (PICS) 3. Section 17200 - Instrumentation and Control Cabinets and Associated


C. Provide all instruments identified in the Contract Drawings.

1.02 REFERENCES

A. International Organization for Standardization (ISO): 1. 9000 - Quality management systems -- Fundamentals and vocabulary. 2. 17025 - General requirements for the competence of testing and calibration

laboratories.

B. National Institute of Standards and Technology (NIST).

C. NSF International (NSF).

1.03 SUBMITTALS

A. Submit the following in accordance with the Section 01330 and 01730 of the Specifications and in accordance to Section 17100 of the Specifications: 1. Shop Drawings and product data. 2. Submit wiring schematics for all equipment. 3. Submit listing of all field instruments tag numbers for verification by OWNER. 4. Test Reports: Completed and certified factory and field calibration data sheets

for instruments and devices that require set-up and calibration. a. Include factory calibration for each instrument with stated accuracy.

5. Operation and maintenance manuals. a. Include all completed and certified test reports in manuals.

1) Refer to specifications herein for transmitter ambient and process fluid temperature ranges to be used for basis of accuracy analysis.

6. Flowmeters: a. Submit a real-time computer generated printout of the actual calibration

data indicating apparent and actual flows at 0 percent, 25 percent, 50 percent, 75 percent, 100 percent, 75 percent, 50 percent, 25 percent, and 0 percent, (a 9-point calibration of both ascending and descending directions) of the calibrated range to the ENGINEER at least 30 days before shipment of the meters to the project site.


b. Calibration data of flow meters shall include effects of all system subcomponent errors as applicable to the flow meter assembly including, but not limited to flow tube/element errors, upstream and downstream pipe fitting/valves installation errors with length of straight pipes and fitting locations verified with actual/proposed field installed piping conditions, instrument/transmitter errors, signal transmission errors, diaphragm/pressure seal errors, and ambient and process fluid temperature fluctuation errors. Ambient and process fluid temperature ranges shall be coordinated with Process Engineer.

7. Submit detailed listing of training class curriculum including, as a minimum, the following at least four (4) months prior to class: a. Specific topics for the instrument, including but not limited to, general

trouble-shooting, calibration, wiring, and general set-up/configuration. b. Anticipated duration of class for the instrument. c. Names of instructor(s) for the instrument training class.

B. Refer to Specification Section 17380 for additional requirements.


A. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials, etc. 2. Physical conditions:

a. Installation and mounting requirements. b. Location within the process. c. Accessories: Verify that all required accessories are provided and are

compatible with the process conditions and physical installation.

C. Notify the Engineer if any installation condition does not meet the instrument manufacturer’s recommendations or specifications.



A. The devices shall be handled carefully to prevent damage. Units shall be stored in a weatherproof structure prior to installation.

1.06 PROJECT OR SITE CONDITIONS

A. Provide instruments suitable for the installed site conditions including, but not limited to, material compatibility, site altitude, site seismic conditions, humidity, and process and ambient temperatures.

1.07 MAINTENANCE

A. Furnish all parts, materials, fluids, etc. necessary for operation, maintenance, and calibration purposes throughout the warranty period. Deliver all of these supplies before project substantial completion.


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Siemens Sitrans: FM Mag 5100W 2. Krohne: IFC. 3. ABB: Watermaster.


A. Magnetic flowmeter: 1. General:

a. Magnetic flowmeters obtain the flow velocity by measuring the changes of induced voltage of the conductive fluid passing across a controlled magnetic field.

b. Complete zero stability shall be an inherent characteristic of the flowmeter system.

c. Include for each magnetic flow metering system: 1) A metering tube with electrodes (sensor). 2) Signal cable. 3) Transmitter integral or remote as indicated on the Drawings. 4) Flowmeter grounding rings.

2. Performance requirements: a. Accuracy:

1) 0.25 percent of flow rate from 10 to 100 percent of full scale for velocities ranging between 1.9 to 10 feet persecond.

b. Repeatability: 1) 0.25 percent of rate.

3. Element: a. Metering tube:

1) Constructed of carbon steel or Type 304 stainless steel (unless specifically noted otherwise in the instrument data sheets) with flanged connections to match with piping material.

2) Liner material in conformance with: a) Manufacturer’s recommendations for the intended service. b) NSF certified for all drinking water applications.

3) Electrodes type and material in conformance with: a) Manufacturer’s recommendations for the intended service. b) Utilize a minimum of 2, self-cleaning electrodes.

4) Meter terminal housing NEMA Type 4X unless specifically noted otherwise in the instrument data sheets.

5) Meter coating consisting of epoxy painted finish. 6) Components:

a) 2 grounding rings: (1) Which are in conformance with the manufacturer’s bore and

material recommendation for the meter’s intended service. (2) Designed to protect and shield from abrasion of the liner’s

edge interface at the meter’s end. 4. Transmitter:

a. Power supply: 1) 120 VAC.


2) Power consumption: 60 VA maximum. b. Outputs:

1) As noted in the instrument data sheets. 2) For all instruments with 4 to 20 mA HART or digital bus protocol,

provide a Device Type Manager (DTM) certification by FDT group. c. Microprocessor-based signal converter/transmitter. d. Utilize DC pulse technique to drive flux-producing coils. e. Contain a 6-digit display for flow rate, percent of span, and totalizer. f. Operator keypad interface. g. Integral zero return to provide consistent zero output signals in response

to an external dry contact closure. h. Integral low flow cut-off zero return. i. Programmable parameters including:

1) Meter size. 2) Full-scale flow rate. 3) Magnetic field frequency. 4) Time constant.

j. Data retention for a minimum of 5 years without auxiliary main or battery power.

k. Self-diagnostics and automatic data checking. l. Protected terminals and fuses in a separate compartment which isolates

field connection from electronics. m. Ambient operating temperature limits of -5 to 140 degrees Fahrenheit (-20

to 60 degrees Celsius). n. The transmitter should support commissioning options via a service

interface or via an internal web server accessible through an RJ-45 Ethernet port.

o. The transmitter should retain all setup parameters and accumulated measurements internally in non-volatile memory in the event of power failure.

p. Device failure modes, self-monitoring characteristics and remedy diagnosis shall follow NAMUR standards NE 43 and NE 107.

2.03 ACCESSORIES

A. Stainless steel tag labeled as specified in the Contract Documents.

B. Provide sunshades for all transmitters located outdoors.

C. Provide galvanic isolation gaskets, nylon/Teflon flange bolt insulation bushings and nylon washers on all meters installed on pipes with cathodic protection.

D. Furnish 1 spool piece for every size of magnetic flow tube being provided.

E. Electronic tester for calibration verification and diagnostics. 1. Transmitter shall have continuous internal meter verification method

comparing current meter system values to base line value. 2. Should variance in readings be determined exceeding a preset limit the

transmitter will provide a alarm condition via a configurable discrete output.



A. Factory calibrate each flow metering system at a facility that is traceable to the NIST. ISO-17025 accredited test facility with certified accuracy traceable to NIST

B. Evidence of accreditation shall originate from a national verification agency such as A2LA.

C. A real-time computer generated printout of the actual calibration date indication actual velocities and as read values of the flow tube. 1. Flow calibration report of the manufacturers flow lab calibration procedure

shall be shipped with the meter system. 2. Minimum calibration shall be a 3 point calibration including 1, 3, and 10 feet

per second velocities for every meter and transmitter system. 3. Manufacturer shall archive all calibration reports for future reference.

D. Refer to Specification Section 17380 for additional requirements.

2.05 INSTRUMENT WIRING SURGE SUPPRESSORS

A. Refer to Section 17200 of the Specifications “Instrumentation and Control Cabinets and Associated Equipment”, Subsections 2.03 J and 2.03 K.

PART 3 EXECUTION

3.01 EXAMINATION (NOT USED)

3.02 PREPARATION (NOT USED)

3.03 GENERAL

A. Refer to Specification Section 17380 for additional requirements.

3.04 INSTALLATION

A. Install in accordance to manufacturer requirements.



A. Provide manufacturer’s services to perform installation inspection.

3.06 ADJUSTING

A. Install, set, adjust and test all devices per the requirements of Section 17100 of the Specifications. Also, setpoint values shall be reviewed by and coordinated with the OWNER/ENGINEER.

B. Field Verification: 1. Verify factory calibration of all instruments in accordance with the

manufacturer’s instructions:


2. The transmitter and sensor to include a method to verify flow meter performance to the original manufacturer specifications.

3. Verification should be traceable to factory calibration using a third party, attested onboard system pursuant to ISO standards.

4. The verification report should be compliant to common quality systems such as ISO 9000 to prove reliability of the meter specified accuracy.

5. Return factory calibrated devices to the factory if they do not meet the field verification requirements for calibration.

3.07 DEMONSTRATION AND TRAINING

A. Demonstrate performance of all instruments to the Engineer before commissioning.


3.08 SCHEDULES


B. Refer to Drawings for additional requirements.

C. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the

Specifications, or both.



END OF SECTION


SECTION 17305

FLOW MEASUREMENT: THERMAL MASS

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Thermal mass flow measurement.

B. Related sections: 1. Section 01330 - Submittal Procedures. 2. Section 17100 – Process Instrumentation and Control Systems (PICS) 3. Section 17200 - Instrumentation and Control Cabinets and Associated


C. Provide all instruments identified in the Contract Documents.

1.02 DEFINITIONS

A. Specific definitions: 1. Surface mount technology: The practice and method of attaching leaded and

non-leaded electrical components to the surface of a conductive pattern that does not utilize leads in feed-through holes. This technology reduces power requirements for the thermal flow instruments.

2. Retract mechanism: A device that holds the sensor probe in place for the flow measurement. This device also includes a mechanism that enables the plant maintenance staff to remove the probe easily for cleaning and other maintenance needed. This device also enables the plant maintenance staff to re-insert the sensor probe back into its original position without leakage for measurement service again.

1.03 SUBMITTALS

A. Submit the following in accordance with the Section 01330 and 01730 of the Specifications and in accordance to Section 17100 of the Specifications: 1. Shop Drawings and product data. 2. Submit wiring schematics for all equipment. 3. Submit listing of all field instruments tag numbers for verification by OWNER. 4. Design calculations: Flow modeling. 5. Provide complete documentation covering the traceability of all calibration

instruments. 6. Test Reports: Completed and certified factory and field calibration data sheets







b. Calibration data of flow meters shall include effects of all system subcomponent errors as applicable to the flow meter assembly including, but not limited to flow tube/element errors, upstream and downstream pipe fitting/valves installation errors with length of straight pipes and fitting locations verified with actual/proposed field installed piping conditions, instrument/transmitter errors, signal transmission errors, diaphragm/pressure seal errors, and ambient and process fluid temperature fluctuation errors. Ambient and process fluid temperature ranges shall be coordinated with Process Engineer.

9. Submit detailed listing of training class curriculum including, as a minimum, the following at least four (4) months prior to class: a. Specific topics for the instrument, including but not limited to, general




A. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials etc. 2. Physical conditions:



B. Notify the Engineer if any installation condition does not meet the instrument manufacturer’s recommendations or specifications.

C. Provide instruments manufactured at facilities certified to the quality standards of ISO 9001.







1.07 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Thermal mass flowmeters: 1. One of the following or equal:

a. Fluid Components International (FCI) - Model No. ST-100 with thermal dispersion flow element, remote transmitter, and probe sensor.

b. Kurz Instruments, Inc. - Model No. 454 series with thermal mass flow element, remote transmitter, and probe sensor.

c. Sierra Instruments, Inc. - Model No. 640S thermal mass flow sensor; remote transmitter, and probe sensor.

d. Fluid Components International LLC (FCI) - Model No. ST98 with thermal dispersion flow element, remote transmitter, and a balance retract mechanism for the probe sensor.

B. Flow conditioner: 1. One of the following, or equal:

a. FCI - Vortab VMR, VIS, or VIP Series. 1) Select the conditioner type/series that is most suitable, complies with

the specified flow conditioner requirements, and provides the greatest accuracy for the installed flowmeter for the given piping/fittings/valves/etc. upstreatm/downstream of the flowmeter

2. Flow conditioner: a. Material:

1) Type 316L stainless steel. b. Length of conditioner:

1) 7 pipe diameters. c. Process connection:

1) For insertion sleeve type: a) Flange.

2) For meter run type: a) Flange.


A. Thermal mass flowmeter: 1. General:


a. Thermal mass flowmeters measure airflow, industrial, and process gas mass flows by detecting the heat transfer from a heated RTD sensor referenced to the temperature of the ambient gas stream sensor.

b. The electronic circuitry shall either maintain a constant differential temperature between the gas temperature and the heated element or a constant power.

c. The electronic circuitry shall deliver a linear signal 4 to 20 mA DC output proportional to the process fluid flow.

2. Performance requirements: a. Accuracy:

1) 1.5 percent of full scale for velocities over 2 feet per second. b. Repeatability:

1) 0.5 percent of full scale. 3. Element:

a. Sensor with terminal enclosure: b. Utilize a sensor with 3/4-inch male NPT process connection. c. No overheat at zero flow.

4. Transmitter: a. Microprocessor-based. b. Enclosure: NEMA Type 4X. c. Power supply:

1) 24 VDC. 2) Power consumption: 50 VA maximum.

d. Outputs: 1) Isolated 4 to 20 mA DC with HART communication protocol.

e. Alphanumeric display for flow rate. f. Ambient operating temperature limits: 0 to 150 degrees Fahrenheit.

5. Components: a. Signal cable between insertion probe and transmitter:

1) Abrasive-resistant, polyurethane jacket. 2) Sensor cable permanently bonded to sensor. 3) Provide enough length of cable to allow removal and inspection of

insertion element.

2.03 ACCESSORIES

A. Provide a balance retract mechanism (hot tap) for insertion and retraction of the probe sensor assembly.

B. Software (if available as either a standard or an option) for fully validation on instrument performances.

C. Provide sunshade for outdoor installations.

D. A hand held device (if available either in RS422/RS485-Modbus, Profibus-DP, DeviceNet or Ethernet) for communications on gas flow measurement.


A. Factory calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the NIST. 1. Submit calibration data sheets to the Engineer at least 30 days before

shipment of the instruments to the project site.





PART 3 EXECUTION

3.01 EXAMINATION

A. Examine the installation location for the instrument and verify that the instrument will work properly when installed. 1. Notify the Engineer promptly if any installation condition does not meet the

instrument manufacturer’s recommendations or specifications.


3.03 GENERAL


3.04 INSTALLATION


B. Install digester gas flowmeters 45 degrees below the horizontal to prevent condensation from building up on the tip.

C. Refer to Specification Section 17380 for additional requirements.


A. Provide manufacturer’s services to perform installation inspection services.

3.06 ADJUSTING





3.08 SCHEDULES


B. Refer to Drawings for additional requirements.


C. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the

Specifications, or both.



END OF SECTION


SECTION 17315

PARSHALL FLUME – PRIMARY FLOW ELEMENT

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Parshall flumes.

B. Related sections: 1. Section 01300 – Submittals. 2. Section 17100 – Process Instrumentation and Control Systems (PICS). 3. Section 17380 – Field Instrumentation and Sensing Devices.


1.02 REFERENCES



1.03 DEFINITIONS


1.04 SUBMITTALS

A. Furnish submittals as specified in Sections 01300 and 17100.

B. Provide complete documentation covering the traceability of all calibration instruments.



B. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials etc. 2. Physical conditions:



C. Notify the Engineer if any installation condition does not meet the instrument Manufacturer’s recommendations or specifications.





A. Project environmental conditions as specified in Section 17100. 1. Provide instruments suitable for the installed site conditions including, but not

limited to, material compatibility, site altitude, site seismic conditions, humidity, and process and ambient temperatures.

1.08 WARRANTY


1.09 MAINTENANCE


PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following, no equals: 1. TRACOM, Inc. 2. Plasti-Fab.


A. Parshall flumes: 1. General. 2. Performance requirements:

a. Accuracy: 1) Flow: Within 5 percent of rate within 0.5 percent of rate repeatability.

3. Element: a. Single-piece construction, 1 inch through 84 inch sizes. b. Two-piece (minimum) construction, 96 inch, 120 inch, and 144 inch sizes.

4. Transmitter: a. As specified in Section 17380 for ultrasonic level transmitter.

2.03 ACCESSORIES (NOT USED)




B. Factory calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the National Institute of Standards and Technology. 1. Submit calibration data sheets to the Engineer at least 30 days before


PART 3 EXECUTION

3.01 EXAMINATION

A. Examine the installation location for the instrument and verify that the instrument will work properly when installed. 1. Notify the Engineer promptly if any installation condition does not meet the

instrument Manufacturer’s recommendations or specifications.


