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SPECIFICATIONS FOR CONTRACT 587-15-C-13 (81)
LOWER HOWARDS CREEK WATER TREATMENT PLANT
WINCHESTER MUNICIPAL UTILITIES CLARK COUNTY, KENTUCKY
VOL. 3
July 2017
107 Forbes Drive Hopkinsville, KY 42240
270/886-5466
28 Schenck Parkway Building 2B
Asheville, NC 28803 828/771-0838
2480 Fortune Drive Suite 350
Lexington, KY 40509 859/278-5412
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INDEX SPECIFICATIONS FOR
CONTRACT 587-15-C-13 (81) LOWER HOWARDS CREEK WATER TREATMENT PLANT
WINCHESTER MUNICIPAL UTILITIES CLARK COUNTY, KENTUCKY
SECTION NO. TITLE PAGE NO. DIVISION 0 GENERAL SPECIFICATIONS, BIDDING REQUIREMENTS,
CONTRACT FORMS AND CONDITIONS OF THE CONTRACT 00010 Advertisement for Bids 00010-1 Thru 00010-3 00200 Instructions to Bidders 00200-1 Thru 00200-7 00220 Geotechnical Information 00220-1 00410 Bid Form 00410-1 Thru 00410-14 00420 Bidder’s Qualification Statement 00420-1 Thru 00420-5 00430 Bid Bond 00430-1 Thru 00430-2 00520 Form of Agreement 00520-1 Thru 00520-5 00610 Performance Bond 00610-1 Thru 00610-2 00615 Payment Bond 00615-1 Thru 00615-2 00700 Standard General Conditions 00700-1 Thru 00700-36 00800 Supplementary Conditions 00800-1 Thru 00800-9 00820 Special Conditions 00820-1 Thru 00820-6- DIVISION 1 GENERAL REQUIREMENTS 01010 Summary of Work 01010-1 Thru 01010-2 01020 Allowances 01020-1 01420 Structural Special Inspection 01420-1 Thru 01420-9 01430 Codes, Regulations, and Standards 01430-1 Thru 01430-5 01500 Construction Facilities and Temporary Controls 01500-1 Thru 01500-4
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SECTION NO. TITLE PAGE NO. 01600 Special Provisions for Material and Equipment 01600-1 Thru 01600-12 01810 Systems Startup—Commissioning 01810-1 Thru 01810-3 DIVISION 2 SITE WORK 02050 Selective Demolition 02050-1 Thru 02050-4 02110 Site Clearing and Grubbing 02110-1 Thru 02110-2 02140 Dewatering 02140-1 02235 Crushed Stone and Dense Graded Aggregate (DGA) 02235-1 Thru 02235-3 02270 Geotextiles 02270-1 Thru 02270-2 02300 Earthwork 02300-1 Thru 02300-15 02326 Steel Cover Pipe 02326-1 Thru 02326-4 02370 Erosion Prevention and Sediment Control 02370-1 Thru 02370-11 02400 Streets, Roads and Parking Areas 02400-1 Thru 02400-3 02500 Asphalt Paving 02500-1 Thru 02500-7 02510 Concrete Paving 02510-1 Thru 02510-3 02610 Pressure Pipe 02610-1 Thru 02610-53 02614 Double Containment Piping Systems 02614-1 Thru 02614-5 02700 Sewer and Drain Pipe 02700-1 Thru 02700-38 02713 Foundation Drainage 02713-1 Thru 02713-3 02930 Sodding and Seeding 02930-1 Thru 02930-10 DIVISION 3 CONCRETE 03152 Cementitious Crystalline Waterstop 03152-1 Thru 03152-6 03300 Cast-in-Place Concrete 03300-1 Thru 03300-34 03305 Permeability-Reducing Admixture 03305-1 Thru 03305-8
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SECTION NO. TITLE PAGE NO. 03410 Structural Precast Concrete—Plant Cast 03410-1 Thru 03410-13 03450 Concrete Splash Blocks 03450-1 Thru 03450-2 03480 Precast Concrete Specialties 03480-1 Thru 03480-8 03490 Storm Drainage 03490-1 Thru 03490-6 DIVISION 4 MASONRY 04200 Unit Masonry 04200-1 Thru 04200-26 DIVISION 5 METALS 05120 Structural Steel Framing 05120-1 Thru 05120-10 05310 Steel Decking 05310-1 Thru 05310-7 05421 Pre-Engineered Cold-Formed Steel Trusses 05421-1 Thru 05421-7 05500 Metal Fabrications 05500-1 Thru 05500-17 05540 Castings 05540-1 Thru 05540-3 DIVISIONS 6 WOOD AND PLASTICS 06105 Miscellaneous Rough Carpentry 06105-1 Thru 06105-5 06162 Sheathing 06162-1 Thru 06162-6 06200 Finish Carpentry 06200-1 Thru 06200-5 06600 Fiberglass Reinforced Plastic Fabrications 06600-1 Thru 06600-10 06651 Solid Surface Fabrications 06651-1 Thru 06651-9 DIVISION 7 THERMAL AND MOISTURE PROTECTION 07113 Bituminous Dampproofing 07113-1 Thru 07113-3 07136 Self-Adhering Sheet Waterproofing 07136-1 Thru 07136-10 07200 Insulation and Air/Water Vapor Barriers 07200-1 Thru 07200-2 07210 Thermal Insulation 07210-1 Thru 07210-5 07214 Foamed-In-Place Masonry Wall Insulation 07214-1 Thru 07214-3
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SECTION NO. TITLE PAGE NO. 07261 Self-Adhering Air and Vapor Barrier 07261-1 Thru 07261-9 07262 Liquid-Applied Air/Vapor Barrier System 07262-1 Thru 07262-20 07413 Metal Roof Panels 07413-1 Thru 07413-14 07530 Modified Bitumen Sheet Roofing 07530-1 Thru 07530-10 07600 Flashing and Sheet Metal 07600-1 Thru 07600-4 07620 Sheet Metal Flashing and Trim 07620-1 Thru 07620-9 07840 Firestopping 07840-1 Thru 07840-9 07920 Joint Sealants 07920-1 Thru 07920-10
DIVISION 8 DOORS AND WINDOWS 08111 Aluminum Flush Doors 08111-1 Thru 08111-9 08113 Hollow Metal Doors and Frames 08113-1 Thru 08113-10 08146 Flush Wood Doors 08146-1 Thru 08146-6 08220 Fiberglass Reinforced Polyester (FRP) Doors and Frames 08220-1 Thru 08220-6 08330 Rolling Service Doors 08330-1 Thru 08330-4 08332 Overhead Coiling Doors 08332-1 Thru 08832-12 08413 Aluminum-Framed Entrances and Storefronts 08413-1 Thru 08413-10 08441 Glazed Aluminum Curtain Windows 08441-1 Thru 08441-12 08513 Aluminum Windows 08513-1 Thru 08513-11 08710 Door Hardware 08710-1 Thru 08710-27 08730 Door Weatherstripping 08730-1 Thru 08730-3 08800 Glazing 08800-1 Thru 08800-10
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SECTION NO. TITLE PAGE NO. DIVISION 9 FINISHES 09265 Gypsum Board Assemblies on Wood Framing 09265-1 Thru 09265-8 09290 Gypsum Board 09290-1 Thru 09290-7 09400 Thin-Set Epoxy Terrazzo Flooring System 09400-1 Thru 09400-8 09510 Acoustical Ceiling System 09510-1 Thru 09510-7 09678 Resilient Wall Base and Accessories 09678-1 Thru 09678-5 09900 Painting 09900-1 Thru 09900-35 DIVISION 10 SPECIALTIES Not Applicable DIVISION 11 EQUIPMENT 11127 Sludge Tanks Jet Mixing Screw Centrifugal Pumps 11127-1 Thru 11127-5 11201 FRP Filter Troughs 11201-1 Thru 11201-3 11214 Vertical Turbine Water Pump Equipment 11214-1 Thru 11214-14 11216 Seal Water Booster Pump System 11216-1 Thru 11216-6 11222 Water Plant Turbine Mixers 11222-1 Thru 11222-7 11223 Vertical Flocculation Equipment 11223-1 Thru 11223-9 11230 Sludge Collection Equipment 11230-1 Thru 11230-5 11235 Stainless Steel Inclined Plate Settlers 11235-1 Thru 11235-7 11240 Dry Chemical Feed Equipment 11240-1 Thru 11240-6 11242 Chemical Systems Equipment 11242-1 Thru 11242-12 11243 Bulk Line Slurry System 11243-1 Thru 11243-10 11244 Potassium Permanganate Loading, Storage and Feed System 11244-1 Thru 11244-4 11251 Tank Level Monitoring Systems 11251-1 Thru 11251-3