3.03 INSTALLATION

A. As specified in 17100.


A. As specified in 17100.

3.05 ADJUSTING


3.06 CLEANING




3.08 PROTECTION


3.09 SCHEDULES

A. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents: 1. Instruments may be indicated on the Drawings, specified in the Specifications,

or both.

END OF SECTION


SECTION 17380

FIELD INSTRUMENTATION AND SENSING DEVICES

PART 1 GENERAL

1.01 SUMMARY

A. The work performed under this Section consists of furnishing, installing, calibrating and placing into satisfactory service the following field mounted devices as specified hereinafter: 1. Dissolved Oxygen Analyzers and Sensors 2. Ultrasonic Level Controllers and Transducers 3. Ultrasonic Open Channel Level Controllers and Transducers 4. Submersible Level Transducer and Indicating Transmitter 5. Mechanically Activated Level Switches 6. Intelligent Pressure Measuring Indicators/Transmitters 7. Intelligent Temperature Measuring Indicators/Transmitters 8. Tubing, Hand Valves and Fittings 9. Instrument Hoods (Sun Shields)

B. Additionally, coordinate, install, assist in calibration, test, and place into satisfactory service the following field mounted devices furnished as described in Sections 17302, 17305, 17502 and 11376E of the Specifications: 1. Magnetic Flow Meters 2. Thermal Mass Flow Meters 3. Oxidation Reduction Potential Analyzers 4. Additional field mounted devices as specified and/or as provided by the Multi-

Stage Centrifugal Blower Systems manufacturer.

C. Instrument Type Code: 1. An Instrument Type Code identifies each instrument and consists of an

alphabetical character(s) followed by three numeral characters. a. Example Instrument Type Code: “A123”.

2. The Type Code serves as a means to reference each instrument in the specifications.

D. The subsequent document entitled “Section 17380 Appendix A – Hornsby Bend Side Stream Treatment Plant Relief Project Instrument List” is hereto made part of this section and includes a listing of the proposed instruments: 1. The minimum and maximum range in the Instrument List provides the required

calibrated span of each instrument. 2. Where the instrument functions as a switch, the minimum/maximum value

indicates the low/high switch setting. Where the value is noted as “N/A”, the low or high setting is not applicable for the instrument.


3. The Instrument List is not inclusive of all instruments required by this contract. Refer to Part 1 of this section for quantities of spare parts and instruments in addition to those listed in the Instrument List. Refer to the PLANS and other specification sections for additional instruments required by these contract documents.

4. Where a PLAN sheet number is shown in the list, and a “/” is listed, the number shown prior the “/” refer to a specific detail number on that sheet.

5. The list includes PLAN drawing numbers applicable to the specific instrument installation and wiring. This list of drawing numbers is not complete. Refer to the PLANS for additional instances and requirements for these instruments.

6. Where items in the list are left blank and/or not entered, the CONTRACTOR shall note these items on the data submittals and request input from the Process Mechanical ENGINEER for clarification during submittal review.




1.03 - 1.05 (NOT USED)

1.06 SUBMITTALS







b. Calibration data of flow meters shall include effects of all system subcomponent errors as applicable to the flow meter assembly including, but not limited to flow tube/element errors, upstream and downstream pipe fitting/valves installation errors with length of straight pipes and fitting locations verified with actual/proposed field installed piping conditions, instrument/transmitter errors, signal transmission errors,


diaphragm/pressure seal errors, and ambient and process fluid temperature fluctuation errors. Ambient and process fluid temperature ranges shall be coordinated with Process Engineer.

7. Submit detailed listing of training class curriculum including, as a minimum, the following at least four (4) months prior to class: a. Specific topics for each instrument, including but not limited to, general

trouble-shooting, calibration, wiring, and general set-up/configuration. b. Anticipated duration of class for each instrument type. c. Names of instructor(s) for each specific instrument. d. Refer to instrument by Instrument Type Code as listed in this specification

section where applicable.


A. Standardization: All equipment of the same Instrument Type Code to be the product of a single manufacturer.

B. Examine the complete set of Contact Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials, etc. 2. Physical conditions:



C. Notify the ENGINEER if any installation condition does not meet the instrument manufacturer’s recommendations or specifications.

D. Material Compatibility: 1. Material selections of instrument components noted in this section provide a

basis for the minimum material compatibility requirements. 2. Instrument component material selections shall be subject to additional

restrictions and compliance with recommendations of instrument manufacturers for the intended service.

3. Provide instrument component materials in compliance with specific process fluid temperature, pressure, chemical compatibility, and other process fluid parameters.

1.08 - 1.10 (NOT USED)


A. Furnish the following spare Field Instrumentation and Sensing Devices in conformance with the Specifications: 1. One set of complete Type A213 Dissolved Oxygen Element and Indicating

Transmitter, furnished complete with accessories specified. 2. One set of complete Type L102 Ultrasonic Level Element and Indicating

Transmitter, furnished complete with accessories specified. 3. One set of complete Type L223 Open Channel Ultrasonic Level Element and

Indicating and Transmitter, furnished complete with accessories specified.


4. One set of complete Type L205 Submersible Level Transducer and Indicating Transmitter, furnished complete with accessories specified.

5. One set of complete Type L410 Mechanically Activated Level Switch, furnished complete with accessories specified.

6. One set of complete Type P104 Intelligent Pressure Measuring Indicator/Transmitter, furnished complete with accessories specified.

7. One set of complete Type T103 Intelligent Temperature Measuring Indicator/transmitter, furnished complete with accessories specified.

8. Five sets of Instrument Tubing Hand Valves. 9. Five sets of Instrument Tubing Elbow Fittings and Tee Fittings.

B. Spare instrument shall be configured to match one of the installed instruments. 1. Where multiple instruments of the same type are installed: 2. Configuration of spare instrument shall be as directed by Engineer during

construction. 3. Request input from Engineer during submittal process as to which

configuration is desired for the spare instrument.

C. Furnish the following tools: 1. Three (3) handheld HART communicator configurators, each complete with

120 VAC charging station, test lead kit, rechargeable battery, USB cable, carrying case, hand strap, SD card, and software as manufactured by Yokogawa Model YHC5150X FieldMate Handheld Communicator, no equal.

1.12 ACCEPTABLE MANUFACTURERS

A. Each type of Instrument shall be manufactured by a single Instrument manufacturer and additional requirements as follows: 1. All level indicating controllers/transmitters shall be manufactured by a single

Instrument manufacturer. 2. All mechanically activated level switches shall be manufactured by a single

Instrument manufacturer. 3. All pressure indicating transmitters shall be manufactured by a single

Instrument manufacturer. 4. All temperature indicating transmitters shall be manufactured by a single

Instrument manufacturer.

B. Refer to the individual instrument subsection in PART 2 - PRODUCTS, below.

PART 2 PRODUCTS

2.01 DISSOLVED OXYGEN ANALYZER ELEMENTS AND INDICATING TRANSMITTERS

A. A200: Series General Requirements: 1. The Analyzer Indicating Transmitter/Controller shall have the following

features: a. General: The transmitter shall be a microprocessor-based device capable

of functioning with up to two sensors. b. Local Indicator: The transmitter shall have a menu-driven operation

system, graphical interface unit dot matrix LCD display with LED backlighting, and a real-time clock.


c. SD Card: The transmitter shall have an SD card reader for data download and controller software upload.

d. Enclosure Rating: NEMA 4X/IP66 e. Interface: The interface unit shall allow operators to control sensor and

network functions with menu-driven software, and shall provide data logging of measurement data and the capability to transfer data to a computer or printer via an RS232 serial input/output device. The interface unit shall be housed in a NEMA-4X enclosure.

f. Operating Ambient Temperature Range: -4°F to +140°F, g. Operating Ambient Humidity Range: 95% relative humidity, non-

condensing h. Power Requirements: 120 VAC, 60Hz. i. Remote Sensor Inputs:

1) Two (2) digital inputs, minimum. 2) Provide an analog input in lieu of a digital input if required for each

specified sensor. j. Outputs:

1) Isolated 4-20mA DC with output span programmable over any portion of the range.

2) Relay outputs: Two (2) Form C programmable contacts each rated 5 amps at 230 VAC.

k. Relays: 1) Four (4) electromechanical SPDT (Form C) user configured contacts

each rated at 5A. l. Certifications:

1) General Purpose UL/CSA 61010-1 with cETLus safety mark. 2) CE compliant for conducted and radiated emissions CISPR 11 (Class

A limits), EMC Immunity EN 61326-1 (Industrial limits). m. Mounting Hardware: Type 316 Stainless Steel. n. Each Analyzer Indicating Transmitter/Controller assembly shall be as

manufactured by HACH SC200 Universal Controller with specified options and accessories, or Engineer approved equal.

B. A213: Dissolved Oxygen Analyzers and Sensors Requirements 1. General Requirements for A200 Series Process Analyzers and Sensors apply

to this type of instrument. 2. The Dissolved Oxygen Sensor element for each Analyzer Indicating

Transmitter/Controller shall have the following features: a. Wetted Materials:

1) Sensor Cap: Acrylic; 2) Probe Body: CPVC, polyurethane, Viton, Noryl, 316 Stainless Steel

b. Sensor Mounting Style: 1) 1 inch NPT designed to be directly fastened to the end of a

pipe/conduit for submersion mounting. 2) Refer to sensor mounting details on the PLANS for additional

requirements. c. Cable Length: 33 feet minimum, and additional length as required for

installation as shown on PLANS. d. Operating Temperature Range: 32°F to 122°F e. Sensor Immersion Depth: Pressure limit at 112 ft. shall be 50 psi. f. Measuring Range: 0 – 200 ppm / 0 – 200% saturation


g. Accuracy: 1) Below 5 ppm: ±0.1 ppm 2) Above 5 ppm: ±0.2 ppm 3) Temperature: ±0.36°F

h. Response Time: At 68°F: To 95% in less than 60 seconds; to 90% in less than 40 seconds

i. Resolution: 0.01 ppm / 0.1% saturation j. Repeatability: ±0.1 ppm k. Mounting Hardware: Type 316 Stainless Steel. l. Each Dissolved Oxygen Sensor element shall be as manufactured by

HACH LDO Model 2, optical Process Dissolved Oxygen Probe complete with specified options and accessories, or Engineer approved equal.

2.02 ULTRASONIC LEVEL CONTROLLERS AND TRANSDUCERS

A. L100 Series General Requirements: 1. The Transmitter/Controller shall have the following features:

a. Operation and Performance: 1) Solid-state microprocessor controlled digital circuitry. 2) Operating Temperature: -5 to +122 degrees Fahrenheit. 3) Temperature Compensation: Equipped with air temperature

compensation corrosion resistant probe. The temperature probe shall be a separate device from the ultrasonic transducer.

4) Range/Span Adjustment Resolution: 0.012 inches for operating span of 1 to 50 feet and direct reading zero adjustments.

5) Minimum Span: 0 to 4 inches. 6) Maximum Span: 0 to 60 feet. 7) Accuracy: +/- 0.25 percent of span. 8) Blanking: adjustable distance from 16-inches to maximum span

limits. b. Enclosure: NEMA-4X, wall mount, corrosion resistant, watertight, and

rated/suitable for use in NEC Class-1 Division-2 area installation. c. Interface and Display:

1) LCD indicator reading; level in engineering units. 2) Keypad for programming the system and accessing diagnostics.

d. Signals: 4-20mADC output proportional to level measurement and all of the full-scale volume or head range.

e. Auxiliary Relays: 1) Furnished with six (6) auxiliary relays for remote alarm/process

equipment control. a) Four relays shall each have a Form A normally open dry

contact, rated 5 amps at 120VAC. b) Two relays shall have single-pole-double-throw (SPDT) dry

contacts, rated 5 amps at 120VAC. 2) In the case of momentary signal loss, relays shall maintain their last

state. f. Power:

1) Main Supply: 120VAC, 60Hz power source. 2) Program Memory: Non-volatile for a period of six (6) months via a Ni-

Cad battery pack (furnished with the system); charged continuously.


g. Hand-Held Programmer: 1) The infra-red hand-held programmer shall include an integral key-

pad and shall assist to configure and program the instrument such that no additional software or remote data link is required. The programmers shall each be suitable/interchangeable for all furnished instruments of the same instrument type code.

2) For each Instrument Type Code of instruments to be furnished under this L100 series of instruments, furnish a quantity of three (3) factory hand-held infra-red programmers suitable for the specific Instrument Type Code manufacturer and model number. If this Contract, including Appendix A Instrument List and/or spare parts list of this section, require a total of more than one (1) unit of each Instrument Type Code for this Contract, furnish a total of only three (3) hand-held programmers for this Contract for each Instrument Type Code.

3) Furnish each hand-held programmer to OWNER in a separate sealed/taped cardboard package with neatly typed label font size 14 minimum on the package to describe its content, including instrument tag(s) as shown on PLANS, instrument manufacturer, and instrument model number for which the programmer is suitable.

2. Temperature Transducer and Signal Cable shall have the following features: a. Enclosure: Totally encapsulated corrosion resistant ETFE. b. Mounting: Refer to the PLANS for mounting requirements of the

temperature transducer. c. Connections: 3/4-inch conduit hub for conduit/wire termination. d. Cable: Length: As required per PLANS for connection to the

transmitter/controller without any cable splices. Transmitter may be located up to 1,000 feet from the transducer.

3. Each Ultrasonic Level Indicator/Transmitter and Transducer assembly shall be as manufactured by Siemens HydroRanger 200 with Siemens TS-3 remote mounted Transducer/Temperature Sensor (compensator), or Engineer approved equal.

B. L102: General Purpose Ultrasonic Level Transducer Requirements 1. General Requirements for L100 Series Ultrasonic Level Element and

Indicating Transmitter apply to this type of instrument. 2. Transducer and Signal Cable shall have the following features:

a. Operation: 1) Beam Angle: 3.0 degrees maximum from centerline. 2) Operating Temperature: -40 to +203 degrees Fahrenheit. 3) Span: Refer to Appendix A “Instrument List”. Provide transducer from

approved series to provide greatest precision within span. b. Enclosure: PVDF, watertight, corrosion resistant, hermetically sealed NEC

Class-1 Division-1 rated and submersible. c. Submergence: Skirt/coupling for submergence detection. d. Signal to Transmitter/Controller: 24 volts. e. Cable:

1) Type: RG-62U Coaxial type instrumentation cable, plenum rated as manufactured by Belden, or Engineer approved equal.

2) Length: As required per PLANS for connection to the transmitter/controller without any cable splices. Transmitter may be located up to 1,000 feet from the transducer.


f. Mounting: Flange, suspended, or conduit mounting as specifically shown on the PLANS. Provide factory flange adaptor for required installation.

g. Connections: 1-inch conduit hub for conduit/wire termination. The use of plastic fasteners or special gaskets to prevent ringing is unacceptable.

3. Each Ultrasonic Transducer shall be as manufactured by Siemens Echomax XPS Series Transducer or Engineer approved equal.

2.03 ULTRASONIC OPEN CHANNEL LEVEL CONTROLLERS AND TRANSDUCERS

A. L223: Requirements: 1. The Transmitter/Controller shall have the following features:

a. Operation and Performance: 1) Solid-state microprocessor controlled digital circuitry. 2) Operating Temperature: -4 to +122 degrees Fahrenheit. 3) Temperature Compensation: Equipped with air temperature

compensation corrosion resistant probe. The temperature probe shall be a separate device from the ultrasonic transducer.

4) Range/Span Adjustment Resolution: 0.012 inches for operating span of 1 to 196 feet and direct reading zero adjustments.

5) Accuracy: a) Within 9.84 feet range: +/- 0.04 inch. b) Greater than 9.84 feet range: +/- 0.04 inch plus 0.17 % of

measured distance. 6) Resolution:

a) Within 9.84 feet range: +/- 0.02 inch. b) Greater than 9.84 feet range: 0.1% of range or 0.08 inch,

whichever is greater. b. Enclosure: NEMA-4X, wall mount, corrosion resistant, polycarbonate,

watertight, and rated/suitable for use in NEC Class-1 Division-2 area installation.

c. Interface and Display: 1) LCD indicator reading; level in engineering units. 2) Keypad for programming the system and accessing diagnostics.

d. Signals: 4-20mADC isolated output proportional to level or flow measurement. 1) Refer to the “Appendix A” Instrument List for the required unit of

measure and configure the instrument accordingly. e. Auxiliary Relays:

1) Furnished with three (3) auxiliary relays for remote alarm/process equipment control. a) One (1) single-pole-double-throw (SPDT) Form C, normally-

open or normally-closed relay, rated 1A at 250 V AC, non-inductive and 3A at 30 V DC.

b) Two (2) single-pole-single-throw (SPST) Form A, normally-open relays, rated 5A at 250 V AC, non-inductive and 3 A at 30 V DC.

2) In the case of momentary signal loss, relays shall maintain their last state.

f. Power: Main Supply: 120VAC, 60Hz, 36VA power source. g. Program Memory:

1) 512 kB flash EPROM. 2) 1.5 MB flash for data logging.


2. Temperature Transducer and Signal Cable shall have the following features: a. Enclosure: Totally encapsulated corrosion resistant ETFE. b. Mounting: Refer to the PLANS for mounting requirements of the

temperature transducer. c. Connections: 3/4-inch conduit hub for conduit/wire termination. d. Cable: Length: As required per PLANS for connection to the

transmitter/controller without any cable splices. Transmitter may be located up to 1,000 feet from the transducer.

3. Transducer and Signal Cable shall have the following features: a. Operation:

1) Beam Angle: 5.0 degrees maximum from centerline. 2) Operating Temperature: -4 to +149 degrees Fahrenheit. 3) Span: Refer to Appendix A “Instrument List”. Provide transducer from

approved series to provide greatest precision within span. b. Enclosure: PVDF, watertight, corrosion resistant, hermetically sealed NEC

Class-1 Division-1 rated and submersible. c. Submergence: Skirt/coupling for submergence detection. d. Signal to Transmitter/Controller: 24 volts. e. Cable:

1) Type: RG-62A/U Coaxial type instrumentation cable, plenum rated as manufactured by Belden, or approved equal.

2) Length: As required per PLANS for connection to the transmitter/controller without any cable splices. Transmitter may be located up to 600 feet from the transducer.

f. Mounting: Flange, suspended, or conduit mounting as specifically shown on the PLANS. Provide factory flange adaptor for required installation.

g. Connections: 1-1/2 inch conduit hub for conduit/wire termination. 4. Each Ultrasonic Level Indicator/Transmitter and Transducer assembly shall be

as manufactured by Siemens SITRANS LUT440 High Accuracy OCM with a Siemens TS-3 remote mounted Transducer/Temperature Sensor (compensator), and Siemens Echomax XRS-5 Ultrasonic Transducer with specified options and accessories, or Engineer approved equal.

2.04 SUBMERSIBLE LEVEL TRANSDUCER AND INDICATING TRANSMITTER

A. L205: Requirements 1. General:

a. The Submersible Pressure Transducer/Transmitter shall be designed to operate in a wastewater clarifier scum well level monitoring application.

b. The Submersible Pressure Transducer/Transmitter shall convert the pressure applied to one diaphragm, with the low side open to atmosphere, to a 4 to 20mADC output signal that is proportional to pressure.

2. The Submersible Pressure Transducer/Transmitter shall have the following features: a. Two-wire 4-20mADC (loop powered) proportional to head Pressure, 9 to

35 VDC power. b. Alarm Module: 5 amp, SPDT output. c. Minimum range as shown in the Instrument List. d. Transducer shall be suitable for continuous submergence e. Temperature Range:

1) Sensor: -20°F to +220°F


2) Electronic Module: -20°F to +180°F f. Sensor Full Scale Accuracy: Plus or minus 0.25 percent of full span g. Thermal Error: Plus or minus 0.015 percent of full span per degree

Fahrenheit maximum. h. Barometric Effect: None. i. Transducer Internal Pressure Relief Means:

1) Dedicated breather tube integral with Teflon jacketed hose/cable assembly that terminates in a sealed rugged vent tube isolation air bladder located inside of the transmitter enclosure.

2) Pressure relief means shall require no refilling or maintenance. j. Pressure Transducer:

1) Body Housing: Type 316-Stainless Steel. 2) Face Type: Open slack heavy-duty BUNA-N diaphragm, 3-inch

minimum diameter activity size. 3) Diameter of Transducer Body: 4-inches maximum at face of

diaphragm section. 4) Support: Factory furnished bail hanger for cable support. Provide

complete support system assembly, including bail, clamps, hooks, and 1/8-inch diameter metal cable for a complete installation. All support components, including but not limited to the bail, clamps, hooks, and metal cable, shall be Type 316 Stainless Steel. Refer to the PLANS for additional requirements.

k. Provide adjustments for field calibration of transmitter signal output 1) Adjustments: Capability to span from 30% to 100% of sensor range.

l. Indicator Features: 1) Calibrated in “feet and tenths of a foot”, and to the range of the

transmitter. 2) Digital type with liquid crystal display (LCD), 3.5 minimum digit type. 3) Driven by the loop power (4-20mA at 24 VDC) 4) Visible through the front face of the transmitter enclosure.

m. The Submersible Level Transmitter and local indicator shall be enclosed in a NEMA-4X rated with all Type 300 Stainless Steel construction enclosure; rated for explosion proof; Classes 1 & 2; Divisions 1 & 2; Groups BCD, EFG.

n. Submersible Level Transducer/Transmitter interconnect jacketed hose/cable assembly shall have the following features: 1) Teflon jacket 2) Contains signal cable and flexible breather tube. 3) Water-resistant. 4) Minimum cable length: Coordinate cable length with the PLANS and

provide the length necessary for the application, inclusive of the additional cable that is to be coiled adjacent to the transmitter as shown on the PLANS.

3. Mounting: a. Provide all necessary Type 316 Stainless Steel hardware to interconnect

all components. b. Provide 1/8-inch diameter Type 316 Stainless Steel transducer

suspension cable for suspension of transducer. Coordinate cable length with the PLANS and provide the length necessary for the application.

c. Provide a factory furnished Type 316 Stainless Steel 2-inch pipe stand housing mounting bracket or a factory furnished Type 316 Stainless Steel


wall/panel mounting bracket as required for installation of transmitter. Refer to the PLANS.

d. Comply with the requirements of the PLANS. e. Install in accordance to Manufacturer’s recommendations and coordinate

final setpoint with the Owner. 4. Each Submersible Level Transducer/Transmitter, transmitter/indicator

enclosure, and all other accessories specified shall be furnished by the same manufacturer. Submersible Level Transducer/Transmitters shall be as manufactured by Delta Controls Corporation, Series 566, complete with Cable, Digital Indicating Meter and the additional specified accessories, or Engineer approved equal.

2.05 MECHANICALLY ACTIVATED LEVEL SWITCHES

A. L411: Requirements 1. The Non-metallic tilting Float Level SPDT Switch with non-metallic tilting float

shall have the following features. 2. Float Construction: Corrosion resistant PVC 3. Certification: U. L. Listed, suitable for suspension mounting as shown on the

PLANS 4. Switch:

a. Normally closed hermetically sealed. b. Mounted integrally with float and mechanically activated with float

position. c. Opens on the level condition as described on the PLANS. Refer to the

PLANS. d. Single-pole-double-throw (SPDT) and rated 13 Amp inductive load at

120VAC. e. Switch shall not contain mercury.

5. Cable Connection: a. Flexible 14 AWG, 3-conductor SJOW-A water resistant cable integrally

connected to float body. b. Of sufficient length to be routed without any splice to the cable termination

box as shown in PLANS. c. Coil a minimum of 4 feet of slack of level switch cable within the cable

termination box. 6. Weight:

a. Field moveable weight installed on the cable for level adjustment. b. Float is to have a minimum “SET-RESET” level differential angle of 85-

degrees (plus or minus 5 degrees). c. Weight shall be made of corrosion resistant material.

7. Mounting: a. Provide all necessary mounting hardware for a secure installation of level

switch complete with all accessories. b. Comply with the additional requirements as shown on the PLANS.

8. Each level switch shall be as manufactured by “SJ Electro Systems, Inc.” Series SJE Pump Master SPDT with “S.J. Electro Systems, Inc.” liquid-Tight round cable connectors (one per float) and S.J. Electro Systems complete Cable Weight Assembly or approved equal.


2.06 INTELLIGENT PRESSURE MEASURING INDICATORS/TRANSMITTERS

A. P100 Series General Requirements: 1. The Pressure Indicator/Transmitter shall have the following features:

a. Signal: Two-wire 4-20mAdc (loop powered) proportional and linear to Pressure with HART communication protocol. 1) Alarm: Configure the unit fault/alarm at 3.4 mAdc output signal.

b. Accuracy: 1) Spans greater than or equal to 10% of Upper Range Limit (URL):

0.06 percent of span. 2) All Other: 0.025 + 0.0035 (URL/Span) percent of span.

c. Ambient Temperature Range: -40°F to + 175°F. d. Process Temperature Range: -50°F to +250°F. e. DC Loop Supply Voltage Range: 12 to 42 VDC. f. Signal Output Load Range: 200 to 1,450 ohms. g. Transmitter Total Error: 0.1 percent (RMS), at a reference range of 0 to

100 PSI inclusive of all effects. h. Measurement Range: Select the measurement range offered by the

instrument manufacturer for the specified model series that offers the greatest available accuracy for the required span of measurement as listed in Appendix A – Instrument List.

i. Indicator Requirements: 1) Type: Digital LCD integral to transmitter 2) Calibration: Field configurable, as desired by the user

a) Span: As listed in Appendix A – Instrument List. b) Measurement Unit: As listed in Appendix A – Instrument List.

j. Power: Loop powered (4-20mA at 24 VDC) with 1/2" NPT conduit connection.

k. Sensor Wetted Parts Material: Type 316L Stainless Steel. l. Sensor traditional bottom works, process covers and process connectors:

Type 316-Stainless Steel with supply vent screw in side of each process cover with traditional bottom works (not coplanar) configuration.

m. Sensor Fill Fluid: Silicone oil. n. Process Connection: 1/2 inch NPT. o. Transmitter Housing: Epoxy coated aluminum, explosion proof NEMA-4X. p. Hardware: Type 316 Stainless Steel. q. Local Operation: The Indicator/Transmitter shall be equipped with

operators on the face of the unit adjacent to the local indicator for configuration and calibration functions. The face of the unit is the side of the unit that includes the local indicator.

2. Process Pipe Pressure Tap Valves: Refer to PLANS for valving on process piping pressure tap, in addition to any instrument valves specified in this section.

3. Mounting: Manufacturer’s Type 316 Stainless Steel mounting bracket suitable for mounting transmitter assembly on 2-inch pipe stand, support channel, wall/panel or other surface as shown on PLANS with manifold installed between transmitter and bracket. Provide stainless steel flange to mount vertical pipe stand to floor. Refer to the PLANS for additional requirements.

4. Each Intelligent Pressure Measuring Indicator/Transmitter shall be as manufactured by Foxboro Series IGP20-T (Intelligent Gauge Pressure Transmitters) or Series IAP20-T (Intelligent Absolute Pressure Transmitters)


as noted for application with specified accessories, or Engineer approved equal.

B. P104: Intelligent Pressure Measuring Indicating Transmitter with Block Valve and Tubing 1. General Requirements for P100 Series Intelligent Pressure Measuring

Indicating Transmitters apply to this type of instrument. 2. Instrument Valves: Provide factory furnished, 2-way Valve Block Manifold;

constructed of 316 Stainless Steel wetted and non-wetted parts, to accept 1/2 inch NPT; with gaskets and 316 Stainless Steel bolts; Anderson Greenwood Foxboro Model M4TP-VIS4 with Model AMS Type 316 Stainless Steel mounting bracket or Engineer approved equal. Refer to PLANS for additional valving on process piping pressure tap.

3. Mounting of Manifold and Transmitter: Mount manifold directly with specified manifold mounting bracket. Manifold shall be installed between Transmitter bottom works and bracket. Transmitter shall be supported by manifold.

4. Instrument Tubing: Provide instrument tubing to process line connections at valve block process port. Refer to tubing and fittings requirements in this Specification Section. Refer to PLANS for additional requirements.

2.07 INTELLIGENT TEMPERATURE MEASURING INDICATORS/TRANSMITTERS

A. T100 Series General Requirements: 1. The Temperature Indicators/Transmitters shall be of the intelligent type with

integral Temperature Element for ambient air temperature measurement. The Temperature Indicators/Transmitters shall measure and convert the temperature from a temperature sensor element to a 4-20 mAdc electrical and digital output that is Linear with the actual temperature of ambient air temperature being measured.

2. The Temperature Indicator/Transmitters shall have the following features: a. Communication Signal: Two-wire 4-20 mAdc (loop powered) and HART

digital output (software selectable) proportional and Linear with the actual measured temperature of the process variable.

b. Temperature Span: 140°F to 1200°F. c. Accuracy: 0.02 percent of calibrated span of the 4-20mA analog output d. Stability: 0.25 percent of calibrated span or 0.5°F, whichever is greater,

for five years e. Operating Temperature: –40°F to +185°F f. DC Loop Supply Voltage: 12 to 42 VDC g. Output Load: 0 to 1,250 (Ohms) h. Conduit Connection: 1/2 inch NPT i. Digital Accuracy: +/- 0.18°F j. Hardware: All bolts, process connections, and hardware shall be Type

316 Stainless Steel. k. Housing:

1) Enclosure of the Indicator/Transmitter shall be Low-copper aluminum.

2) Rated for use in Class-I, Division 1, Groups C and D hazardous areas (as classified by NFPA 70 National Electrical Code).


l. Local Indication: 1) Local indicator (integral to Indicators/Transmitters) which is calibrated

in “degrees F” and to the range of the transmitter (or to the range of the process variable range selected by the Owner).

2) The indicator shall be of the digital type with liquid crystal display (LCD), driven by the loop power (4-20mA at 24 VDC), and have an accuracy within 0.075 percent full scale.

m. Local Operators: 1) The Indicator/Transmitters shall be equipped with operators on the

face of the unit for configuration and calibration functions. 2) External and/or internal source/devices (such as handled

programmer and/or Portable Computer) shall not be required in order to configure, program, and calibrate the Indicators/Transmitters.

3. The Temperature Sensor Element for each Indicator/Transmitter shall have the following features: a. General: 4-wire, single element, 100 (Ohms) Resistance Thermometer

Detector (RTD), Platinum, in accordance with IEC 751 Class A. b. Enclosure: Enclosed in a Type 316 Stainless Steel sheath. c. Sensor Assembly: Type 316 Stainless Steel spring-loaded style sensor

assembly having 1/2 inch NPT. d. Temperature Range: -328°F to +932°F e. Length: Provide length of element required to span entire length of

thermowell and required sensor connections. 4. The Sensor Element Thermowell shall have the following features:

a. General: Each Sensor Element shall be provided with a Type 316 Stainless Steel Full Length thermowell (protecting tube).

b. Shank Style: Tapered shank geometry, with smaller diameter at terminal tip of thermowell.

c. Hardware: The thermal well assembly shall be furnished complete with external threads, explosion proof union, and required accessories/hardware for installation onto process mechanical piping, duct/chamber and/or raceways. All mounting accessories/hardware shall be constructed of Type 316 Stainless Steel. 1) Exception: Union is not required when thermowell is mounted only to

transmitter and not mounted to process mechanical piping, duct/chamber, raceways or other fixed element.

5. Mounting: Manufacturer’s Type 316 Stainless Steel mounting bracket suitable for mounting transmitter assembly on 2-inch pipe stand, support channel, wall/panel or other surface as shown on PLANS. Provide stainless steel flange to mount vertical pipe stand to floor. Refer to the PLANS for additional requirements.

6. Each Intelligent Temperature Measuring Indicator/Transmitter along with the associated Temperature Sensing Element and System shall be as manufactured by Rosemount Series 644 Intelligent Temperature Transmitters with Series 78 Sensor Element, Series 91 Thermowell and specified manufacturer furnished accessories, or Engineer approved equal.

B. T103: Intelligent Temperature Measuring Indicators/Transmitters with Integral Temperature Element for Ambient Temperature Measurement 1. General Requirements for T100 Series Intelligent Temperature Measuring

Indicators/Transmitters apply to this type of instrument.


2. The Temperature Indicator/Transmitters shall have the following features: a. Mounting: Integral to sensor.

3. The Sensor Element Thermowell shall have the following features: a. Length: 6 inches. b. Sensor Assembly Connection: Mounted directly to Indicating Transmitter

with required 316 Stainless Steel connector fittings.