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SECTION NO. TITLE PAGE NO. 11285 Sluice and Slide Gates 11285-1 Thru 11285-14 11312 Submersible Plant Decant Pumps and Accessories 11312-1 Thru 11312-8 11313 Submersible Sludge Pumps and Accessories 11313-1 Thru 11313-8 11319 Sump Pumps 11319-1 Thru 11319-4 11375 Positive Displacement Blowers 11375-1 Thru 11375-10 11445 Jet Aeration and Mixing Systems 11445-1 Thru 11445-8 DIVISION 12 FURNISHINGS 12345 Inset Steel Laboratory Casework 12345-1 Thru 12345-20 DIVISION 13 SPECIAL CONSTRUCTION 13200 Fiberglass Reinforced Plastic Storage Tanks 13200-1 Thru 13200-14 13201 Upright Polyethylene Storage Day Tanks 13201-1 Thru 13201-12 13220 Filter Underdrains, Media, and Equipment 13220-1 Thru 13220-20 DIVISION 14 CONVEYING SYSTEMS Not Applicable DIVISION 15 MECHANICAL 15010 Basic Mechanical Materials and Methods 15010-1 Thru 15010-8 15060 Non-Metallic Strut, Pipe Hangers, and Support Systems 15060-1 Thru 15060-5 15100 Small Plumbing Valves, Plumbing Specialties and Service Accessories 15100-1 Thru 15100-18 15102 Valves (Water Related) 15102-1 Thru 15102-20 15104 Specialty Valves (Water) 15104-1 Thru 15104-13 15140 Hangers and Supports 15140-1 Thru 15140-8 15190 Mechanical Identification 15190-1 Thru 15190-4
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SECTION NO. TITLE PAGE NO. 15230 Plastic Process Valves and Accessories 15230-1 Thru 15230-16 15260 Mechanical Insulation 15260-1 Thru 15260-19 15261 Process Pipe Insulation 15261-1 Thru 15261-4 15310 Dry Pipe Sprinkler , System Fire projection 15310-1 Thru 15310-16 15400 Building Drainage and Plumbing System 15400-1 Thru 15400-13 15530 Refrigerant Piping 15530-1 Thru 15530-2 15535 Refrigerant Specialties 15535-1 Thru 15535-2 15780 Split System Air Conditioners, Furnaces, and Heat Pumps 15780-1 Thru 15780-5 15781 Self-Contained Wall Mounted Vertical Air Conditioners 15781-1 Thru 15781-6 15830 Unit Heaters 15830-1 Thru 15830-2 15862 Power Ventilators and Fans 15862-1 Thru 15862-5 15890 Low Pressure Ductwork and Accessories 15890-1 Thru 15890-5 15910 Louvers and Vents 15910-1 Thru 15910-3 15990 Balancing, Testing, and Adjusting of HVAC Systems 15990-1 Thru 15990-3 DIVISION 16 ELECTRICAL 16010 General Electrical Requirements 16010-1 Thru 16010-12 16060 Secondary Grounding 16060-1 Thru 16060-4 16070 Supporting Devices 16070-1 Thru 16070-3 16075 Electrical Identification 16075-1 Thru 16075-3 16120 Conductors, Cables, and Circuits 16120-1 Thru 16120-6 16130 Raceways 16130-1 Thru 16130-10 16131 Boxes 16131-1 Thru 16131-6 16140 Wiring Devices 16140-1 Thru 16140-4
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SECTION NO. TITLE PAGE NO. 16150 Wire Connections and Connecting Devices 16150-1 Thru 16150-4 16220 Motors 16220-1 Thru 16220-11 16230 Standby Power Generator Systems—Fixed 16230-1 Thru 16230-11 16280 Surge Protection 16280-1 Thru 16280-7 16430 Low Voltage Switchboard 16430-1 Thru 16430-8 16440 Motor Control 16440-1 Thru 16440-18 16442 Panelboards 16442-1 Thru 16442-5 16444 Solid State Reduced Voltage Motor Controls 16444-1 Thru 16444-7 16455 Cable Tray 16455-1 Thru 16455-3 16460 Transformers 16460-1 Thru 16460-3 16483 Adjustable Frequency Drives 16483-1 Thru 16483-9 16495 Switchboard Matting 16495-1 16496 Automatic Transfer Switch 16496-1 Thru 16496-11 16500 Lighting 16500-1 Thru 16500-5 16580 Occupancy Sensors 16580-1 Thru 16580-3 16670 Lightning Protection Systems 16670-1 Thru 16670-3 16710 Building Telecommunications Cabling System 16710-1 Thru 16710-14 16711 Network Switching/Routing 16711-1 Thru 16711-4 16726 Life Safety Alarm System Addressable/Voice 16726-1 Thru 16726-22 16745 Video Surveillance Equipment 16745-1 Thru 16745-4 16821 Telephone System 16821-1 Thru 16821-4 16900 Controls and Control Panels 16900-1 Thru 16900-8
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SECTION NO. TITLE PAGE NO. DIVISION 17 SCADA 17100 Process Instrumentation 17100-1 Thru 17100-16 17200 SCADA Panels 17200-1 Thru 17200-7 17250 SCADA Computer Hardware 17250-1 Thru 17250-5 17350 Filter Control System 17350-1 Thru 17350-12 17400 SCADA Software 17400-1 Thru 17400-3 17500 Antenna Tower System 17500-1 Thru 17500-3 17610 Electric Valve Actuators 17610-1 Thru 17610-4
END
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SECTION 11127
SLUDGE TANKS JET MIXING SCREW CENTRIFUGAL PUMPS
PART 1 GENERAL
1.01 THE REQUIREMENT
A. A. The Contractor shall furnish all labor, materials, tools, and equipment necessary for installation, testing, and placing into satisfactory operation all screw centrifugal pumps, associated piping, valves and operators, supports, anchor bolts, anchoring accessories and other appurtenances required for satisfactory installation and operation, as shown on the Contract Drawings and specified herein. All pumps shall be supplied by the same manufacturer.
B. Equipment shall be provided in accordance with the requirements of Section 00700, General Conditions and 11445, Jet Aeration and Mixing Systems.
1.02 OPERATING CONDITIONS AND PERFORMANCE REQUREMENTS
Sludge Storage Recirculation Pump No. 2
Number of Units 1
Design Capacity (gpm) 3,200
Sludge Solids 0.0-1.5%
Total Dynamic Head (feet) 24.4
Minimum Hydraulic Efficiency 75
Maximum Pump Speed (rpm) 1,200
Temperature of Liquid Pumped Ambient
Suction Condition Flooded
Maximum Size of Solids (Spherical Diameter, Inches)
4.5
Drive Arrangement Direct Drive
Minimum Suction Diameter (inches) 10
Minimum Discharge Diameter (inches) 10
1.03 SUBMITTALS
A. The following items shall be submitted with the Shop Drawings in accordance with, or in addition to the submittal requirements specified in Section 00700, General Conditions:
1. Performance Affidavit
1.04 QUALITY ASSURANCE
A. Each screw centrifugal pump complete with motor, coupling, baseplate, necessary guards, and all other specified accessories and appurtenances shall be furnished by the pump manufacturer as a complete unit to insure compatibility
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and integrity of the individual components. The manufacturer shall provide the specified warranty for all components as a complete unit. The pump manufacturer shall accept unit responsibility for each complete pump assembly.
B. The materials covered by these Specifications are intended to be equipment of proven reliability, and as manufactured by reputable manufacturers having experience in the production of such equipment. The Contractor shall furnish the names of not less than 5 successful installations with over 1 year of operation of the manufacturer's equipment of the same size and model of that offered under this contract. Manufacturer shall have at least 5 years experience in design, application and supply of pumps similar as specified herein.
1.05 WARRANTY AND GUARANTEE
A. Warranty and Guarantee shall be as specified in Section 00700, General Conditions.
PART 2 PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. See Bid Form for acceptable manufacturers.