2.08 DIGITAL LOOP POWERED INDICATOR

A. I107 Requirements 1. Display:

a. 3 and 1/2 digit, 1.0 inch high bright Liquid Crystal Display (LCD). b. Watertight/gastight and corrosion resistant lens that will enable reading

the indictor display without opening any cover door of the indicator's enclosure/housing.

2. Input Signal: a. 4-20mA at 24VDC b. Signal proportional to the process variable measured.

3. Units: a. Calibrated in engineering units (applicable to the specific system and

measured variable) in order to indicate and control the process variable in the same units (i.e., GPM/MGD for Flow, Inches/Feet for Level, PSI for Pressure, °F/°C for Temperature, etc.).

b. The engineering units shall be permanently marked on the surface of the indicator.

c. Refer to “Section 17380 Appendix A – Hornsby Bend Side Stream Treatment Plant Relief Project Instrument List” for additional information.

4. Readout Accuracy: Plus or minus 0.1 percent of calibrated span plus or minus 1 count.

5. Calibration Range: a. 4 ma input: -1000 to +1000 display. b. 20 ma input: between 20 to 2000 counts greater than 4 ma display.

6. Voltage Drop: 1 VDC maximum at 20 mA. 7. Conversion Rate: 2.5 conversions per second. 8. Calibration:

a. Two-step, non-interacting zero and span. b. Indicator and enclosure assembly zero and span adjustment shall be

external to the indicator housing/enclosure such that zero and span shall be adjusted externally without opening any cover/door of the indicator's enclosure/housing.

9. Enclosure: a. NEMA 3, 4, 7 and 9 rated. b. Corrosion resistant and watertight/gas-tight. c. Explosion-proof cast aluminum housing. d. FM approval.

10. Nameplate: Each indicator shall be equipped with an engraved nameplate that will display the total range of the indicator. This information may be incorporated on the instrument identification nameplate.

11. Operating Temperature: -40 to +176 degrees Fahrenheit. 12. Power: Two-wire loop powered.


13. Wiring Connections: a. 3/4" NPT male conduit hub connection. b. Terminal block inside enclosure.

14. Mounting: Provide manufacturer furnished Type 316 Stainless Steel U-bolt mounting kit for installation on a 2-inch pipe stand. Provide stainless steel flange to mount vertical pipe stand to floor. Refer to the PLANS for additional requirements.

15. Each Indicator shall be as manufactured by Precision Digital Model PD6870 complete with specified accessories or Engineer approved equal.

2.09 LARGE DIGIT DIGITAL INDICATOR

A. I115 Requirements 1. Display: 5 digit, 7 segment, 5.0 inch high, red, Light Emitting Diode (LED)

suitable for reading in sunlight. 2. Input Signal:

a. 4-20mA at 24VDC b. Signal proportional to the process variable measured.

3. Units: a. Calibrated in engineering units (applicable to the specific system and

measured variable) in order to indicate and control the process variable in the same units (i.e., GPM/MGD for Flow, Inches/Feet for Level, PSI for Pressure, °F/°C for Temperature, etc.).

b. Refer to “Section 17380 Appendix A – Hornsby Bend Side Stream Treatment Plant Relief Project Instrument List” for additional information.

4. Readout Accuracy: Plus or minus 0.01 percent of calibrated span. 5. Enclosure:

a. Black, powder-painted aluminum housing with stainless steel hardware b. sealed for outdoor installation, NEMA-4X rated

6. Power: 120 volts AC 7. Environmental:

a. Operating Temperature: 0°C to 55°C b. Storage temperature: -40°C to 85°C

8. Mounting: a. Universal mounting brackets. b. Furnish and install an aluminum, 18 inches long, field adjustable pendant

mounting arm with vertical and horizontal rotational adjustment, as manufactured by Hoffman Compact Pendant Arm Series I, Catalog Number CCS1H5V, or Engineer approved equal. Refer to the details shown on the PLANS. 1) Furnish a 1/4-inch thick aluminum plate sized to accommodate the

overall dimensions of the indicator enclosure with the universal mounting brackets installed. The edge of the aluminum plate shall extend a minimum of 1/2-inch beyond the outer edge of the indicator enclosure and mounting bracket assembly in each direction. Fasten the aluminum plate to the pendant mounting arm and fasten the indicator to the plate with 316 stainless steel hardware.

c. Furnish and install additional mounting hardware as shown on the PLANS.

9. Each Indicator shall be as manufactured by Electro-Numerics, Inc. Mighty-5 Series, complete with all specified accessories, or Engineer approved equal.




2.11 TUBING, HAND VALVES AND FITTINGS

A. General: Provide tubing, hand valves, and fittings for pressure and differential pressure instruments and other devices as required. Provide as required for a functional installation.

B. Tubing: 1. Material: ASTM A-213 Type 316 Stainless Steel annealed seamless 2. Size:

a. Indoor (Inside Building): 3/8” outer diameter tubing with 0.035” wall thickness.

b. Outdoor (Outside of Building): 1/2” outer diameter tubing with 0.049” wall thickness.

c. Stand Pipe Ventilation or Other System Ventilation Piping: 1” outer diameter tubing with 0.109” wall thickness.

d. Provide other larger size(s) as required. 3. Pressure Rating: 3,000 psi minimum working pressure at 100°F

C. Metal fittings and Accessories: 1. Type: Swage ferrule design 2. Material: Type 316 Stainless Steel 3. Size: Same size as tubing 4. Pressure Rating: Same as tubing 5. Manufacturer: Crawford "Swagelok", Parker "CPI", Hoke "Gyrolok", or

Engineer approved equal.

D. Valves: 1. Type: Full port ball valves 2. Material: Type 316 Stainless Steel trim and body 3. Seats and packing: Teflon 4. Size: Same size as tubing 5. Pressure Rating: Same as tubing 6. Manufacturer: Parker CPI, Whitey, Hoke, or Engineer approved equal.

E. Provide stainless steel reducer/transition fittings at instrument/process piping and tubing connections.

F. Bulkhead Fittings: 1. General Requirements:

a. Material: Type 316 Stainless Steel trim and body b. Size: Same size as tubing c. Pressure Rating: Same as tubing d. Manufacturer: Parker CPI, Whitey, Hoke, or Engineer approved equal.

2. Tubing to Tubing Unions: a. Fitting: Bulkhead Union, Hoke BU or Engineer approved equal. b. Connection Type, Both Ends: Swage ferrule design

3. Tubing to Test Port:


a. Fitting: Bulkhead Union, Hoke BU or Engineer approved equal. b. Connection Type, Both Ends: Swage ferrule design

4. Tubing to Vent Screen Fitting: a. Fitting: Bulkhead Union, Hoke BU with or Engineer approved equal. b. Tubing Connection Type: Swage ferrule design with standard nut. c. Screen Connection Type: Swage ferrule design with knurled nut, Hoke

KN or Engineer approved equal.

G. Vent Screen Fittings: 1. Material: Type 316 Stainless Steel trim and body 2. Size: Same size as tubing or pipe vent screen fitting is connected to.

a. Available vent screen fitting sizes shall include 1/4", 3/8”, 1/2”, 3/4", and 1” in diameter.

b. Vent screen fitting shall be of equal diameter or the next listed size greater than the tubing/piping the vent screen fitting is connected to.

c. Provide reducer fitting between vent screen fitting and tubing/piping as required.

d. Where tubing/piping is larger than 1” diameter, provide 1” size vent screen fitting and necessary reducer fitting to connect to tubing/piping.

3. Pressure Rating: Same as tubing 4. Fitting: Screen, Hoke SCRN or Engineer approved equal. 5. Manufacturer: Parker CPI, Whitey, Hoke, or Engineer approved equal.

H. Tubing Support System: 1. UNISTRUT Cush-A-Clamp Assembly Pipe/Tube Clamp (1-5/8" Series), or

Engineer approved equal, with controlled squeeze shoulder bolt for all clamping of instrument tubing.

2. Refer to Specification Section 16150 “Raceways, Fittings, and Supports” for instrument tubing support channel system additional requirements.

I. Manifolds: 1. Instrument Valves: Provide factory furnished, 2-way Valve Block Manifold;

constructed of 316 Stainless Steel wetted and non-wetted parts, to accept 1/2 inch NPT; with gaskets and 316 Stainless Steel bolts; Tyco Flow Control Anderson Greenwood Model M4TP-VIS4 or approved equal.

2.12 HOODS (SUN SHIELDS)

A. Furnish and install an aluminum HOOD (Sun Shield) on top of Indicator Instruments, Transmitter Instruments, Indicating/Transmitter Instruments, Analyzer Instruments, Controller Instruments and Instrument Elements that are mounted OUTDOORS or below flanges mounted OUTDOORS: 1. Aluminum HOOD installation shall apply for all field instrumentation installed

OUTDOORS, inclusive of field instrumentation specified in this Section and specified in Sections 11376E, 17302 and 17305 as well as instruments specified or provided by the Blower manufacturer.

2. Secure HOOD to the instrument, instrument flange mounting assembly and/or instrument support rack and provide all additional mounting hardware necessary for the installation of the Hood Assembly.

3. HOOD shall be a fabricated component and shall be fabricated from minimum 0.1" thickness, aluminum alloy 3003-H14 sheet (ASTM B209). All seams or joints of HOOD shall be closed by continuous weld.


4. Secure HOOD to the associated instrument supports utilizing 316 Stainless Steel hardware. The top of the Hood shall clear the top of the associated instrument by 6 inches. The side visors of the Hood shall clear both sides and rear of the associated instruments by 4 inches.

5. Proposed aluminum HOOD shall have a double-wall aluminum construction top plate and a minimum one inch thick phenolic foam insulation board installed between the two top walls/plates. Phenolic foam material shall comply with the following: a. Block shape cut to fit entire double-wall void within the double-wall top

plate. b. Shall be rigid, expanded, closed-cell structure in compliance with ASTM C

1126, Type II, Grade 1. c. As manufactured by:

1) Kingspan Tarec Industrial Insulation NV; Koolphen K, 2) Resolco International BV; Insul-phen, or 3) Engineer approved equal.

B. Refer to PLANS for additional requirements for construction and mounting of HOOD.

2.13 WIRE MESH GRIP

A. General: Furnish and install heavy duty wire mesh grip to support suspended floats, transducers, etc. as required. Refer to the details shown on the PLANS. Coordinate size of mesh grip required with cable to be supported. Mesh grip shall have the following features: 1. Material: Type 316 Stainless Steel 2. Breaking Strength: 1000 lbs, minimum 3. Manufacturer: Hubbell- Kellums “Heavy Duty, Single Eye, Closed Mesh, Multi-

Weave” model series 024170xx, where “xx” is adjusted according to cable diameter. Coordinate cable diameter with the PLANS.

2.14 STAND PIPES

A. Where PLANS show a stand-pipe (also referred to as a stilling-well), provide the following pipe, flange and blind flange components: 1. Indoor Applications not Exposed to Sunlight:

a. The stand-pipe shall be an ASTM D 1784 Schedule 80 PVC Pipe of diameter and length as shown on PLANS. Manufactured by Havel Pipe or approved equal.

b. Provide an ASTM D 1784 Schedule 80 single piece socket flange fitting with slip-on solvent weld connection to pipe. Carefully apply solvent so as not to drip past fitting. Flange shall be Class 150 ANSI B16.5. Flange diameter to match stand-pipe diameter shown on PLANS. Manufactured by NIBCO or approved equal.

c. Provide a Type 316 Stainless Steel Schedule 40 Blind Flange with Type 316 Stainless Steel bolts, washers, and nuts hardware assembly to fasten blind flange to flange fitting. Pipe flange and blind flange bolt patterns shall match. Blind flange cap diameter to match stand-pipe diameter shown on PLANS. Manufactured by Warren Alloy or approved equal.


d. Fabricate a handle made of the same material as the blind flange and welded to the top face of the blind flange. Refer to the PLANS for additional requirements, including blind flange handle geometry.

2. Outdoor and/or Sunlight Applications: a. Where stand-pipe is mounted outdoor and/or under sun light, the stand-

pipe shall be an ASTM B 221 Schedule 40 Type 6061-T6 Schedule 40 Extruded Aluminum Pipe of diameter and length as shown on PLANS.

b. Provide a Type 6061-T6 Aluminum Flange with full aluminum welded connection to pipe. Flange shall be Class 150 ANSI B16.5. Flange diameter to match stand-pipe diameter shown on PLANS.

c. Provide a 6061-T6 Stainless Steel Schedule 40 Blind Flange with Type 316 Stainless Steel bolts, washers, and nuts hardware assembly to fasten blind flange to flange fitting. Pipe flange and blind flange bolt patterns shall match. Blind flange cap diameter to match stand-pipe diameter shown on PLANS.

d. Fabricate a handle made of the same material as the blind flange and welded to the top face of the blind flange. Refer to the PLANS for additional requirements, including blind flange handle geometry.

3. Stand-pipe mounting hardware and support brackets shall be manufactured from Type 316 Stainless Steel. Refer to the details on the PLANS.

PART 3 EXECUTION


A. The field instrumentation and control devices shall be handled carefully to prevent damage. Units shall be stored in a weatherproof structure prior to installation.

3.02 INSTALLATION

A. General: The following apply to all products in this Section: 1. Unless otherwise specified, all instrument mounting channels, pipes, pipe

caps, etc. shall be Type 316 stainless steel; also, all hardware connecting and securing the mounting hardware and instruments such as nuts, bolts, instrument tubing Cush-A-Clamp Assembly Pipe/Tube Clamp etc. shall be Type 316 Stainless Steel.

2. All field mounted sensor/control/instrument devices shall be permanently identified. The device designations shall agree with those shown on the PLANS. Each device shall be provided with permanent type identifying nameplate. Nameplates, unless otherwise specified, shall be shaped as a circle and shall be constructed of 3-ply “White-Black-White” laminated phenolic material having engraved letters approximately 1/4 inch high extending through the white face into the black layer. Securely hang nameplates from each sensor/control/instrument device by a flexible stainless steel snap-on type hanger/key-chain cord (neatly drill a hole through the top of the identification nameplate for this purpose).


paper base engraving stock per ASTM D-709, Type I. Nameplates shall be ASTM Grade ES-1, ES-2, or ES-3 as applicable for the face and


lettering colors specified hereinafter. Flexible or acrylic tags will be not be accepted.

b. Color: White-Black-White c. Lettering: 1/4 inch height, minimum, engraved through the face layer to

the melamine middle layer. d. Accessories: Provide holes for mechanical fastening. e. Attachment Means: Securely hang nameplates from each

sensor/control/instrument device by a flexible stainless steel snap-on type hanger/key-chain cord (neatly drill a hole through the top of the identification nameplate for this purpose).

4. Submit listing of all field instruments tag numbers for verification by OWNER. 5. Install, set, adjust and test all devices per the requirements of Section 17100

of the Specifications. Also, setpoint values shall be reviewed by and coordinated with the OWNER/ENGINEER.

6. The pressure instruments specified under this Section of the Specifications shall be tested by applying known pressure to each unit prior to installation.

7. The pressure instruments specified under this Section of the Specifications shall be tested by applying known pressure to each unit prior to installation.

8. The instruments specified under this Section of the Specifications shall be installed and calibrated to match its respective system and per the requirements of the Contract Documents and as recommended by the manufacturers.

9. Verify ranges with Owner and Engineer prior to ordering instruments. 10. Refer to Specification Section 16150 “Raceways, Fittings, and Supports” for

instrument support channel system requirements. 11. Make all final connections and terminations per the instrument manufacturers’

recommendations. 12. Unit and Range of each instrument from the Instrument shall as required and

shall be clearly noted on the instrument Submittals. Instrument ranges shall be confirmed via the submittal process with the Owner prior to ordering any of the Field Instrumentation and Sensing Devices specified under this Section of the Specifications. Select instruments within approved manufacturer series that provide the greatest level of accuracy within the span of required measurement.

13. Submit comprehensive calibration sheets to the OWNER indicating “as found” and “final settings”. Submit a typical (blank) field calibration sheets/forms to the OWNER for review and comment prior to utilizing the same for recording calibration parameters. Include final field calibration settings in the Operation and Maintenance Manuals.

14. Coordinate the installation with all trades to ensure that the mechanical system has all necessary appurtenances including weld-o-lets, valves, etc. for proper installation of instruments.

15. Provide manufacturer’s services to perform start-up and calibration/verification. 16. Verify factory calibration of all instruments in accordance with the

manufacturer’s instructions. Return factory calibrated devices to the factory if they do not meet the field verification requirements for calibration.

17. Furnish and install an aluminum HOOD (Sun Shield) on top of Indicator Instruments, Transmitter Instruments, Indicating/Transmitter Instruments, Analyzer Instruments, Controller Instruments and Instrument Elements that are mounted OUTDOORS or below flanges mounted OUTDOORS. Refer to the


PRODUCT PART 2 Section of this specification and the PLANS for additional requirements on the construction and installation of each HOOD.

B. Analyzers: 1. Install analyzers per the manufacturer requirements with all required

kits/accessories to allow a complete and fully functional system. 2. Furnish and install the necessary mounting kit/pole/assembly necessary per

the analyzer manufacturer requirements to allow the Owner to periodically remove the sensor element to clean/maintain/replace the sensor element.

3. Refer to the PLANS for additional requirements.

C. Pressure Instruments: 1. Testing:

a. The pressure instruments specified under this Section of the Specifications shall be tested by applying known pressure at 0%, 50% and 100% minimum increments of span to each unit prior to installation.

2. Pressure Indicating/Transmitters Serving Liquid Process Lines: a. Install instruments with instrument tubing such that the elevation of

pressure tap(s) on transmitter bottomworks is 3” minimum below the elevation of the pressure tap(s) on the process piping//flow-tube element (i.e. venturi, orifice plate, etc.) served and all instrument tubing is above the transmitter bottomworks pressure tap(s) and sloping up towards the pressure tap(s) of the process piping/flow-tube element served.

D. Ultrasonic Level Element and Indicating/Transmitters: 1. Position and orient instrument beam as required for optimal and most accurate

level measurements for well/tank/container application and to reduce interference from side walls of wells/tanks/containers.

E. Level Switches and Submersible Level Transducers: 1. Coordinate with Owner and process/mechanical for all level switch elevation

requirements prior to installation.

F. Instrument Tubing: Gas and Liquid Tubing 1. Install tubing and supports so as not to interfere with work space/maintenance

access of existing and proposed equipment. 2. Make all instrument tubing system connections air/water tight. Provide proper

thread/joint sealant such as Teflon brand strips or other approved sealant where connecting to equipment/accessories/fittings.

3. Requirements herein relate to process pressure port taps/connections shall apply to flow-tube element (i.e. venturi, orifice plate, etc.)connections as well.

4. Tubing Support Systems: a. Clamp all instrument tubing onto channel supports. As a minimum,

support and clamp all instrument tubing as follows: 1) Gas and Liquid Tubing: at 2’-6” intervals on horizontal and vertical

runs, and no more than 3” from each elbow and tee fitting. 2) Capillary Tubing: at 12” intervals on horizontal and vertical runs.

b. Provide suitable floor mounted or ceiling hung channel support systems necessary for mounting/fastening of instrument tubing.

c. Overhead or wall support systems for tubing shall be independent of other conduit/pipe support systems and shall solely support instrument tubing systems.


5. Instrument Tubing Conveying Liquid: a. Pressure port tubing connections to process piping and flow-tube

elements shall be installed on the side (spring line) of horizontal process pipes and flow-tube elements.

b. Horizontal runs of tubing installed lower than the process pipe tap connection shall be sloped 10% up towards process pipe.

c. Tubing installed higher than the process pipe tap connection shall have a vent valve installed at its highest point. Slope tubing 10% up towards valve. Provide additional vent valves at highest points/segments of instrument where air/gas can accumulate. 1) Note:

a) Instrument tubing serving pressure indicating/transmitter having no diaphragm seal shall not be installed above the process pipe tap connection. Refer to pressure indicating/transmitter installation requirements.

d. Do not install instrument tubing conveying liquids directly over electrical panels/equipment. Provide a 3’-0” distance, as seen in plan view, between liquid filled instrument tubing and electrical power distribution equipment.

6. Instrument Tubing Conveying Air/Gas: a. Pressure port tubing connections to process piping and flow-tube

elements shall be installed on the top crest position of horizontal process pipes and flow-tube elements.

b. Horizontal runs of tubing installed higher than the process pipe tap connection shall be sloped 10% down towards process pipe connection.

c. Tubing installed lower than the process pipe tap connection, shall have a condensate drip leg and drain valve. Drip leg pipe segment shall be 6” long. Install instrument tubing at a 10% slope down towards drip leg.

7. Instrument Tubing Cutting and Fittings: a. Cut tubing with sharp cutting tool. Do not flatten tubing or in any way

distort the manufacturer original tube diameter dimensions. b. File edges of tubing after cutting and remove any filings/shavings prior to

making connections. c. Provide elbow fittings, tee fittings, reducer fittings, and valves at tube

connections. Bending tubing in lieu of elbow fittings is not acceptable. d. Clean inside of tubes prior to operation. Clean by blowing out to ensure

there is no debris in tubes.

G. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents. Instruments may be shown on the PLANS, in the Specifications or both.

3.03 OPERATION AND MAINTENANCE TRAINING

A. Start-up Training: Provide required instruction to the OWNER's personnel during start-up period.

B. Special Training School: Provide services of a factory-trained instructor or instructors for each of the specified and installed Field Instrumentation and Sensing Devices for a total period of not less than two (2) working days for the purpose of instructing the OWNER’s personnel in the correct operating and maintenance


procedures for all the Field Instrumentation and Sensing Devices specified under this Section of the Specifications and installed in this project. This is in addition to the training requirements defined in other Sections of Division 17 of the Specifications. The date of this school shall be scheduled with the OWNER, but will be after the entire instrument and control system is in operation and respective Operation and Maintenance Manuals have been submitted and revised per ENGINEER comments. Also, refer to the additional training requirements defined in other Sections of Division 17 of the Specifications. 1. Provide one (1) month prior notice to schedule class events with OWNER. 2. Submit detailed listing of class curriculum including, as a minimum, with the

following at least four (4) months prior to class: a. Specific topics for each instrument, including but not limited to, general

trouble-shooting, calibration, wiring, and general set-up/configuration. b. Anticipated duration of class for each instrument type. c. Names of instructor(s) for each specific instrument. d. Refer to instrument by Instrument Type Code as listed in this specification

section where applicable.



END OF SECTION

SE

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March 1, 2019 – CONFORMED 17502-1 9080B11

SECTION 17502

ANALYZERS – OXIDATION REDUCTION POTENTIAL

PART 1 GENERAL

1.01 SUMMARY

A. Section includes: 1. Oxidation Reduction Potential (ORP) instruments.

B. Related sections: 1. The Contract Documents are complementary; what is called for by one is as

binding as if called for by all. 2. It is the CONTRACTOR’s responsibility for scheduling and coordinating the

Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR’s Work.

3. The following sections are related to the Work described in this Section. This list of related sections is provided for convenience only and is not intended to excuse or otherwise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents. a. Section 01330 - Submittal Procedures. b. Section 17100 – Process Instrumentation and Control Systems (PICS) c. Section 17200 - Instrumentation and Control Cabinets and Associated

Equipment. d. Section 17380 - Field Instrumentation and Sensing Devices.


1.02 REFERENCES

A. International Organization for Standardization (ISO): 1. 9000 - Quality management systems -- Fundamentals and vocabulary. 2. 17025 - General requirements for the competence of testing and calibration

laboratories.

B. National Institute of Standards and Technology (NIST).

C. NSF International (NSF).

D. CSA International (CSA).

1.03 SUBMITTALS


for instruments and devices that require set-up and calibration.


a. Include factory calibration for each instrument with stated accuracy. 5. Operation and maintenance manuals.

a. Include all completed and certified test reports in manuals. 1) Refer to specifications herein for transmitter ambient and process

fluid temperature ranges to be used for basis of accuracy analysis. 6. Submit detailed listing of training class curriculum including, as a minimum, the

following at least four (4) months prior to class: a. Specific topics for the instrument, including but not limited to, general


B. Provide complete documentation covering the traceability of all calibration instruments.



A. Examine the complete set of Contract Documents and verify that the instruments are compatible with the installed conditions including: 1. Process conditions: Fluids, pressures, temperatures, flows, materials etc. 2. Physical conditions:



B. Notify the ENGINEER if any installation condition does not meet the instrument manufacturer’s recommendations or specifications.

C. Provide instruments manufactured at facilities certified to the quality standards of ISO 9001.






1.07 MAINTENANCE



PART 2 PRODUCTS

2.01 MANUFACTURERS

A. One of the following or equal: 1. Emerson Rosemount:

a. Sensor Model 396P. b. Transmitter Model 1056.

2. Yokogawa: a. Sensor Model FU20 with adapter. b. Transmitter Model FLXA21.

3. ABB: a. Sensor Model TB551. b. Transmitter model AX460.

B. All instruments of similar nature must be furnished by the same manufacturer.


A. ORP analyzer: 1. General:

a. The oxidation reduction potential (ORP) is a unit of measurement for the state of equilibrium between oxidation and reducing components of a media. A platinum or gold electrode shall be used with integrated nobel metal reference system. The measuring electrode shall generate a voltage output relative to the oxidation or reducing reactions.

2. Performance requirements: a. Accuracy: Within 1.0 millivolt. b. Stability: Within 1.0 millivolt per month. c. Repeatability: Within 1.0 millivolt.

3. Element: a. Sensor material:

1) Titanium pin ORP electrode. 2) Molded reinforced polypropylene body with 1 inch NPT thread

designed to be directly fastened to the end of a pipe/conduit for submersion mounting. a) Furnish manufacturer adapter accessory, where needed, to

provide 1 inch NPT threaded connection. b) Refer to sensor mounting details on the PLANS for additional

requirements. 3) Steady reference signal from the reference electrode junction by

resisting plugging in dirty applications. 4) Integral temperature sensor.

b. ORP measuring range: -1,500 to 1,500 millivolts. c. Temperature measuring range: 0 to 100 degrees Celsius. d. Operating temperature range: 0 to 100 degrees Celsius. e. Operating pressure range: 0 to 87 pounds per square inch. f. Process connection:

1) Immersion. g. Cable:

1) Integral cable having minimum length of 25 feet. 4. Transmitter:


a. Power supply: 1) 24 VAC/DC. 2) Power consumption: 10 volt-amperes maximum.

b. Outputs: 1) 2 Isolated 4 to 20 milliamperes DC with HART communication

protocol. 2) Relay outputs:

a) 3 Form C contact. b) Rated 3 amps at 250 VAC. c) Programmable.

c. Display: 1) Backlit LCD digital display.

d. Measurement ranges: -1200 to 1200 millivolts. e. Temperature: 0 to 50 degrees Celsius. f. Displayed resolution: Within 1.0 millivolts. g. Ambient conditions:

1) Operable from 0 to 50 degrees Celsius. 2) Relative humidity 0 to 95 percent non-condensing.

h. Mechanical: 1) Enclosure rating: NEMA Type 4X (IP65). 2) Mounting:

a) Surface/wall mount enclosure. 3) Provide all mounting hardware for proper installation and servicing of

the sensor assembly. i. Conduit connection:

1) 1/2 inch NPT. j. Electrical certification: NRTL certified to UL and CSA standards, and CE

approved. 5. Components:

a. Sensor cable: 1) Provided watertight sensor-to-cable connector that prevents cable

twisting and eliminates rewiring when replacing the sensor. 2) Cable length: Minimum length of 25 feet.

2.03 ACCESSORIES

A. Preamplifier: Use manufacturer recommended: 1. Preamplifier required on coaxial cable runs longer than 15 feet.

B. Provide sun shields as specified in Section 17380.


A. Factory calibrate each instrument with a minimum 3-point calibration or according to Manufacturer’s standard at a facility that is traceable to the NIST. ISO-17025 accredited test facility with certified accuracy traceable to NIST 1. Submit calibration data sheets to the ENGINEER at least 30 days before


B. Evidence of accreditation shall originate from a national verification agency such as A2LA.



PART 3 EXECUTION

3.01 EXAMINATION (NOT USED)


3.03 GENERAL


3.04 INSTALLATION




A. Provide manufacturer’s services to perform installation inspection.

3.06 ADJUSTING


B. Field Verification: 1. Verify factory calibration of all instruments in accordance with the

manufacturer’s instructions: 2. The transmitter and sensor to include a method to verify oxidation ORP

analyzer performance to the original manufacturer specifications. 3. Verification should be traceable to factory calibration using a third party,

attested onboard system pursuant to ISO standards. 4. The verification report should be compliant to common quality systems such

as ISO 9000 to prove reliability of the meter specified accuracy. 5. Return factory calibrated devices to the factory if they do not meet the field

verification requirements for calibration.




3.08 SCHEDULES


B. Refer to PLANS for additional requirements.

C. The provided information does not necessarily include all required instruments. Provide all instruments identified in the Contract Documents:


1. Instruments may be indicated on the PLANS, specified in the Specifications, or both.



END OF SECTION


SECTION 17600

DISTRIBUTED CONTROL SYSTEM

PART 1 GENERAL

1.01 SUMMARY

A. Furnish all labor, materials, equipment, and incidentals required, and shall install complete, ready for operation, and test the distributed control system, hereinafter termed the System as shown on the PLANS and as specified.

B. The Instrument and Control System Contractor (ICS) shall provide equipment, materials, software, calibrations, training, startup assistance and system check-out, and other services that are required to successfully interface and interconnect the System and associated equipment that are specified or designated in PLANS or provisions of these specifications for the purpose of providing a fully integrated and functional control system as specified.

C. The ICS shall be responsible for furnishing and installing the Communication System for the Distributed Control System “DCS” shown on the PLANS, and as specified hereinafter.

D. The ICS shall be responsible for all modifications to the Owner’s existing distributed control system as also shown on the PLANS.

E. The subsequent document entitled “Section 17600 Appendix A Hornsby Bend BMP - Proposed PLC Input/Output Schedule” is hereto made part of this section and includes a listing of proposed PLC input/output interface points and other requirements. This schedule in “Appendix A” is not inclusive of all related contract requirements. Refer to the PLANS and other subsections of this Specification Section for additional requirements in addition to those listed in “Appendix A”.

1.02 DISTRIBUTED CONTROL SYSTEM DESCRIPTION

A. General: 1. The Distributed Control System (DCS) as shown on the PLANS and specified

herein, includes, but is not limited to, the following: a. Programmable Logic Controllers Subsystem (PLCs), b. Communication System Application and System Software,. c. PLC networking/data communications over existing and proposed

Ethernet TCP/IP network as well as Modbus Plus network d. Interface with Power Monitoring Units, Protective Relays, and other

devices as shown on the PLANS. e. Interface with process/mechanical equipment having packaged control

systems as shown on the PLANS.


1.03 RELATED SPECIFICATIONS

A. Refer to Section 17100.

B. This Section covers work related to the Distributed Control System DCS and its Subsystems. Note that this Section does not stand-alone. Many key technical definitions, functional requirements, training, submittals, etc. requirements for the DCS are given in Section 17100 “Process Instrumentation and Control Systems (PICS)”.

1.04 DISTRIBUTED CONTROL SYSTEM (DCS) SUBMITTALS

A. General: Submit the following in accordance with the Section 01330 of the Specifications.

B. Hardware: 1. Shop drawings, product data, bill of materials 2. Control system architecture block diagram, 3. Wiring diagrams 4. Spare parts listing.

C. Fiber-Optic Cable Plant Design: Submit fiber-optic cable types, installation procedure, and fiber flux budget/gain margin calculations.

D. Fiber Optic and Ethernet System Copper Cable Testing Submittal: Provide a complete set of cable test results for the testing required under subsection 3.02 “Fiber-Optic System and Ethernet System Copper Cable – Source Quality Control”, this Section of the Specifications. Format and quantity of reports shall be per the requirements of Section 01330 of the Contract Specifications Provide the OWNER with a typewritten results of all tests, including a description of the equipment tested, the date and time of day tested, test values, results. Test reports shall be signed by the ICS representative

E. PLC I/O “Host Pack Template” Spreadsheets: 1. The Owner has standard Excel spreadsheet templates, termed the “Host Pack

Template” of enumerating information about the I/O points for the installation of the system. Upon completion of the system installation and PAT, the Owner shall supply to the ICS the Host Pack Template in Excel format for the contractor to complete.