2.02 MATERIALS
A. Casing shall be constructed of close grained cast iron, conforming to ASTM A48, Class 30, and shall provide smooth unobstructed passages large enough to pass solids of the specified size. A cleanout handhole with removable cover shall be provided for non-clog, helical screw type pumps. The inner contours of the handhole cover shall match the contours of the casing in which it fits. Casing shall be enclosed by a removable suction and seal housing cover or cone carefully machined and aligned. The pump casing shall be so arranged that all rotating parts may be removed without disturbing either suction or discharge piping. Suction and discharge connections shall be 125 pound ANSI Standard flat faced flanges. Suction and discharge nozzles shall be drilled and tapped for gauges. The highest point of the pump casing shall have a drilled and tapped vent with plug and the lowest part of the casing shall have a drilled and tapped drain with plug. The necessary lifting bolts and eye lugs shall be provided for installation and maintenance of the pumps. Taps for gauge connections shall be provided on all nozzles or on adjacent suction and discharge piping. Gauges shall be furnished and installed per plans and specifications.
B. Impeller shall be of helical screw, non-clog type and shall be made from high-chrome iron, conforming to ASTM A532-CLIII-Type A1 with Brinell hardness of 450 or better and shall be statically, hydraulically, and dynamically balanced. The impeller shall be designed with smooth flow passages to pass solids of specified size and to prevent clogging by stringy materials. The impeller shall be keyed and locked to pump shaft at the factory. The impeller shall be secured against reverse rotation and shall be designed so that any solids in the pumped fluid are removed from between the back of the impeller and the backplate.
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C. Suction cone shall be constructed of ASTM-A48, Class 30 cast iron. Suction cone shall be integrally cast with 125 pound ANSI standard flange. A liner shall be installed in the suction cone and shall match the conical geometry of the impeller of the pump. The liner shall be of the replaceable type and shall be constructed of wear resistant Hi-Chrome Iron, or equal, hardened to 450 Brinell or better. Liner shall be securely held in place per manufacturer’s recommendations.
D. Rotation of pumps shall be clockwise when viewed from the driven end.
E. Seal housing shall be readily accessible and isolated from contaminants in the pumped media by a labyrinth fit between the impeller backside and the volute backplate and by pump-out grooves machined into the impeller back shroud and into the volute backplate. Seal housing cover shall be constructed of cast iron, ASTM A48, Class 30, and shall be designed with a machined self-centering fit with the pump casing. The seal housing shall be designed to accommodate commercially available seal designs such as single, double, tandem and cartridge mechanical seals, or standard packing. Tapped, threaded hole shall be provided for seal water connection as specified. Leakage shall be retained by a drainable reservoir, integral with the bearing housing. A 1/2-inch NPT threaded hole shall be provided to connect seal water drainage piping.
F. Shaft sealing shall be accomplished by a split mechanical seal, Model # 442 by Chesterton or equal. The mechanical seal shall consist of silicon carbide seal faces, ethylene propylene flexible members, 316 stainless steel metal parts. The stuffing box shall be provided with a flushing water connection and shall be equipped with a spiral bushing to remove air and solids from seal chamber. Bushing shall be Spiral-Trac Version N made of 316 stainless steel, or equal.
G. Shaft shall be 4140 carbon steel sufficiently large in diameter to transmit safely the maximum torque developed by the drive unit and of such design as to provide a rigid support for the impeller and to prevent excessive vibration. The shaft shall be ground and polished over its entire length.
H. Shaft sleeve shall be a removable, 316 stainless steel or hardened chrome alloy shaft sleeve with seal to prevent leakage, and shall be secured to prevent reversal of rotation. An “O” ring seal shall be provided between the shaft sleeve and the impeller hub to prevent leakage under the sleeve. In addition, an O-ring between the sleeve and shaft shall prevent pumped fluid from contacting the shaft. The shaft sleeve shall not be threaded.
I. Bearings shall be of the radial and thrust bearing, anti-friction ball or roller type, oil or grease lubricated in a dust proof housing. Each thrust bearing shall be adjustable and all bearings shall be readily accessible and designed for convenient repair or replacement. Drain plugs shall be provided for the lubrication and cleaning of the bearings. Bearings shall be sized for minimum AFBMA B-10 life of 100,000 hours under severe operating conditions without credit for hydraulic balancing by pump-out vanes, grooves or balancing rings.
J. The bearing frame shall be constructed of heavy cast iron ASTM A48, Class 30 and shall be bolted to the frame adapter. For oil lubricated bearings, the bearing
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frame shall contain a large oil reservoir, with oil level to be maintained at proper level by means of a constant level oiler. Oil level shall be monitored by a sight glass mounted integrally with the pump. For grease lubricated bearings, the bearing housing shall contain suitable grease relief plugs to ensure positive purging of old grease during re-lubrication.
K. Wear Adjustment –Adjustment of impeller to suction cover wear liner clearances shall be accomplished by adjusting the jacking screws on the volute cover. Use of shims to adjust the impeller to suction cover liner shall not be acceptable.
L. Base - The pump shall be supported by a cast iron pedestal cast integrally with, or especially fabricated for, the pump casing and sufficiently sized to ensure rigid support. The common pump and motor base shall be heavy welded steel construction or cast iron suitably constructed to support the equipment and shall be provided with bolt and grout holes and drain connections with drip-lip.
M. Pumps shall be direct driven: An OSHA approved guard shall be provided.
2.03 ELECTRICAL AND CONTROL REQUIREMENTS
A. All motors shall be in accordance with Division 16, Motors.
B. Electrical Requirements
Sludge Storage Recirculation Pump
No. 2 Motors Rating 460V, 3 ph, 60 Hz Maximum Horsepower 40 Maximum Speed, rpm 1,200 Enclosure TEFC Motor Drive Non-VFD Insulation Class F Inverter Duty No Service Factor 1.15 Seal Water Yes Space Heater Yes Motor Winding Temperature Switches
Yes
Separate Cooling Fan No 2.04 SPARE PARTS
A. Spare parts shall be provided in accordance with Section 00700, General Conditions and shall include the following for each series of pumps.
One (1) - Impeller One (1) - Liner One (1) - Shaft sleeve
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One (1) - Set of motor and pump bearings One (1) - Complete mechanical shaft seal assembly Two (2) - Sets of gaskets and O-ring seals
PART 3 EXECUTION
3.01 MANUFACTURER’S FIELD SERVICES
A. The services of a qualified manufacturer's technical representative shall be provided in accordance with Section 00700, General Conditions. For each series of pumps, field services shall include the following site visits as a minimum. The technical representative shall provide whatever time, services, and components are required to ensure that pumps meet all plan and specification requirements and are operating as required.
Service Number of Trips Number of Days/Trip
Installation and Testing 1 1 Startup and Training 1 1 Services after Startup 1 1
3.02 SHOP TESTING
A. Shop testing shall be as specified in Section 00700, General Conditions.
3.03 FIELD TESTING
A. Field testing shall be as specified in Section 00700, General Conditions.
3.04 PAINTING
A. Painting shall be as specified in Section 09900.
END OF SECTION
***
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SECTION 11201
FRP FILTER TROUGHS
PART 1 GENERAL
1.01 SECTION INCLUDES
A. FRP filter troughs.
B. Stainless steel trough supports. Filter troughs and supports shall be provided by the filter system supplier. Their design shall be as specified in this Section.
1.02 REFERENCES
A. ANSI/NSF 61 - Drinking Water System Components - Health Effects; NSF International.
B. ANSI/AWWA F101 - Contact Molded, Fiberglass-Reinforced Plastic Wash Water Troughs and Launders; American Water Works Association.
C. ASTM A276 – Standard specification for Stainless Steel Bars and Shapes
D. ASTM D 638 - Standard Test Method for Tensile Properties of Plastics.
E. ASTM D 790 - Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials.
1.03 SUBMITTALS
A. Submit under provisions of Section 00700/ 00710.
B. Product Data: Test results of fiberglass reinforced plastic laminate.
C. Critical dimensions, jointing and connections, fasteners, anchors and supports.
D. Materials of construction.
E. Sizes, spacing, and locations of structural members, connections, attachments, openings, fasteners, supports and loads.