2. The Contractor is to complete and submit in Excel format the Owner provided Host Pack Template.

F. Operations and Maintenance O&M Manuals: 1. Hardware: As minimum, provide the following:

a. Final approved versions of all shop drawing submittals. b. Component Manufacturers’ O&M Manuals including manuals to cover

installation, operation, maintenance, troubleshooting, and calibration. c. List of spare parts and expendables provided and list of spare parts

recommended.

G. Training Submittals: Submit not less than 4 weeks prior to the time that the associated training is to be provided. Submit per Section 17100.


H. Additional submittals as required by Specifications Section 17100, Section 01330 and Section 01730 of the Contract Specifications.

I. Refer to the requirements of Specifications Section 17100.

J. Configuration System Submittal per subsection 2.09, this Section of the Specifications.

1.05 SPARE PARTS

A. Provide the following spare parts at minimum: 1. Provide the following SPARE equipment, complete with all accessories:

a. PLC processor units (CPU Modules): Two (2) of each type used b. PLC power supply units: Ten Percent (minimum of 2) of the number

required for each type of PLC used c. PLC RIO Head module: Ten Percent (minimum of 2) of the number

required for each type of PLC used d. PLC RIO Drop Module: Ten Percent (minimum of 2) of the number

required for each type of PLC used e. PLC I/O Module (AI, AO, DI, DO, RTD): Ten Percent (minimum of 2) of

the number of each type used. f. PLC rack: One (1) of each type used. g. Local Area Network (LAN) system component (converter, modem,

transceiver, etc.): Ten percent (minimum of 2) of each type provided h. Ethernet NOE module: Ten Percent (minimum of 2) of the number

required for each type of PLC used. i. One (1) Ethernet switch complete will all modules for each type used j. One (1) spare Type 1 OIU complete with all accessories. k. All spare parts shall be of the same manufacturer, model, and software

revision as the installed component, and shall be provide complete with all accessories.

PART 2 PRODUCTS

2.01 GENERAL


B. General Requirements: 1. Power source parameters:

a. 120 volts A.C., plus or minus 10 percent, 60 Hertz b. Regulators and power supplies required for compliance with the above

shall be provided. 2. Materials and equipment used shall be U.L. approved wherever such

approved equipment and materials are available. 3. All components and interconnecting wiring shall be provided as required to

satisfy the functional and operational requirements of this Specification. 4. All equipment to be installed in a control panel or on a rack, including switches,

etc., shall be tagged according to the guidelines outlined in Section 17200 of these Specifications.


5. Unless otherwise specified, tag each outlet face plate with white Label with black lettering of minimum height ¼” where label is TTP Continuous polyester thermal transfer label as manufactured by Tyco, or approved equal, with ribbon and printer by label manufacturer.

6. Communication Cables: Provide all cables for interconnection between all components of the DCS inside the and/or in duct/conduit banks, as applicable. These cables shall include cables to the various PLCs I/O racks, power supplies, central processing units, patch panels, ethernet switches, computers, etc. All cables shall be tagged per Section 17200.

7. All equipment cabling, including copper Ethernet cable, all patch cords, etc., shall be tagged according to the guidelines and tagging labeling system outlined in Section 17200 of these Specifications. For tagging of cables with manufacturer pre-connected cable ends, e.g. patch cords, power cords, etc., furnish and install SP self-laminating polyester labels (minimum 2” long along length of cable) with thermal transfer printable, low profile translucent polyester film with a permanent acrylic adhesive as manufactured by Tyco, or approved equal, with respective printer and ribbon type by label manufacturer. Tag all S.O. type power cords with the tag of the equipment served.

2.02 PROGRAMMABLE LOGIC CONTROLLERS (PLCS)

A. General: 1. Provide all hardware and software features required to make the PLCs totally

operational. 2. The PLCs shall include, but not be limited to, the equipment components

called for on the PLANS and in these specifications. Capacities and/or quantities shown are minimum. Provide additional capacity or units as necessary to meet the functional requirements.

3. Availability: a. Subsystem Availability Calculation: The Subsystem availability (A) for the

PLC’s is defined as average of the individual PLC availabilities (Ai) times the nonspecific availability (NA). That is, A = NA*(Al*A2*A3 ... *An)/n, where n is the number of PLC’s.

b. Availability Requirements: The PLC’s availability shall be at least 99 percent.

c. Component and Backup Definitions: For purposes of the availability calculations, each PLC, each PLC power supply, its process I/O, and data highway interface is considered to be an individual component. There are no backup components.

4. Communications: a. Failure of any PLC or DCS component connected to the communications

system network shall not affect the ability of the remaining components on the network to communicate with each other.

b. Data Highway DH Link Requirements: 1) Fast Ethernet (100BaseFX), as minimum 2) Minimum operating distance: 10,000 feet 3) Rate: 10/100 Mbps.


c. Fiber Optic Link Requirements: 1) Minimum gain margin: 4 dB. The Flux Budget/Gain margin is the

difference between the system gain of the fiber-optic transmitter/receiver and the calculated loss budget of the fiber-optic link (fiber-optic cable, connectors, patch cords, and splices) when both are expressed in decibels (dB)).

d. All copper Ethernet cables shall have a category 6A RJ-45 connector and category 6A cable. The connector end shall be the Boot type connector and preinstalled by the Ethernet patch cable manufacturer.

e. Modbus and Modbus Plus shall be in accordance to the Square D standard for cable pin out and cable type, as well as the end devices to be interconnected. The cables shall be shielded. Refer to the Square D Modicon Hardware Reference Guide for Modbus serial cable pin out and guidelines. Furnish and install ruggedized taps and terminators were available from the manufacturer.

B. Programmable Logic Controllers (PLCs): 1. Each programmable logic controller shall consist of central processor, process

controller, power supply, memory, input/output, interconnecting cables, and optional items as specified

2. Power Supply: a. Manufacturer: MODICON M340 Automation Series model number BMX

CPS 3500, No Equal b. Accessories: Provide screw clamp type removable terminal blocks,

Modicon M340 model number BMX XTS CPS10 No Equal. 3. Central Processor:

a. Memory: 4096 Kbytes, at minimum b. Ports: 1 mini B Universal Serial Bus (USB) port, 1 Modbus

communication port, and 1 Ethernet Modbus TCP/IP port c. Accessories: Provide a 16 MB FLASH Memory Card, as manufactured by

the CPU manufacturer. d. Manufacturer: Schneider Electric MODICON M340 BMX P34 2020, No

Equal 4. Discrete Input Module DI:

a. Manufacturer: MODICON M340 Automation Series Model number BMX DAI 1604 No Equal

5. Discrete Output Module DO: a. Manufacturer: MODICON M340 Automation Series model number BMX

DRA 0805 No Equal 6. Analog Input Module AI:

a. Manufacturer: MODICON M340 Automation Series model number BMX AMI 0810 No Equal

b. For each such module, furnish and install 28-pin terminal block, Schneider Electric BMX FTB 2800.

7. Analog Output Module AO a. Manufacturer: MODICON M340 Automation Series model number BMX

AMO 0410 No Equal


8. Network Option Ethernet (NOE) a. Manufacturer: Modicon M340 Automation Series model number BMX

NOE 0100 Module, No Equal 9. RTD Module:

a. Accessories: Provide an RTD extension module for each RTD module provided, model number MODICON model number Telefast ABE-7CPA412. Provide an extender cord, length as required per PLANS, model number BMX FCW series No Equal.

b. Manufacturer: MODICON M340 Automation Series model number BMX ART 0414 No Equal

10. PLC Racks: a. Manufacturer: MODICON M340 Automation Series model number BMX

XBP 1200 No Equal 11. PLC Rack Extender Module:

a. Accessories: Provide extender cord, length as required per PLANS, manufactured by Extender Module manufacturer, model number BMX XBC series No Equal.

b. Manufacturer: MODICON M340 Automation Series model number BMX XBE 1000 No Equal

12. Accessories: a. Provide 20-way screw clamp type removable terminal block with each

module, except where specifically noted otherwise in this specification section, Modicon Model BMXFTB2010, no equal.

2.03 LAPTOP PROGRAMMING COMPUTER

A. Furnish a quantity of Two (2) Laptop Programming Computers. These laptop computers be purchased under the Bid Allowance. Refer to Section 300L “Bid Form” of the Contract Specifications.

2.04 TYPE 1 OPERATOR INTERFACE UNIT

A. General: The Operator Interface Unit (OIU) shall effectively be a Graphical front end to the local PLC network and have complete read/write access to all registers of the local PLC network to which the OIU is connected. 1. Communication:

a. The OIU shall utilize Ethernet communication protocols to communicate to other peripheral devices, including PLC’s, as shown in the contract drawings.

b. The ICS shall provide the necessary cabling for communicating with the OIU for programming and configuration purposes with a personal computer. The program cabling shall be USB and minimum of 12 feet in length.

c. The ICS shall install the necessary cabling, connectors, and termination for communication between the OIU Ethernet interface and the Ethernet network.

2. Software: a. Operating System: Magelis Operating system, with latest service Pack,

preinstalled by the OIU manufacturer. b. Software: Vijeo Designer run time software, preinstalled by the OIU

manufacturer.


c. All additional necessary software, software drivers, etc. complete will all licenses, as necessary for the proper operation of the OIU.

3. Mounting: a. Mount in control panel door as shown on the Drawings. All

communication ports shall be accessible with OIU installed in the control panel.

b. Provide mounting hardware as required and install OIU according to manufacturer’s instructions and requirements. Provide trim accessories to seal the gap between the OIU and control panel door.

4. Accessories: a. 1 Gigabyte secure digital (SD) card, manufactured by the OIU

manufacturer. b. All necessary cables, connectors, and terminators. Minimum cable length

shall be 12 feet.

B. Display Module: 1. Type: Flat Color Active Matrix (TFT) LCD display type, with touch screen

capability 2. Size: 15” diagonal 3. Minimum Resolution: 1024 x 768 pixels, 4. Colors: 16,000,000 colors 5. Power Input: 24 volts DC. 6. Communication Ports:

a. One (1) USB 2.0 Type A port, b. One (1) USB 2.0 Mini-B port

7. Physical Environment: a. Ambient Air Temperature: +32° to +140° Fahrenheit b. Ambient Air Humidity: 10% to 90% Relative Humidity Non-condensing c. Free of corrosive gases

8. Cooling Method: Natural air circulation 9. Enclosure: NEMA 4X rated 10. Manufacturer: Schneider Electric Magelis GTU HMIDT732, No Equal.

C. Box Module: 1. Power Input: 24 volts DC. 2. Memory:

a. System Card: SD Card 1 GB b. Internal Memory: 256 MB RAM c. Backup Memory: 512 kB NVRAM

3. Communication Ports: a. Two (2) RJ-45 Ethernet ports, b. Two (2) USB 2.0 Type A ports, c. One (1) USB 2.0 Mini-B port, d. One (1) RJ-45 RS-485 serial port, e. One (1) 9 pin RS-232/422/485 serial port, f. Two (2) SD card slots [one (1) system and one (1) storage]

4. Communication Protocol: Ethernet, Modbus TCP/IP 5. Output Interface:

a. One (1) 300 mW speaker output, b. One (1) 24 VDC auxiliary alarm output


6. Physical Environment: a. Ambient Air Temperature: +32° to +140° Fahrenheit b. Ambient Air Humidity: 10% to 90% Relative Humidity Non-condensing c. Free of corrosive gases

7. Cooling Method: Natural air circulation 8. Manufacturer: Schneider Electric Magelis GTU HMIG3U, No Equal.

2.05 OIU DESKTOP COMPUTER

A. General: 1. Furnish and install each OIU Desktop Computer complete with dedicated

mouse, keyboard, monitor, uninterruptible power supply, operating, utility, and SCADA software, cabling, and all accessories as specified hereinafter.

2. Install each OIU Desktop Computer as also shown on the PLANS. Coordinate final installation location with the Owner. All communication ports shall be accessible with the equipment installed.

3. Furnish and install all required cabling (data and power) for each computer installed. Wire as shown on the PLANS and make all final connections.

B. Workstation: 1. Furnish a quantity of One (1) Workstation OIU Desktop Computer. The

Workstation OIU Desktop Computer is to be purchased under the Bid Allowance. Refer to Section 300L “Bid Form” of the Contract Specifications.

C. SCADA Software: 1. Latest version of GE Proficy IFix SCADA unlimited tag runtime license, key,

and software media. Owner shall furnish and install this software.

D. Workstation Uninterruptible Power Supply (UPS): 1. Each OIU Desktop Computer shall be supplied with a workstation UPS as

follows: a. Rated a minimum of 1000 VA b. Boost and Trim Automatic Voltage Regulation (AVR) without use of

onboard battery system c. Intelligent battery management and temperature compensated battery

charging d. USB interface ports e. UPS manufacturer’s USB cabling for power management/ controlled

computer shutdown in power loss event f. Free standing enclosure and not the rack mount type. Install on the

Mobile Desk adjacent to the workstation computer. g. Manufacturer: APC Smart-UPS, 700 Watts / 1000 VA, Input 120V /

Output 120V, with all associated power management software and USB and serial cabling, or approved equal.

2.06 ETHERNET SWITCHES

A. General: 1. Provide and install Ethernet switches for the Distributed Control System DCS.

The ICS shall schematically design the routing and specify component make and model. The components herein shall be provided as minimum for bidding purposes. It is anticipated that Ethernet Switch technology will advance over


time and the latest model of Ethernet switch having the features specified hereinafter as a minimum shall be furnished and installed.

2. All switches shall be provided with the latest firmware from the manufacturer, where applicable. Switches to be stacked must be supplied with the same feature set, IP LAN, IOS, etc.

3. All switches shall be supplied with the manufacturers support contract for the duration of two years starting from final completion of the project. At minimum switches manufactured by Cisco shall have the Cisco SMART NET for a minimum of two (2) years starting from final completion of the project and registered in the name of the Owner.

4. Should the specified switch be designated as “End of Life” and/or discontinued by its manufacturer, contractor shall furnish and install an alternate switch, whose specifications meet or exceed the specified switch, by the same manufacturer and that is not designated as “End of Life” and/or discontinued by the switch manufacturer.

B. Type 1 Ethernet Switches: 1. Power Input: 120 volts A.C., 60 Hz 2. Port Quantity and Type: 24 10/100/1000BaseTx ports, 4 of which are dual

purpose ports which the user may elect to use as a 10/100/10000Base TX port or as a socket for an SFP module. Note: The previously specified quantity of ports shall be provided even if the PLANS show lesser quantity of ports.

3. Module: Provide minimum four (4) 1000BaseLX/LH SFP modules with each switch. All SFP modules shall be the 1000BASE-LX/LH Long Haul module with duplex LC single mode connector.

4. Accessories: Provide a one year support contract with the manufacturer, to begin from the time that the system is commissioned and turned over to the OWNER

5. For each switch having “ESWA” or “ESWB” in its tag name, as shown on the drawings, furnish and install two (2) FlexStack modules.

6. For each switch having “ESWA” in its tag name, as shown on the drawings, furnish and install two (2) FlexStack cables, of sufficient length, to interconnect one end of each cable to FlexStack ports on the switch and the other end of the cable to the FlexStack port of the same type Ethernet switch in the same control panel but having “ESWB” in its tag name.

7. Manufacturer: Cisco Catalyst WS-C3650-24TS, or approved equal.

C. Type 2 Ethernet Switches: 1. Provide Type 1 Ethernet Switch per Section SS17600.2.05.B, with the

exception that only two SFP modules are required.

D. Type 3 Ethernet Switches: 1. Provide Type 1 Ethernet Switch per Section SS17600.2.05.B, with the

exception that the four SFP modules are not required.

E. Type 4 Ethernet Switches: 1. Power Input: 120 volts A.C., 60 Hz 2. Port Quantity and Type: Eight (8) 10/100 BaseTx Ethernet ports and 2 dual

purpose uplinks. Each dual-purpose uplink shall consist of one (1) 10/100/1000BaseTx Gigabit Ethernet port and one SFP based Gigabit Ethernet port, with one port active at a time.


3. Module: Provide minimum one (1) 1000BaseLX/LH SFP modules with each switch. All SFP modules shall be the 1000BASE-LX/LH Long Haul module with duplex LC single mode connector.

4. Mounting: Suitable for surface mounting on the backpanel, unless shown otherwise on the PLANS. Refer to the PLANS.

5. Type 5 Ethernet Switch: a. Power Input: 120 volts A.C., 60 Hz. Unit shall be equipped with its own

power supply. b. Port Quantity and Type: 12 sockets for SFP modules. c. The switch shall have layer 3 routing capability. d. Module: Provide minimum four (4) SFP 1000BaseLX/LH modules with

each switch. All SFP modules shall be the 1000BASE-LX/LH Long Haul module. Refer to drawings for required quantity of SFP modules to interconnect fiber cabling to switch.

e. For each switch, furnish and install two (2) GigaStack modules. f. For each switch furnish and install two (2) GigaStack cables to

interconnect with other proposed switches adjacent to this switch. g. Accessories: Provide a two year support contract with the manufacturer,

to begin from the time that the system is commissioned and turned over to the Owner.

h. Manufacturer: Cisco Catalyst Cisco WS-C3850-12S-E, no equal. 6. SFP Module:

a. Where proposed SFP module is shown in existing Ethernet switch on the drawings, furnish and install 1000BaseLX/LH SFP module into existing Ethernet Switch. The SFP module shall be the 1000BASE-LX/LH Long Haul module with duplex LC single mode connector as manufactured by Cisco. Furnish and install single mode patch cord with duplex LC and SC-duplex connectors to interconnect between SFP module and the Fiber Optic Patch Panel.

7. Accessories: a. IP Services image b. Provide a one year support contract with the manufacturer, to begin from

the time that the system is commissioned and turned over to the OWNER c. For each Ethernet switch, furnish and install 120VAC Ethernet Switch

power supply, model PWR-IE3000-AC= by Cisco, or approved equal. Furnish and install Expansion Module 8 10/100 TX ports, model IEM-3000-8TM= by Cisco, or approved equal, as required, to assure that Each Ethernet switch has minimum 35% spare/unused Ethernet ports of the total count of Ethernet ports on each Ethernet Switch.

8. Manufacturer: Cisco Industrial Ethernet IE-3000-8TC-E, or approved equal.

F. Type 5 Ethernet Switches: 1. Power Input: 24 volts D.C. 2. Port Quantity and Type: Eight (8) 10/100 BaseTx Ethernet ports 3. Switch shall be the unmanaged type and without power over Ethernet 4. Operating Temperature Range: -40 degrees Celsius to 85 degrees Celsius 5. Accessories: 2 year support contract with the manufacturer, to begin from the

time that the system is commissioned and turned over to the Owner. 6. Manufacturer: N-Tron 508TX, or approved equal


G. Type 6 Ethernet Switches: 1. Power Input: 24 volts D.C. 2. Port Quantity and Type: Five (5) 10/100 BaseTx Ethernet ports 3. Switch shall be the unmanaged type and without power over Ethernet 4. Operating Temperature Range: -40 degrees Celsius to 85 degrees Celsius 5. Accessories: 2 year support contract with the manufacturer, to begin from the

time that the system is commissioned and turned over to the Owner. 6. Manufacturer: N-Tron 405TX, or approved equal.

H. Type 7 Ethernet Switches: 1. Power Input: 24 volts D.C. 2. Port Quantity and Type: Four (4) 10/100 BaseTx Ethernet ports with one (1)

SC Duplex fiber optic uplink port 3. Switch shall be the unmanaged type and without power over Ethernet 4. Operating Temperature Range: -20 degrees Celsius to 70 degrees Celsius 5. Accessories: 2 year support contract with the manufacturer, to begin from the

time that the system is commissioned and turned over to the Owner. 6. Manufacturer: N-Tron 405FXE, or approved equal.

I. Provide a one year support contract with the manufacturer, to begin from the time that the system is commissioned and turned over to the OWNER

J. Accessories: 1. Furnish and install mounting brackets and hardware as required to install each

Ethernet Switch according to manufacturer's instructions and requirements 2. Furnish and install all necessary cables, connectors, and terminators as

required for a complete and functional installation

2.07 FIBER-OPTIC CABLES AND CONNECTORS AND HARDWARE GENERAL SPECIFICATIONS REQUIREMENTS

A. General: Provide and install fiber-optic cables, connectors, panels, cords, and enclosures for the Distributed Control System DCS. The ICS shall schematically design the routing and specify component make and model. The components specified herein shall be provided as minimum for bidding purposes.

B. Each fiber cable, as depicted on the PLANS, represents a minimum of two (2) fiber strands. A loose tube fiber cable, as depicted on the PLANS, represents the quantity of fiber strands equal to the loose tube fiber strand count as specified in this section of the specifications.

C. Fiber-Optic Cables: 1. Type: Single-Mode fiber type. Refer to the PLANS. 2. Cable Type: Loose tube fiber-optic cables

a. Fiber Strand Count: 1) Type I: 36 strands 2) Type II: 12 strands.

b. Construction: Loose tube construction, allowing for thermal expansions and free movement of the fiber within the protective container.

c. Protective Coverings: Continuous and be of the same material, free from holes, splices, blisters, and other imperfections.

d. Flooding Compound: Applied into the interior of the fiber buffer tubes.


e. Strength members: 1) Integral part of the cable construction 2) Sufficient to support the stress of installation and to protect the cable

in service. f. Outer cable jacket: polyethylene (PE), except for the fiber that is run

inside a building. g. Additional Requirements:

1) Lightning resistant. 2) Fully water blocked.

h. Manufacturer: ALTOS loose tube type Fiber-Optic cable as manufactured by Corning Cable Systems LLC, or approved equal.

3. Optical fibers: a. Coated with a suitable material to preserve the intrinsic strength of the

glass. b. Protected by a protective tube, a jacketed strength member, and an

exterior jacket. 4. Fibers that are single-mode shall be solid glass waveguides with the following

characteristics: a. Nominal core diameter: 8.3 microns. b. Outside clad diameter: 125 microns. c. Maximum attenuation (1310 nm): 0.5 db/Km d. Maximum attenuation (1550 nm): 0.4 db/Km

5. Glass cladding: Nominally concentric with the fiber core. 6. Each fiber shall be continuous with no factory splices

D. Fiber Optic Cable Terminations: 1. Furnish and install a spider fan-out kit at each end of the cable with the

following features: a. Modular 6 fiber inserts b. Buffer inserts shall consist of size 1 meter long fan-out buting secured in a

composite encasing c. Fan-out tubing shall consist of Teflon inner tube, an aramid yarn strength

member, and an outer protective jacket d. Kit shall be suitable for use with multi-mode cable e. Manufacturer: Corning “Spider Fan out Kit”, or approved equal.

2. Additional Requirements: a. Provide a minimum 20.0-foot coil of spare fiber in each manhole

throughout the cable length as well as at each patch panel. b. Terminate fiber optic cable only at the low voltage control panel and motor

control center as shown on the PLANS. Do not splice fiber optic cables elsewhere.

c. Terminate all strands of a loose tube fiber optic cable in one, and only one, spider fan out kit.

d. All fiber optic cables shall be tested for performance and loss after termination and installation to verify that at least a 4dB power safety margin is obtained between all transmitters and receivers. Test data for each fiber and safety margin calculations for each fiber path shall be provided to the OWNER and ENGINEER after installation to verify conformance with this specification.


E. Fiber Optic Connectors: 1. General:

a. Provide same type mating connectors for the fiber-optic device and the fiber cable end.

b. Fiber Strand Connector Type: 1) For all loose tube fiber cable, furnish and install SC single mode

splice-on connector at each end of the strand. The connector shall be factory pre-polished connector and shall have a factory terminated pre-cleaved fiber strand pigtail that is suitable for machine aligned fusion splicing. The connector shall have a ceramic ultra polish Zirconia ferrule, color coded buffer, cleave protector, splice protection boot, and dust protection cap. Connectors shall be manufactured by “FIS Cheetah Splice-On Connector”, or approved equal.

2) Coordinate type of connector with the device termination. c. Termination Location: All outdoor Fiber Optic Cable shall be

connectorized, at each end of the cable, to a patch panel located inside the building to which the cable is routed.

d. Each loose tube fiber strand ends shall be terminated to a patch panel connector panel.

2. Terminology: a. An “SC-Duplex” connector is two (2) SC connectors abutted next to each

other. Hence, a single “SC-Duplex” connector shall carry two fibers. Similarly, a single “SC-Duplex” adapter shall accept two fibers

b. The Insertion loss is the db loss across two(2) connectors, of the same type, which are mated with each other using a fiber optic adapter of that same type

3. Type: a. Use fusion splice-on type connectors, except for those patch cords which

are to be preconnectorized by the manufacturer. The connector shall conform to the following. The connector shall conform to the following: 1) Single-mode insertion loss (typical/maximum): 0.2db/0.3db 2) Cable Retention: 2.5 pounds. 3) Type: Factory pre-terminated and pre-polished ceramic ultra-polish

zirconia ferrule with fiber stub previously specified.

F. Fiber-Optic Patch Panels: 1. General Requirements For Each Patch Panel:

a. Each port on a fiber optic patch panel, as depicted on the PLANS, represents an interconnection to a minimum of two (2) fiber strands. Those ports depicted on the PLANS connected to a loose tube fiber cable represents an interconnection to a minimum of the number of fiber strands within the loose tube fiber optic cable, in accordance to the loose tube fiber strand count as specified in this section of the specifications.

b. All Fiber Optic Cables shall be attached to connectors that are then manually inserted into adapters on the patch panel. The fiber optic may be attached by a means that is removable in the future, e.g., wire ties.

c. Labeling: 1) In addition to the device/wire tagging requirements described in

Section 17200, provide additional labels as described below. 2) Overall Connector Panel Labels: Printed on the patch panel case by

the Manufacturer. Provide unique, alphanumeric designation.


3) Connector Panel Adapter Label: Each adapter on each Connector Panel shall have clearly labeled, printed, alphanumeric designation that is unique to that Connector Panel and printed on the connector panel by the Manufacturer.

d. Each patch panel shall be accompanied with a typed patch panel schedule with the following columns: Adapter ID, Cable Side, User Side, described as follows: 1) adapter ID: The adapter ID shall be of the form XX-YY, where:

a) XX is the Connector Panel identifier shown by the panel manufacturer

b) YY shall represent the adapter number within the Connector Panel.

2) Cable Side: a) Indicate the source of the fiber optic strands. Use the “patch

panel tag”-XX-YY designation where applicable. 3) User Side:

a) Indicates the device (PLC, patch panel, etc.) connected to the adapter.

4) A Hard Copy print out of each Patch Panel Schedule shall be provided to the OWNER and ENGINEER. A soft copy on CD-R media of the patch panel schedule shall also be provided to the OWNER and ENGINEER.

e. Employ consistent and uniform application of identifier and adapter numbering assignment to individual fiber strands along the entire span and route of each fiber optic cable.

2. Each Type 1 Fiber Optic Patch Panel shall be as follows: a. Mounting: 19” rack mountable, with necessary brackets. Refer to the

PLANS b. Capacity: Up to 12 connector panels c. Connector Panels: Minimum of six (6) connector panels, with six (6) SC-

Duplex single mode adapters of ceramic type. Furnish and install additional connector panels as required to terminate all fiber strands of cables terminated to patch panel. Refer to PLANS. Unused slots of patch panel shall be covered with blank panels. Commence termination of panels from the left side of patch panel (when viewing front/user accessible side of panel), and leave right most panels un-terminated, where applicable, as spare

d. All unused fiber optic connector ports shall be covered with a dust protector covering provided by manufacturer of connector

e. Manufacturer: Corning Cable Systems LLC, Model CCH-04U, or approved equal.

3. Each Type 2 Fiber Optic Patch Panel shall be as follows: a. Mounting: Wall mounted with necessary mounting bracket kit and any

additional accessories. b. Capacity: Up to two (2) connector panels c. Connector Panels: Two (2) connector panel, with six (6) SC-Duplex

single mode adapters of ceramic type per connector panel. d. All unused fiber optic connector ports shall be covered with a dust

protector covering provided by manufacturer of connector. e. Manufacturer: Corning Cable Systems LLC, Model WCH-02P, or

approved equal.



PLANS b. Capacity: Up to 4 connector panels c. Connector Panels: Minimum of (2) connector panels, with six (6) SC-

Duplex single mode adapters of ceramic type. Furnish and install additional connector panels as required to terminate all fiber strands of cables terminated to patch panel. Refer to PLANS. Unused slots of patch panel shall be covered with blank panels. Commence termination of panels from the left side of patch panel (when viewing front/user accessible side of panel), and leave right most panels un-terminated, where applicable, as spare

d. All unused fiber optic connector ports shall be covered with a dust protector covering provided by manufacturer of connector

e. Manufacturer: Corning Cable Systems LLC, Model CCH-02U”. or approved equal.


PLANS b. Capacity: Up to 2 connector panels c. Connector Panels: Two (2) connector panel, with six (6) SC-Duplex

single mode adapters of ceramic type per connector panel. d. All unused fiber optic connector ports shall be covered with a dust

protector covering provided by manufacturer of connector e. Manufacturer: Corning Cable Systems LLC, Model CCH-01U, or

approved equal. 6. Fiber-Optic Patch Cords:

a. General: 1) Use for indoor runs of fiber cable between a fiber-optic device and a

fiber-optic patch panel, between adapters on the user side of two patch panels, or between two fiber optic devices

2) All fiber patch cords shall not consist of any splices of the fiber strands

3) Each fiber in each patch cord shall be placed in individual tight thermoplastic buffer tubes and protected with kevlar strength members and enclosed with a thermoplastic jacket with an outer diameter of at least 2.8mm for each strand.

4) Each patch cord shall consist of at least two (2) fiber strands, according to the fiber count requirements of the communication devices the cable is interconnecting

5) Each patch cord shall be pre-connectorized with the appropriate type connector by the manufacturer

6) Provide minimum length of six feet. Provide additional length as required for the application

7) Patch cords shall be selected with connector ends to mate/match the equipment/device/patch panel connector to which they interconnect. Duplex devices/patch panel connectors shall interconnect with duplex patch cords. Patch cord mode type (single mode or multi mode) shall be the same as that of device mode type and fiber patch panel connector connected fiber strand mode type with which patch cord is interconnecting


8) Patch cord Connectors: connectors on each end of fiber optic patch cord shall mate/match that of the device/patch panel connector to which it is interconnecting on that respective end. All connectors shall have ceramic zerconia ferrule. All single mode connecters shall be Ultra PC Polish. The connector mode type (single mode or multi mode) shall be the same as that of the fiber strand of the patch cord. a) In particular, single mode SC-Duplex to LC-Duplex Single Mode

Patch Cords shall have SC-Duplex connector on one end of the patch cord and LC-Duplex with spring on the other. The SC-Duplex connectors shall be single mode, with ceramic zirconia ferrule and Ultra PC polish. The LC-Duplex connectors shall be single mode, with ceramic zirconia ferrule, with an integrally mounted spring, and Ultra PC polish

b) In particular, single mode SC-Duplex to SC-Duplex Single Mode Patch Cords shall have SC-duplex connectors on both ends of the patch cord. SC-duplex connectors shall be single mode, with Ultra PC polish ceramic zirconia ferrule.

9) Single Mode Fiber Optic Patch Cords: a) Diameter: 8.3/125 micron b) Type: Single Mode Fiber c) Features: Adhere to the attenuation and bandwidth parameters

as previously specified for fiber-optic cable and connectors as described in these specifications.

10) Manufacturer: Corning Cable Systems LLC, Model Zipcord cables, or approved equal.

2.08 ETHERNET COPPER CABLES AND CONNECTORS AND HARDWARE GENERAL SPECIFICATIONS REQUIREMENTS

A. General: 1. Provide and install copper cables, connectors, patch panels, and cords for the

Distributed Control System DCS. The ICS shall schematically design the routing and specify component make and model. The components herein shall be provided as minimum for bidding purposes.

2. Ethernet Copper Connectors: All copper Ethernet cables shall have a Category 6A boot type RJ-45 connector.

3. The installed Ethernet copper media system (including cable, data outlets, connectors, patch cords, patch panels, etc.) shall at minimum meet the TIA/EIA-568-C.2-10 Category 6A standards.