F. Manufacturer's installation instructions.
1.04 DELIVERY, STORAGE, AND HANDLING
A. Store products indoors and protect from construction traffic and damage.
PART 2 PRODUCTS
2.01 MANUFACTURER
A. Provide products manufactured by Warminster Fiberglass Company; P.O Box 188, Southampton PA 18966-0188; ASD. Tel. (215) 953-1260, Fax. (215) 357-7893; or equal.
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2.02 WASH TROUGHS
A. Material: Fiberglass reinforced polyester resin, minimum 1/4-inch thick, average; inside surface of smooth gel coat finish; outside surface resin sealed with no exposed glass fibers; molded-in color with ultraviolet inhibitor.
1. Tensile strength (ASTM D 638): 14,000 psi.
2. Flexural strength (ASTM D 790): 25,000 psi
3. Flexural modulus (ASTM D 790): 1,000,000 psi.
4. Color: White.
B. Construction: Comply with requirements of ANSI/AWWA F101 and ANSI/NSF 61; provide NSF labeled products and proof of certification.
1. Designed to support applied water loadings at each location.
2. Designed to resist deflection under full buoyant and gravity water loads with maximum upward and downward deflection less than or equal to L/1000 where L equals the unsupported trough length; maximum deflection at midpoint not greater than 1/8 inch.
3. Round bottom, vertical sides.
4. Top edges straight with not more than 1/8 inch deviation from true plane.
5. Longitudinal steel stiffening ribs integrally molded on the outside of troughs to prevent deflection.
6. Spacer rods to maintain uniform width over the length of trough, up to 21 inches in width use solid 1 inch diameter PVC, 24 inches and above use solid 1 inch diameter stainless steel.
7. 2-inch wide, 1/2-inch thick wall, grouting rib molded to outside of each trough at the gullet end to act as a water stop when trough is grouted in place. The grouting rib noted is for the section of the trough that is grouted into the wall. The rib also applies if the trough is cast in place when the wall is placed.
8. The outlet end shall be flanged. The design of the flange and the unit’s connection to the filter forebay wall shall be by the filter manufacturer and included in the shop drawing. When troughs become too long to easily handle as a single piece, unit flanges shall be provided for assembling the pieces. Flanges are not required for short single piece units unless specifically called for or noted on the Drawings.
9. Stainless steel wall anchors and flat bars.
10. Saddle at blind end.
11. Straight edge weir plates, factory-installed.
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12. Provide stabilizers (cable sets or stainless steel tubing) where necessary to restrict lateral movement.
2.03 FILTER TROUGH SUPPORTS
A. Filter trough supports shall be Type 304L stainless steel with Type 316 stainless steel bolts, nuts, and washers.
PART 3 EXECUTION
3.01 EXAMINATION
A. Verify that dimensions are correct and project conditions are suitable for installation. Do not proceed with installation until unsatisfactory conditions have been corrected.
3.02 INSTALLATION
A. Install products in accordance with manufacturer's instructions.
B. Ensure that products are installed plumb and true, free of warp or twist, within tolerances specified by the manufacturer and as indicated in the contract documents.
C. Set in place with weir edges to elevations indicated.
D. Level weir edges to within 1/8-inch of level over entire length.
E. Grout in place after leveling.
3.03 ADJUST AND CLEAN
A. Clean surfaces in accordance with manufacturer's instructions.
B. Remove trash and debris, and leave the site in a clean condition.
END OF SECTION
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SECTION 11214
VERTICAL TURBINE WATER PUMP EQUIPMENT PART 1 GENERAL 1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install vertical turbine water pumps as shown on the Contract Drawings and as specified herein.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Sections 00700/00710 and 01600.
B. Pressure pipe is specified in Division 2.
C. Painting is specified in Division 9.
D. Valves are specified in Division 15.
E. Electrical work is specified in Division 16.
F. Motors are specified in Division 16, Section 16220.
G. Special sequence or schedule requirements (if any) are specified in Section
01010 - Summary of Work. 1.03 SYSTEMS DESCRIPTION
A. It is the intent of these Specifications to provide a completely functional and operational pumping system as planned and specified with all necessary equipment, materials, parts, controls and other components and proper installation of these items of equipment, materials, etc., to perform the functions specified.
1.04 QUALIFICATIONS
A. Vertical turbine water pump equipment shall be furnished by a single
manufacturer who is experienced, reputable, and qualified in the manufacture of the equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with best practices and methods. The equipment shall be manufactured by Peerless Pump, Flowserve, Goulds, Layne Christensen, Floway, or equal.
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1.05 SUBMITTALS
A. Prebid submittals are required only if called for in Section 00521 - Form of Proposal, and shall be in accordance with Section 00820 - Special Conditions and Section 00700/00710 – General Conditions.
B. Shop drawings and other items needed to establish compliance with the
Drawings and the Specifications for all products in this Section shall be submit-ted to the ENGINEER in accordance with Section 00700/00710 – General Conditions.
C. O&M instructions shall be submitted to the ENGINEER in accordance with Section
01600. 1.06 EQUIPMENT OR SYSTEM WARRANTY
A. Refer to Section 01600 for warranty requirements. 1.07 REFERENCES A. Where standards for materials or construction of equipment, etc., are noted
such as ANSI, AWWA, ASTM, etc., the standard to be used shall be the latest published edition as of July 2016, unless a specific year’s standard is noted.
PART 2 PRODUCTS 2.01 VERTICAL TURBINE PUMPS
A. General
1. These pumps shall meet or exceed all applicable provisions of ANSI/AWWA E101 (E103). Unless otherwise noted, all further reference to section and paragraph numbers shall be those of ANSI/AWWA E101.
2. All treated water pumps shall be lubricated by the water they pump.
B. Pump Base
1. The pump base shall be of the unit drive construction. It shall be of cast iron or fabricated steel and shall be so constructed as to facilitate trapping of water from packing gland and be provided with a ½-inch female IPS drain connection. It shall also provide a port(s) for access for connecting the motor and pump line shaft.
2. The above ground discharge outlet shall be flanged. Flanges shall be
rated in accordance with ANSI conventions with respect to pump shut-off head.
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C. Driver
1. The driver shall be in accordance with Section 16220, with the following exceptions and/or additions:
a. The thrust bearing shall be of such size and quality that the
average life rating is no less than 5 years continuous operation. b. To prevent damage to rotating parts of all pumps and motors due
to reverse rotation, a non-reverse ratchet, in the drive head of the motor, must be provided.
c. Motor suppliers or pump suppliers must not, under any condi-
tions, attempt to quote pump motors without reference to detailed electric motor specifications under Division 16 of these Specifications.
d. When electrical variable speed drive and automatic speed control
are required, specifications for these features are to be found in Division 16 of these Specifications. The high service pump motors shall be inverter-duty, and all motors shall have embedded winding thermostats.
D. Suction Strainer
1. Suction strainers are not required for finished water pumps.
E. Anti-Vortex Suppressor
1. An anti-vortex suppressor shall be provided if, in the opinion of the pump supplier, the minimum water level as noted on the plans or specified herein is too close to the pump’s minimum water level that vortexing could happen.
F. Suction Case
1. All pumps shall be equipped with bell type suction cases. These cases are
to be of cast iron or ductile iron as needed by the pressure. They shall be carefully designed to bring the flow efficiently into the pump with gradually increasing velocities and directing it properly into the eye of the first impeller. Where suction strainers or vortex suppressors are specified or called for, provision must be made for supporting it from the bell lip. Suction cases may also contain the bottom or tail pump bearing.
G. Pump Bowls
1. Pump bowls shall be in accordance with Section A4.3.1 for pumped water
lubricated pump column with the following exceptions and/or additions:
a. Bowl wear rings are not required on finished water pumps.
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b. The elevation of the bottom of the suction bell or suction can, shall
be by the equipment manufacturer, shall be shown on the shop drawings and shall meet the requirements of the Hydraulics Institute Standards.
H. Impeller
1. Impellers shall be in accordance with Section A4.3.2 for pumped water
lubricated pump column with the following exceptions and/or additions:
a. High service and backwash pumps shall have semi-open or enclosed impellers.
b. Impellers shall be bronze or ductile ni-resist (comparable to ASTM
439), able to handle up to 4 ppm chlorine in the finished water.
c. Impellers shall be balanced mechanically, dynamically, and hydraulically, in accordance with HI standards.
d. Impeller wear rings are not required for finished water pumps.
e. Unless otherwise specified for a specific service, mixed flow or
propeller type pumps are not acceptable.
I. Bowl Assembly (Pump) Shaft
1. The bowl assembly shaft shall be in accordance with Section A4.3.3 for pumped water lubricated pump column with the following exceptions and/or additions:
a. Bowl assembly shafts shall be of 416 stainless steel.
J. Line Shafts
1. Line shafts shall be in accordance with Section A4.3.4. for pumped water
lubricated pump column with the following exceptions and/or additions:
a. Line shafts on all water lubricated pumps, either pumped or treated water lubrication, shall be of 416 stainless steel.
b. Line shafts shall be furnished in interchangeable sections having a
nominal length not to exceed 5 feet.
K. Line Shaft Bearings
1. Line shaft bearings shall be in accordance with Section A4.3.5 for pumped water lubricated pump column. Bearing spacing shall be 5 feet, maximum.
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L. Discharge Column Pipe
1. Discharge column pipe shall be in accordance with Section A4.3.6 for pumped water lubricated pump column with the following exceptions and/or additions:
a. The inside diameter of the pipe shall be such that water velocities
at design capacity will not be less than 4 feet per second nor more than 10 feet per second.
b. The pipe shall be furnished with threaded sleeve coupling connec-
tions in sizes up to and including 8 inches; over 8 inch size the column pipe connections shall be flanged.
c. For pump columns larger than 16 inches, pump column wall
thicknesses and weights shall not be less than those shown in the following table:
Nominal ANSI Wall Weight/Ft. Size Schedule Diameter (Inches) Thickness Plain End (Inches) Number Outside Inside (Inches) (Pound) 18 NA 18.000 17.250 0.375 70.59 20 20 20.000 19.250 0.375 78.60 24 20 24.000 13.250 0.375 94.62 26 NA 26.000 25.250 0.375 102.63
M. Discharge Head Assembly
1. Discharge head assembly shall be in accordance with Section A4.3.7 for pumped water lubricated pump column bearings with the following exceptions and/or additions:
a. A special wrench for each size of tube tension nut shall be
provided.
b. A water slinger shall be provided on the top pump shaft above the packing box.
c. Tops shall be provided for pressure gauges.
N. Ratchets
1. Non-reverse ratchets are required for all pumps and motors.
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O. Head Base Plate (Sole Plate)
1. There shall be furnished with each pumping unit a rectangular steel or cast iron plate or casting, with all mating surfaces machine finished, that supports discharge head, and may become a permanent part of the pump foundation after initial installation. The plate or casing shall be of suitable design and of ample thickness to carry the superimposed loads over spans indicated on the Drawings without deflection.
2. The plate shall be sized to span the opening of the size shown on the
Drawings.
P. Pump Shaft Bearing Lubrication
1. Pumped Water Lubrication
a. Pump shaft bearing lubrication shall be essentially the same as that specified for "oil lubrication" except that the shaft enclosing tube and provisions for sealing and bypassing are not required.
Q. Pump Packing
1. Packing shall be heat dissipating GFO body plus abrasive-resistant
Aramid fiber corners in an interwoven braid. 2. Packing temperature range shall be 500 degrees Fahrenheit. Packing
shall be suitable for use with fluids having a pH range of 3 to 11. 3. PV factor shall be 300,000. 4. Packing shall be good to 2,000 psi, with standard clearances. 5. Tensile pressure shall be 35,000 psi for GFO and 400,000 psi for
Aramid. 6. Packing shall handle minimum shaft surface speeds of 2,500 feet per
minute. Heat transfer shall be higher than TFE filament. 7. Packing shall be Palmetto Style 1359, or equal.
R. Pump Acceptance Test
1. All pumps shall meet the pump test acceptance grade and corresponding tolerance band of 10 with regard to flow rate, head, power, and efficiency, as stated in the Hydraulic Institute 14.6. Values outside this grade shall be grounds for rejection.
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S. Pump Service and Operating Conditions 1. Backwash Pump a. General (1) Backwash water pumps shall be pumped water lubricated. (2) A total of 2 pumps will be required. Units will be housed
inside a heated structure. (3) Under normal operating conditions, minimum
submergence shall be 8 feet. (4) The total dynamic head, as listed below, does not include
pump column losses; these losses must be taken into account by the pump manufacturer in quoting pump field efficiencies and preparation of expected pump performance curves.
(5) Head-capacity curve of the pumps must have a continuous rise from specified operating range to shutoff.
b. Operating Conditions Item Condition Design Capacity 7680 gpm TDH at Design Capacity 55 feet Min Pump Bowl Effic. @ Design Capacity 82 % Maximum Pump & Motor Speed 1800 rpm Maximum Motor Hp 150 Hp 2. High Service Pumps a. General (1) High service pumps shall be pumped water lubricated. (2) A total of 3 large capacity and 2 small capacity pumps will
be required. All units will be housed inside heated structures.
(3) Under normal operating conditions, minimum submergence will be 8 feet.
(4) The total dynamic head, as listed below, does not include pump column losses; these losses must be taken into account by the pump manufacturer in quoting pump field efficiencies and preparation of expected pump performance curves.
(5) Head-capacity curve of the pumps must have a continuous rise from specified operating range to shutoff.
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b. Operating Conditions Large Small Capacity Capacity Item Condition Condition Design Capacity 3125 gpm 1800 gpm TDH at Design Capacity 365 feet 255 feet Min Pump Bowl Effic. @ Design Capacity 82 % 81 % Maximum Pump & Motor Speed 1800 rpm 1800 rpm Maximum Motor Hp 400 Hp 150 Hp R. Painting 1. Only ferrous metals shall be painted. 2. All ferrous metals, including inside and outside of pump column pipes
and cans, and exterior of pump bowl assemblies, shall be finish painted at the factory in accordance with PAINTING, as specified under Division 9 of these Specifications.
PART 3 EXECUTION 3.01 DELIVERY, STORAGE, AND HANDLING
A. Delivery, storage, and handling shall be in accordance with Section 01600.
B. Storage
1. General
a. Consider a unit in storage when:
(1) It has been delivered to the job site and is awaiting instal-lation.
(2) It has been installed, but operation is delayed pending
completion of plant construction.
(3) There are long periods (30 days) between operation cy-cles.
(4) The plant is shut down.
2. Pumps and Motors
a. If the pump(s) and motor(s) are in storage as defined in
3.01.B.1.a. above, or are taken out of service and put into stor-age, the following precautions shall be taken:
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(1) Store indoors.
(2) Pumps and motors should not be stored on vibrating bases or floors. Any motor so stored should be disassembled and inspected for bearing damage, prior to service. If bearing damage is evident, replace bearing.
(3) Check the rust preventative coating on external machined
surfaces (including shaft extension) for damage. If necessary, recoat the surfaces with Rest Veto No. 342 (Manufactured by E.F. Houghton Co.) or equivalent. The condition of the rust preventative coating should be checked periodically and surfaces should be recoated as recommended by the coating manufacturer.
(4) Oil lubricated bearings - drain oil from bearing housing
and refill, to maximum level, with a circulating type oil. Oil should be changed every 12 months while motor is in storage.
(5) Grease lubricated bearings - once a month, inject a small
quantity of grease into the grease fill such that grease is purged from the drain. Inspect purged greases for water condensation or oxidation. If water condensation or oxidation is evident, the motor should be disassembled and contaminated grease removed, and replaced with new grease.
(6) Take precautions as necessary to prevent rodents, snakes
or other small animals from nesting inside motor.
(7) If pump and motor are covered by plastic or similar material, additional precautions such as heated or circulating air and silica gel may be necessary, to protect against moisture or condensation.
(8) Rotate pump and motor shaft several revolutions by hand
once every two weeks while in storage to insure a protec-tive oil film on bearing surfaces.
(9) Start-up preparation after storage:
(a) Thoroughly clean and inspect motor.
(b) Change oil or grease in bearing housing.
(c) Secure all plugs, fittings, etc., to prevent leakage.
(d) Check insulation resistance.