B. Ethernet Copper Patch Cords: 1. The Ethernet Copper Patch Cord shall be used to connect a communication

device with a patch panel or Ethernet Copper Data Outlet. The Ethernet Copper Patch Cord shall also be used to connect devices directly to one another. At minimum, furnish and install copper patch cords for all Ethernet cabling between devices or between device and patch panel within the same cabinet. Refer to PLANS for required interconnections

2. Each patch cod connector end shall be RJ-45 and shall be the Boot type connector. The connectors at each end shall be preinstalled by the Ethernet patch cord manufacturer


3. The Patch Cord shall be unshielded twisted pair and shall be rated Category 6A

4. The Ethernet copper cable outer jacket shall be Blue.

C. Patch panels: 1. General:

a. Approvals: Meet or exceed requirements for Category 6A per TIA/EIA-568-C.2-10

b. In addition to the device/wire tagging requirements described in Section 17200, provide additional labels as described below: 1) Overall Connector Panel Labels: Printed on the patch panel case by

the Manufacturer. Provide unique, alphanumeric designation 2) Connector Panel Adapter Port Label: Each adapter port on each

Connector Panel shall have clearly labeled, printed, alphanumeric designation that is unique to that Connector Panel port and printed by the patch panel manufacturer

3) Terminate copper cabling to patch panel in accordance to TIA/EIA-568-C.2-10 standards

4) Label each port of each patch panel. Furnish and install TTP Continuous polyester thermal transfer label as manufactured by Tyco, with ribbon and printer by label manufacturer. Label shall be white with black lettering of minimum height ¼”

c. Each patch panel shall be accompanied with a typed patch panel schedule with the following columns: Adapter ID, Cable Side, User Side, described as follows: 1) adapter ID: The adapter ID shall be of the form XX-YY, where:

a) XX is the Connector Panel identifier shown by the panel manufacturer

b) YY shall represent the adapter number within the Connector Panel

2) Cable Side: Indicate the source of the cable. Use the “patch panel tag”-XX-YY designation where applicable

3) User Side: Indicates the device (PLC, patch panel, etc.) connected to the adapter

4) A Hard Copy print out of each Patch Panel Schedule shall be provided to the OWNER and ENGINEER. A soft copy on CD-R media of the patch panel schedule shall also be provided to the OWNER and ENGINEER

5) Employ consistent and uniform application of identifier and adapter numbering assignment to Ethernet Copper cables along the entire span and route of each copper cable.

2. Each Type 1 patch panel shall be as follows: a. Construction: Metal, primed and painted with manufacturer’s standard

black finish. b. Quantity of Ports: minimum 24. c. Miscellaneous: Color coded front port labeling. d. Mounting: 19” rack mountable. Mount on 19” rack, with all necessary

brackets and hardware. Refer to the PLANS. e. Manufacturer: Siemon, Panduit, Hubbell, CommScope, or approved equal

3. Each Type 2 patch panel shall be as follows: a. Construction: Plastic, fully enclosed type,


b. Quantity of ports: minimum 2 c. Mounting: surface mounted. Secure patch panel to backpanel with

screws. d. Manufacturer: “Panduit”, Model CC688IW and blank cover plates, or

approved equal.

D. Copper Ethernet Data Communication Cabling: 1. Copper Ethernet Communication Cabling shall be used to interconnect copper

patch panels with each other, or to interconnect Ethernet data outlets to copper patch panels.

2. The copper Ethernet cabling shall be unshielded, twisted pair, rated Category 6A cabling.

3. Agency Compliance: TIA/EIA-568-C.2, TIA/EIA-568-C.2-10 Category 6A, IEEE 802.3an 10GBASE-T Ethernet, UL Listed

4. Number of Pairs: Four 5. Wire: #23 AWG Bare Copper 6. Type of Conductors: solid copper conductors, twisted 7. Individual Conductor Insulation: minimum 300 volt polyolefin 8. Individual Conductor Insulation Color: White/Blue Stripe, Blue, White/Orange

Stripe, Orange, White/Green Stripe, Green, White/Brown Stripe, Brown 9. Overall Jacket: PVC, include ripcord 10. Overall Jacket Color: Blue 11. Manufacturer: Belden 10GX32, or approved equal.

E. Copper Ethernet Cable System Testing: 1. After installation of Copper Ethernet Cable System, ICS shall perform testing

of the cable system to assure compliance of the installed system with the TIA/EIA-568-C.2-10 Category 6A requirements. Testing shall be performed for all installed copper cable systems, including used and unused links, from end-to-end, including all data outlets, connectors, patch panels, patch cords, etc

2. Copper Ethernet Cable System Test reports shall be submitted to the engineer and owner for review and approval. The test report shall document, for each copper data link, description of the link and components therein, the testing method used, test results, and demonstrate compliance with TIA/EIA-568-C.2-10 of the link. If any installed link does not meet the TIA/EIA-568-C.2-10 Category 6A requirements, ICS shall repair/modify link to assure it is compliant with TIA/EIA-568-C.2-10 Category 6A standard at no additional cost to the owner.

F. Ethernet Data Outlets: 1. Faceplates shall be available with multiple module spaces for both vertical and

horizontal applications. 2. Each faceplate shall accept individual modules for both copper and fiber optic

applications. 3. Faceplates shall be flush mounted with a clean look and be available with

labels. 4. Faceplate color shall be white. 5. For each faceplate, furnish and install a minimum of two (2) MINI-COM TX6A

10GIG UTP Jack Modules as manufactured by Panduit, or approved equal. 6. Data outlet faceplate shall be manufactured by Panduit model CFPL4, or

approved equal, with Four Module Space, with white color. The spaces,

1


starting with the top two spaces, shall be occupied by the specified mini com 10Gb data devices, according to the quantity of ports shown on the outlet on the drawings, with unused ports covered with mini com blanks for future use.

7. Furnish and install data label with plastic cover as manufactured by Panduit, or approved equal. Provide label and clear plastic cover as manufactured by Panduit, or approved equal, for all mini com module spaces, even the unused, blank spaces. Label each non-blank device data outlet on each face plate with indelible, permanent printing system with black color imprinted ¼” high capital lettering attached to faceplate and covered by plastic clear cover, as manufactured by Panduit, or approved equal.

8. Submit proposed data labeling for review and approval by owner and engineer prior to commencing data labeling.

9. All data outlet assemblies, including face plate, connector, labels, etc. shall be by one and the same manufacturer.

10. Clearly distinguish SCADA data outlets from other data outlets using color coded mini com data outlet color and faceplate icon color. Coordinate with owner for color preference of the data outlets and icons.

2.09 CONFIGURATION SYSTEM

A. Provide a configuration system, including hardware necessary to allow Engineer configuration of and programming of the PLC system. PLCs equipment provided as part of the Configuration System shall be fully compatible with the DCS equipment provided for this system.

B. Ship and temporarily install the Configuration System at the Engineer’s designated facility.

C. Include at least the following components for the Configuration System: 1. All proposed Programmable Logic Controllers (PLCs), including all racks,

power supplies, microprocessor modules, I/O modules, communication modules, remote I/O modules, etc, with the exception of PLCs supplied as part of vendor packaged control systems per specification section 13390.

2. All proposed Remote I/O units, including all racks, power supplies, I/O modules, communication modules, remote I/O modules, etc, with the exception of units supplied as part of vendor packaged control systems per specification section 13390.

3. All Communications interface hardware and fiber optics electronics for PLC-to-PLC interface, and PLCs to programmer PC interface, OIU interface, etc.

4. Provide the following per specifications, to be included with the configuration system (These units may be counted amongst the spare units): a. one (1) GE Multilin 469 unit complete with the Ethernet communication

capability, b. one (1) GE Multilin EPM 9450 (Transducer Module) complete with three

line LED combination display and keypad Model PL900040N. Furnish and install all required cabling to power the units and to interconnect display with EPM 9450 unit

5. With exception to those items in packaged system vendor control panels per specification section 13390, provide the following: a. Provide all Ethernet Switches


6. One (1) Desktop OIU Workstation Computer complete with all accessories and software

7. All laptop computers complete with all accessories and software 8. Provide 19” rack(s) and install PLC racks and other configuration equipment

on 19” rack(s). For each 19” rack, secure rack to base with four (4) lockable, caster wheels that shall allow the cabinet to be pushed/carted forward, backward, and rotated at least 90 degrees. Overall rack assembly height shall not exceed 60”.

9. Prior to assembly and delivery of configuration system, submit to engineer a drawing detailing the front and back elevations of proposed arrangement of PLC equipment on 19” rack(s). Upon approval of submittal, contractor is to then configure rack according to approved submittal and ship configuration system to Engineer’s location.

10. When directed by the Engineer, recreate and ship Configuration System from the Engineer’s designated facility to Owner’s facility.

11. Provide property and shipping insurance and include the Engineer and Owner as insured. Insure against fire and all-risk for physical loss and damage. The Owner and Engineer will not provide insurance for the Configuration System.

PART 3 EXECUTION

3.01 GENERAL INSTALLATION

A. The ICS shall furnish labor, materials, equipment, and incidentals required to install the system in accordance with specification section 17100 and 17600.

B. The ICS shall be responsible for ensuring that field wiring for power and signal circuits is correct and wired in accordance with best industry practice. Also, the ICS shall be responsible for providing all necessary system grounding to insure a satisfactory functioning installation.

3.02 FIBER-OPTIC SYSTEM AND ETHERNET SYSTEM COPPER CABLING- SOURCE QUALITY CONTROL

A. Fiber Optic Splice-on Connector Termination: 1. The specified splice-on connectors shall be terminated using a fusion splicer

and splicing oven with fiber holders to ensure the fiber cables are machine aligned prior to splicing. The splicing oven shall be the Fujikura 12S Fusion Splicer, or approved equal. Splicer and oven shall be compatible with the splice-on connectors. The loss of the fusion splice shall be no greater than 0.1 dB.

B. Fiber Optic On-Site Testing: 1. General: The ICS shall provide all equipment, instrumentation, and supplies

necessary to perform all testing. The OWNER/ENGINEER shall have the option to witness and participate actively in the On-Site tests performed by the ICS firm.

2. Cables shall be tested with an Optical-Time-Domain Reflectometer “OTDR”, as described hereinafter. The OTDR shall be designed to test the type of cable required for the project and shall include a laser light source used for transmitting test signals through the fiber under test. Contractor shall use


launch cables of minimum length of 500 feet when performing testing with the OTDR. OTDR test wavelengths shall be as follows: a. Single-mode cable: 1310 nm and 1550 nm b. Multi-mode cable: 850nm and 1300nm.

3. OTDR test results shall include the following, at minimum: a. Cable tested b. Fiber number c. Direction of test d. Wavelength e. Reference power reading, f. Total length of fiber g. Attenuation of the fiber h. Power loss (in dB) across the length of fiber cable i. OTDR traces, legibly plotted j. Additional information as necessary to determine insertion loss across the

connectors and cables. 4. Pre-installation testing: Prior to the physical placement of the fiber optic cable,

each fiber shall be OTDR tested on-Site, while on the spool. Submit test results for approval prior to cable installation.

5. Post-installation Testing: a. Separate OTDR tests shall be performed on all installed fibers (both used

and unused fibers) as follows, with all test results submitted accordingly: 1) Cable after connectorization. Perform test from both ends of the

cable, at each patch panel connector attached to the cable’s fiber strands.

2) Fiber end-to-end attenuation. Test shall be performed on all installed fibers (both used and unused fibers) after connectorization from both ends of the cable, at each patch panel connector attached to the cable’s fiber strands

3) Fiber device-to-device attenuation testing. Perform after all necessary patch fiber patch cords have been installed in the system. This test shall be performed on each fiber optic device-to-device link. A device-to-device link is a fiber optic link which connects two (2) opto-electronic devices via a passive fiber optic network consisting of a series of patch cords, loose tube fiber optic cable strands, and patch panel adapters with mating fiber connectors. The test shall be conducted only after all necessary patch cords to be used in the final system are properly installed. The test shall be performed from both ends of each such device-to-device link. The test should include all installed components of each device-to-device link, excluding the opto-electronic devices themselves.

C. Copper Ethernet Cable System Testing: 1. After installation of Copper Ethernet Cable System, ICS shall perform testing

of the cable system to assure compliance of the installed system with the TIA/EIA-568-C.2-10 Category 6A requirements. Testing shall be performed for all installed copper cable systems, including used and unused links, from end-to-end, including all data outlets, connectors, patch panels, patch cords, etc

2. Copper Ethernet Cable System Test reports shall be submitted to the engineer and owner for review and approval. The test report shall document, for each copper data link, description of the link and components therein, the testing


method used, test results, and demonstrate compliance with TIA/EIA-568-C.2-10 of the link. If any installed link does not meet the TIA/EIA-568-C.2-10 Category 6A requirements, ICS shall repair/modify link to assure it is compliant with TIA/EIA-568-C.2-10 Category 6A standard at no additional cost to the owner.

3.03 TESTS (GENERAL)


3.04 INITIAL ON-SITE SYSTEM DEMONSTRATION TESTS

A. Programmable Logic Controllers PLCs: 1. Test all loop-specific functions and demonstrate all I/O Points. 2. Test all non-loop-specific functions including, but not limited to, the following:

a. Failure Mode and Backup Procedures: Power failure, auto restart, retentive outputs.

3. Refer to Section 17100 for additional test requirements.

3.05 OPERATIONAL READINESS TEST (ORT) AND PERFORMANCE ACCEPTANCE TESTS (PAT)


PART 4 TRAINING

4.01 GENERAL.

A. Provide a training program for the OWNER’s personnel to address all equipment provided. The training program shall meet the specific needs of the OWNER and include the following subjects, at a minimum: 1. Hardware

a. Specific training for the actual hardware configuration provided b. Test, adjustment, calibration, troubleshooting, and component

replacement procedures. 2. Software:

a. Operate the equipment on a day-to-day basis. b. Make programming changes for all aspects of

programming/configuration/functionality. c. Configuration, troubleshooting, software installation procedures. d. Assist the hardware maintenance technicians in diagnosing problems with

the equipment. e. Classes shall be designed for students having the equivalent of a one-

semester class on personal computers, but no professional programmable controller programming experience, OIU programming experience, or Ethernet switch configuration experience.

B. Additional training program requirements: 1. Training duration:

a. Hardware: A minimum of two (2) days, each of eight (8) normal working hours.


b. Software: Provide a minimum of one (1) week, 40 consecutive normal working hours for each of the following: 1) Modicon Unity Pro XL, for PLC’s. Provide at minimum the following

courses: Schneider course PLCUTY13 (Unity Pro Programming Level 1), and Schneider course PLCUTY43 (Unity Pro Programming Level 2).

c. Cisco Ethernet switches/routers: Provide a minimum of one (1) week, 40 consecutive normal working hours for ethernet switches/router training. The training shall be performed in Austin, Texas and shall be a private training session exclusively for the personnel designated for this project by the Owner. It should be clarified that this training class is intended for the students to have hands on knowledge to troubleshoot, configure, and maintain the installed Cisco equipment and not necessarily to obtain Cisco certification. Provide training by New Horizons Worldwide, Inc, or Global Knowledge, Inc., course ICND1 or approved equal. For the Ethernet Switch configuration provide, at least, the following training:

d. How to remotely manage/configure the Ethernet switch/router with an IBM PC compatible computer from: 1) Serial/USB communication port 2) terminal telnet session 3) web browser

e. How to change the configuration settings of the switch, including its name, IP address, user passwords using commands at the command prompt via serial communication or terminal sessions, as well as graphically from a browser.

f. Overview of the Ethernet switch hardware provided. g. Overview of Ethernet switch configuration settings, as well as guidelines

and examples, configured by using commands at the command prompt via serial communication or terminal sessions, as well as graphically from a browser.

h. Provide emphasis and show actual settings for all configuration settings of the switches used in the plant, in particular those settings relating to setting of VLAN’s, VLAN truncking, STP and RSTP setup.

i. Provide training on Cisco management tools that provide overview, from a web browser, of all the switches in the network, link status, and port status, as well as how to configure such a management tool, and viewing logs of system events, such as network link failures, internal diagnostic failures, modules failures, etc.

j. Provide training for upgrading the onboard software of an Ethernet switch k. Provide training for how to store settings from the switch to a file, as well

as how to store settings to a switch from a file. l. Provide this training for both command based as well as browser-based

configuration via direct connection to the switch (console port) as well as from the switch management tool.

m. Diagnostic and Troubleshooting: Capabilities, usage, and interpretation of results.

n. Provide additional time as required by the OWNER. 2. Training Location: OWNER’s designated facility located in Austin, Texas.

Include all associated expenses.


3. Shift Quantity: Total of one shift, at minimum, with a minimum ten (10) of the Owners personnel for each shift. Provide the training coordinated with the OWNER’s schedule.

4. Personnel attending the training will be technical, managerial, administrative, engineers, and maintenance type personnel. The training shall accommodate instruction methods and materials accordingly.



END OF SECTION

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TB

PE

Fir

m F

-240

8

908

0B11