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3. Other Equipment
a. Since many plastics are light sensitive to sun and fluorescent lighting, they should be stored in a protected area to prevent accelerated aging from occurring.
b. All equipment and materials shall be stored to protect them from
rain, snow, and other weather elements, including flooding. 3.02 PUMP AND MOTOR INSTALLATION
A. General
1. All pumps shall be installed by the supplier, or, if by the general CONTRACTOR then under the supervision of a factory trained and qualified representative of the supplier, at no extra cost to the OWNER over and above that bid by the General Contractor.
2. Included as a part of each pump installation are the following items:
a. Concrete Base - Each pump shall set on a concrete base. The
base must be secured to the supporting structure by steel dowels and/or 316 stainless steel pump anchor bolts. The concrete base shall be poured up to a point 1-1/2" below the pump base or sole plate prior to installation of the pump. The last 1-1/2" shall be grouted after the pump is in place and checked for alignment.
b. The pump shall be installed and aligned by a qualified millwright
prior to grouting and of the base. All bolted connections shall be made to the pump prior to grouting the base and the pump casting shall be free of strain from any of these connections.
c. The pump shall be shimmed into place with steel shims and the
base grouted.
d. All pumps shall be equipped with discharge gauge taps, suction gauge taps for centrifugal pumps, air release valves as required for proper operation, gland seal drain and base drain connections. All drains shall be piped to a connection to the floor drainage system near the pump base. No drains shall be run across walking areas.
e. Lubrication - All pumps and motors shall be completely
lubricated in accordance with the pump manufacturers recommendations. All lubricants shall be provided by the CONTRACTOR. This shall include the mechanical seal.
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B. Grouting Base
1. Grouting the base compensates for uneven foundation, distribute the weight of the unit and prevents shifting of the unit. Grout material shall be an approved non-shrinking grout. The grout used shall be a standard or high flow epoxy grout and be Five Star’s DP Epoxy Grout; BASF, Euclid, Sika, or equal with a minimum 7-day compressive strength of 12,000 psi; a positive expansion or height change; a minimum effective bearing area of 95 percent; a minimum tensile strength of 2000 psi; and a minimum flexural strength of 3500 psi. Grout shall be installed as recommended by the grout supplier. The grouting procedure shall be as follows:
a. Form the area to be grouted.
b. Construct headbox for great placement as recommended by
grant supplier.
c. For centrifugal pump, completely fill base plate with grout. If necessary, drill vent holes in base to remove trapped air.
d. After the grout has cured, retighten the anchor bolts.
e. Recheck pump alignment.
C. Alignment
1. The pump shall be aligned with the ambient temperature normal for the
pump operating condition. The coupling shall be checked for angular or parallel misalignment in both the horizontal and vertical plains. Alignment will be by registered machine fit, no shimming required. The CONTRACTOR shall provide a dial indicator for checking alignment.
D. Piping
1. Discharge and suction piping shall be supported by adequate means to
prevent the transfer of any load to the pump casting.
E. Wet Well Cleaning
1. All wet wells or pump suction wells shall be completely cleaned prior to operating a pump. This includes new construction as well as when installing pumps in existing wet wells, intakes or suction wells.
2. All cleaning shall be done by the CONTRACTOR and inspected by the
ENGINEER. All pipes leading into suction wells, etc., shall be flushed to remove wood blocks, gravel, etc.
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F. Vertical Turbine Pumps
1. Many vertical turbine pumps are shipped to the job site unassembled. Pumps shall be assembled in the presence of an ENGINEER or other appointed representative of the supplier. The following points of installation shall be stressed:
a. Properly tightening all joints of shaft, enclosing tube and col-
umn.
b. Metal to metal seating of pump discharge column. (Ends of sections butt together.) The ends shall be thoroughly clean and machined as necessary for proper fit.
c. When lowering additional column, motor, etc., over shaft, use
care not to contact line shaft and cause bending.
d. Installation of proper number of spiders and bearing retainers for flanged pipe column.
e. Adjustment of pump to factory determined setting.
f. The pump column shall be tested by use of a plumb bob to check
vertical alignment in two directions with the plumb bob suspense point being moved 90° for the second check. Vertical alignment shall be true.
G. Motors and Controls
1. The motor and controls shall meet all requirements of the equipment
specifications and Division 16 (Electrical) Specifications. All motors and controls shall be connected and the motor operated while disconnected from the pump to determine proper rotation and to observe for vibration or motor defects. Disconnecting of the pump and motor on certain factory assembled units may be waived by the ENGINEER.
3.03 FIELD PAINTING
A. Field painting is specified in Section 09900.
B. The CONTRACTOR and the equipment manufacturer shall coordinate shop paint and field paint to assure compatibility in accordance with Section 09900.
3.04 PUMP AND MOTOR TESTING
A. Factory Testing 1. Every completely assembled raw water and high service pump shall be
given a standard running test. The test shall be in conformance with the provisions of Section A6.2 of AWWA E101 Specifications. At the
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conclusion of the test, 3 copies of the certified test data sheets and the anticipated field performance curve shall be supplied to the ENGINEER for approval prior to pump shipment.
2. If the efficiency of the unit(s) during the factory test proves to be lower
than the efficiency in the Specifications, it will be cause for rejection of the unit, or at the ENGINEER’S option, a deduction in the Contract amount for the extra costs the OWNER will bear in extra power costs for the high service pumps.
B. Field Testing 1. Pump and Motor Performance a. Each pump and motor will be field tested for conformance with
approved characteristic curves. The tests shall be made by the CONTRACTOR in accordance with Appendix A to AWWA E101 Specifications for field testing of vertical turbine pumps and shall be witnessed by the ENGINEER. The CONTRACTOR shall furnish all test equipment.
2. Pump and Motor Vibration a. Each pump will be tested for vibration amplitude by a represen-
tative of the supplier, in the presence of the ENGINEER, using a vibrometer provided by the supplier. Measurements to be taken on the pump discharge head. Amplitudes shall not exceed the following maximum permissible limits:
Pump Speed Measured Amplitude (RPM) (Inches) 1800 0.004 b. Any pumping unit failing to pass the above vibration test shall have the
vibratory causes rectified to the satisfaction of the ENGINEER. The pump(s) shall then be retested for vibration and a report of the test provided to the ENGINEER. An additional vibration test shall be conducted after 30 days of operation and a report of the test provided to the ENGINEER.
3.05 START-UP AND TRAINING
A. Start-up and training shall be in accordance with Section 01600. 3.06 TOOLS AND SPARE PARTS
A. All special tools required for normal operation and maintenance shall be furnished by the equipment manufacturer.
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B. Spare Parts
1. Vertical Turbine Water Pump
a. The required spare parts for vertical turbine pumps shall be those as recommended by the pump manufacturer and shall include the following items as a minimum, where applicable.
(1) One set of "O" rings and gaskets.
(2) One set of mechanical seals.
(3) One top (head) pump shaft for packed pumps.
(4) Packing
(5) One year supply of all lubricants required for all pumps
and their accessories. (6) One packing removal tool for each different size unit.
3.07 METHOD OF PAYMENT
A. Payment for the complete system shall be included in the lump sum bid for the project and shall include the furnishing of materials, equipment and parts, and installation of all components to provide a completely functional and operational system.
END OF SECTION
***
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SECTION 11216
END SUCTION PUMPS PART 1 GENERAL 1.01 SCOPE OF WORK
A. Provide all materials and equipment required for the supply of end suction, frame mounted, solids handling pumps coupled to a premium efficiency NEMA C face motor driver, and accessories, and all services needed for installation inspection, startup and training for same, as specified herein and as shown on the Drawings.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Sections 00700/00710 and 01600.
B. Pressure pipe is specified in Division 15.
C. Valves are specified in Division 15.
D. Motors and Electrical work are specified in Division 16
E. Special sequence or schedule requirements (if any) are specified in Section
01010 - Summary of Work.
F. Painting is specified in Division 9. 1.03 SYSTEMS DESCRIPTION
A. It is the intent of these Specifications to provide a completely functional and operational pumping system as planned and specified with all necessary equipment, materials, parts, controls and other components and subsequent proper installation of these items to perform the functions specified.
1 04 QUALIFICATIONS
A. The end suction pump equipment shall be furnished by a single manufacturer who is experienced, reputable, and qualified in the manufacture of the equipment to be furnished. The equipment shall be designed and constructed in accordance with best practices and methods. The equipment shall be manufactured by Cornell Pump Company, Goulds, Flowserve, or equal.
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PART 2 PRODUCTS
2.01 END SUCTION PUMPS A. General 1. The supplier shall furnish the number of end suction pumps as applicable
for each application as specified herein. Each unit shall be furnished with a pump and driver. Pumps and drivers shall have rigid, heavy duty frame mounting feet and be mounted on a heavy duty, corrosion resistant baseplate. The driver shall be connected to the pump with a flexible/rigid coupling. The pumps shall be capable of continuous 24 hours per day service. They shall operate without unusual noise in any part. The pumps shall be of the single stage, end suction design. All pumps supplied shall be close-coupled, end suction pumps for general industrial service.
B. Conditions of Operation
1. Design Conditions Large Solids Handling Pumps
Designation Floc and settling basin drainage Fluid Water sludge at ambient temperature Design Capacity 4000 gpm at 30 feet TDH Minimum Design Flow Range
Pump Model Cornell Solids Handling 12NNF Suction Pressure Atmospheric plus 0 to 3 feet NPSHR—maximum 16 ft Pump efficiency— minimum
72%
Pump Type Horizontal End Suction Solids Handling Centrifugal Maximum speed 1200 rpm Connections Flanges drilled to ANSI B16.1 Class 125 Casing ASTM A48 Cast Iron—minimum Class 30 Impeller Enclosed 2 vane cast iron, ASTM A48, Class 30 Shaft High strength alloy steel Shaft Sleeve 420 stainless steel minimum 400 BHN Lubrication Flooded oil bath Seal Type Mechanical –single mechanical seal, John Crane T-2 with
Viton elastomers, stainless steel hardware and tungsten vs. silicon carbide seal faces, or equal.
Seal Lubrication None or water internal flush Seal Manufacturer Flowserve, John Crane, or equal Base Plate Rigid and corrosion resistant Coupling Rex-Omega Elastomeric or equal Motor TEFC
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2. Design Conditions Small Solids Handling Pumps
Designation Settling basin sludge Fluid Sludge at ambient temperature Design Capacity Minimum Design Flow Range
150-600 gpm via a flow control valve
Pump Model Cornell Solids Handling Pump Suction Pressure Atmospheric plus 0 to 3 feet NPSHR—maximum 16 ft Pump efficiency— minimum
Varies
Pump Type Horizontal End Suction Solids Handling Centrifugal Maximum speed 1200 rpm Connections Flanges drilled to ANSI B16.1 Class 125 Casing ASTM A48 Cast iron—minimum Class 30 Impeller Cast iron, ASTM A48, Class 30 Shaft High strength alloy steel Shaft Sleeve 420 stainless steel Lubrication Flooded oil bath Seal Type Mechanical –single mechanical seal, John Crane T-2 with
Viton elastomers, stainless steel hardware and tungsten vs. silicon carbide seal faces, or equal.
Seal Lubrication None or water internal flush Seal Manufacturer Flowserve, John Crane, or equal Base Plate Rigid and corrosion resistant Coupling Rex-Omega Elastomeric or equal Motor TEFC C. Construction 1. The keyed straight bore impeller shall be mounted directly to the pump
shaft. 2. The bearing frame shall be constructed of close grained ASTM A48 cast
iron. Bearings shall be ball or roller type sufficient to withstand radial and axial loads and result in a L-10 Bearing life of minimum 20,000 hours. Bearing lubrication shall be grease/oil (select one) with fittings provided to facilitate lubrication.
3. The pump and bearing frame shall be connected by an ASTM A48
Class 30 fine grain Grey Iron bracket with machined registers to assure proper alignment.
4. The pump casing shall be centerline discharge of back pullout design
allowing for removal of rotating element without disturbing piping connections. The casing shall be constructed of fine grain Cast Iron of ASTM A48 Class 30. All casing sections shall have heavy wall thickness to provide long life under abrasive and corrosive operating conditions. All mating surfaces shall have register fits to ensure proper alignment.
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Piping connections shall be ANSI 125# flat face drilled flange. Flange face surface finish shall be a minimum of 250 micro-inch finish.
5. A replaceable wear ring shall be provided. The ring shall be of the
peripheral design requiring no axial adjustment and shall be press fit into the case. The rings shall be constructed of ASTM A48, Class 30 cast iron.
6. The impeller shall be of heavy section Cast Iron ASTM A48, Class 30 with
four-port design. Impellers shall be capable of passing a 3-inch or larger soft solid. Impellers will have back vanes to reduce axial thrust and lower the stuffing box pressure. Internal vane edges shall be well rounded to present smooth flow. Impeller shall have a straight non-tapered bore (except 4NNTL and 12NNF which are tapered), be statically balanced, keyed to the shaft and further secured with a stainless steel washer and a stainless steel impeller lockscrew. The impeller shall be fixed at location with no expected or required adjustment. A Cornell Cycloseal backplate, or equal, with deflector vanes constructed of ASTM A48 Class 30 Grey Iron shall be provided, including a single mechanical seal, of material, tungsten carbide vs silicon carbide. The design shall allow for continuous operation without the need for external flush water or venting.
8. The shaft shall be of high strength Alloy Steel. The shaft shall be
accurately machined and polished and of sufficient size to transmit full driver output without excessive flexure or stressing. The shaft shall have a minimum diameter as recommended by the supplier for the specified service. All steps in the shaft shall have radius to reduce stress concentrations. Shaft deflection shall not exceed 0.005 inch measured at end of shaft when operating at specified design condition. A complete shaft stress analysis calculation shall be supplied by the pump manufacturer to illustrate conformance with this requirement.
9. The shaft shall be protected by a renewable shaft sleeve which extends
through the stuffing box and under the gland. The sleeve shall be grooved on the inside for an o-ring to prevent leakage along the shaft and shall be positively locked to prevent rotation. The sleeve O.D. shall be a minimum of 0.375 inches wider than the shaft and constructed of 420 S.S H.T. min 400 BHN.
10. The pump and motor shall be mounted on a groutable, fabricated steel
baseplate or a drip rim baseplate with integral drip channels incorporated on each side. Each channel shall include an NPT drain connection and plug. The base shall be sufficiently rigid to support the pump and the motor without the use of additional supports or members.
11. The motor shall be horizontal mount, induction type with rodent screens
on all ventilating passages. It shall be TEFC and non-overloading exclusive of the service factor at any point on the pump head capacity curve. Motor supply power is 230/460 volt, 60 hertz, 3 phase. The motor bearings shall be selected to withstand thrust loads and have a minimum B-10 life of 50,000 hours. The motors shall be equipped with grease fittings and automatic grease reliefs.
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12. Per H1 14.6, the pump shall meet the pump test acceptance grade of 10
for flow, head, and power. PART 3 EXECUTION 3.01 PUMP AND MOTOR TESTING
A. Field Testing 1. Pump and Motor Performance a. Each pump and motor will be field tested for conformance with
approved characteristic curves and motor efficiencies. The tests shall be made by the CONTRACTOR in accordance with Appendix to AWWA 101 Specifications for field testing of vertical turbine pumps and shall be witnessed by the ENGINEER. The CONTRACTOR shall furnish all test equipment. If the efficiency of the unit(s) proves to be lower than approved data shows, it will be cause for rejection of the unit.
2. Pump and Motor Vibration a. Each pump will be tested for vibration amplitude by a
representative of the supplier, in accordance with HI 1.4.6 (latest edition), in the presence of the ENGINEER, using a vibrometer provided by the supplier. Overall displacement (unfiltered) peak-to-peak shall meet the limits set by the Hydraulic Institute.
b. Any pumping unit failing to pass the above vibration test shall
have the vibratory causes rectified to the satisfaction of the ENGINEER. The pump(s) shall then be retested for vibration and a report of the test provided to the ENGINEER. Any unit failing the initial vibration test shall have an additional vibration test conducted after 30 days of operation and a report of the test provided to the ENGINEER.
3. Alignment a. All pumps shall be checked for proper alignment between the
pump and motor according to the latest edition of the Hydraulic Institute Section 1.4.2, by an authorized representative of the manufacturer. Any pumps found to be out of alignment shall be realigned and rechecked. Each pump shall be certified to be in proper alignment by the supplier’s representative before start-up and training occurs.
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B. Factory Testing 1. All completely assembled pumps and motors shall be given a non-
witnessed running test. The test shall be in conformance with the provisions of the latest version of ANSI/HI 1.6 Section 1.6.5, Performance Test. Job motors are not required for the factory tests; standard test motors may be used. At the conclusion of the test, 3 copies of the test data sheet and the anticipated field performance curve shall be supplied to the ENGINEER.
3.02 START-UP AND TRAINING A. Start-up and training shall be in accordance with Section 01600. 3.03 TOOLS AND SPARE PARTS A. All special tools required for normal operation and maintenance shall be
furnished by the equipment manufacturer. B. Spare Parts 1. Horizontal End Suction Pumps a. The required spare parts for pumps shall be those as recom-
mended by the pump manufacturer and shall, as a minimum, include one mechanical seal for each different size pump or each pump operating under different conditions as noted above.
END OF SECTION
***
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SECTION 11222
WATER PLANT TURBINE MIXERS PART 1 GENERAL 1.01 SUMMARY
A. Prospective suppliers must review the Drawings to acquaint themselves with conditions under which their mixing equipment is to operate, to insure that their equipment will meet the specified performance specifications and be compatible with the specified treatment units. Should a manufacturer consider plan revision advisable, such need for revision must be made known to the ENGINEER at least two weeks in advance of the bid date. All mixing equipment will be field tested for conformance with performance specifications.
1.02 REFERENCES
A. Where referenced specifications (ASTM, ACI, PCI, etc.), are mentioned, these standards are deemed to be the minimum standard of quality of materials or methods to apply to this project.
B. Refer to Division 16 for motor requirements and Division 17 for control
requirements. 1.03 SYSTEM DESCRIPTION
A. Raw water, which has been chemically treated to oxidize iron, manganese and remove other undesirable materials, enters and leaves the basins as shown in the Drawings. This water then flows into 3 chambered flocculation basins where it is flocculated before flowing out at the bottom of the basin.
B. The mixer specified herein for the applications noted above shall include the
mixers, impellers, safety guards, couplings, motors, mounting plates, spare parts and the like.
1.04 SUBMITTALS
A. Shop drawings, control drawings, spare parts listing and operation and maintenance instructions shall be submitted in accordance with Section 00700/00710.
1.05 QUALITY ASSURANCE
A. The mixer shall be Mixtec North America, Lightnin, Enviropax's Anco, Philadelphia, or equal.
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PART 2 PRODUCTS 2.01 TURBINE MIXER
A. General
1. Flash Mixer a. The flash mixer shall be a top entering, heavy duty, double
reduction gear drive turbine mixer capable of continuous blending of the applied chemicals and the raw water being supplied to the system. The mixer shall operate satisfactorily at any flow rate in the range of R800 gpm to 9,200 gpm. The mixer design “G” factor shall be 760 based on water at 2 degrees Centigrade (35.6 degrees Fahrenheit). The unit shall have a minimum 10:1 turndown ratio via a variable speed drive.
b. Basin dimensions are as shown on the Drawings.
B. Impeller
1. The flash mix impeller design shall be such as to obtain the specified mixing results in the basin shown on the Drawings, at minimum energy requirement. Included in determining energy efficiency shall be liquid level variation, basin hydraulic stability, blade loading, and process performance. They shall be of 316 stainless steel.
2. If the addition of baffles in the rapid mix basins is required to obtain the
specified degree of mixing, or if they would reduce mixer energy impact, the use of such baffles and their geometry shall be made known to the ENGINEER and they shall be included in the material furnished.
3. The impeller shall be bolted and keyed to a hub which shall be attached
to the mixer shaft in such a manner that it will solidly transmit torque to and support the impeller assembly in the shaft. The mixing turbine shall be designed to maintain dynamic and hydraulic stability while operating under the specified liquid level. The impeller shall be field removable from the shaft.
4. Impellers intended to be opened at the liquid surface shall be connected
to the shaft by a square book type key, designed to transmit full motor torque and to support the impeller assembly on the shaft. An extended keyway shall be provided of sufficient length to permit adjustment of the axial position 6 inches up or down from the design location. When a flanged coupling or a liquid level sensitive type impeller is used , the drive will be provided with a means of changing the elevation of the impeller from the mounting platform.
5. The maximum stress in any impeller component shall not exceed 11,000
psi under maximum loads. The shaft impeller system design shall be
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such that its operating speed, without stabilizing devices, shall not exceed 70 percent of its first lateral critical speed. The shaft shall be safe for operation when the basin water level passes through the impeller while the mixer is running.
6. The impeller shall be at such design and operate at such rotational speed
that dynamic balance is not required to prevent damaging vibration.
7. The impeller shall be adjustable from a nominal setting upward a total of 18 inches in 3 inch increments.
C. Impeller Shaft (316 Stainless Steel)
1. When turned over by hand, the impeller shaft runout or deflection shall
not exceed 1/4 inch for each 10 feet of shaft length.
2. The attachment of the turbine to the impeller shaft is to be made by a hook-key.
D. Guards
1. All rotating shafts above platform levels must be supplied with guards in
accordance with OSHA standards.
E. Couplings
1. When flanged couplings are supplied on the impeller shaft they must be designed to transmit 200 percent of the full torque and 150 percent of the axial load on the coupling.
2. A rigid coupling shall be provided to connect the mixer motor shaft to
the impeller shaft. The coupling shall assure proper alignment and true running and connect the 2 shafts above the mixer mounting surface.”
F. Drive Unit
1. Each drive unit shall consist of a cast iron or fabricated steel heavy-duty
speed reducer. The speed reducer shall be directly connected through a flexible coupling to the electric motor driver. The reducer shall be specifically designed for mixing service, and shall be capable of 24 hour/day continuous operation in the environment shown on the Drawings or as otherwise specified.
2. The basic rating of the speed reducer shall adhere to appropriate AGMA
standards, and the reducer shall bear an AGMA nameplate, showing that the speed reducer is designed to the specific AGMA standards. The speed reducer shall be designed for a service factor of 1.5, based upon its driving motor nameplate horsepower.
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3. The drive shall be right angle type comprised of helical gear and spiral bevel gearing.
4. General maintenance, including motor changes, speed changes,
replacement of anti-friction bearings (except the bearing supporting the output shaft), and oil system maintenance, shall not require removal of the speed reducer housing from its foundation. The reducer shall be provided lifting lugs.
5. Pressed-on type bearings are not acceptable. The bearings shall be
grease-lubricated with grease inlet and relief accessible from the mounting surface. Each grease fitting shall be protected with a removable neoprene cover.
G. Motor
1. The motor shall be TEFC for 230/460 volt, 3 phase, 60 Hz., electric
current and shall be connected to the drive unit through a flexible coupling. Manufacturers must refer to Section 16 of these Specifications for detailed motor and controller specifications, including variable speed drives. Motors shall be inverter-duty, premium-efficiency with winding thermostats included.
H. Sole or Mounting Plate
1. A suitable and adequate steel or cast iron sole or mounting plate for
mounting the unit to the concrete slab as shown shall be provided. This plate shall be anchored by stainless steel bolts. The plate shall not be grouted until the unit has been installed and proper alignment attained, after which it will become permanent. A pedestal type base shall be furnished for access to the coupling and lubricant drains above the mounting platform. The sole/mounting plate may be part of the pedestal or a separate component. Mounting of the pedestal or sole plate shall be according to the manufacturer’s instructions.
I. Protection Coatings
1. Wetted parts shall have all mill scale, rust and contaminants removed and
sharp corners or cuts of sheared edges drilled by power grinding or filing, after which they shall be painted by the supplier in the factory or by the CONTRACTOR in the field in accordance with Section 09900 of these Specifications.
2. Normally painted surfaces not subjected to continuous wetting shall
receive a protective coating capable of withstanding heating below 250°F. The paint shall be the manufacturer's standard for such services.
3. During manufacturer's shop testing and before shipment, the drive unit
shall be run with a polarizing rust inhibitive oil. Also, each unit shall receive a vapor phase inhibitor such as Shell, VIP-260, power sprayed into
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the reducer housing interior to further guard against internal corrosion during field storage.
4. All openings in the equipment shall be covered with vapor phase inhibitor
impregnated paper and water repellent tape. The same shall be applied over any adapter sleeves, locknuts, reducer oil reservoir dipsticks and breather assemblies or other areas requiring special protection.
J. Marking
1. Each mixing unit shall be provided a nameplate or other permanent
means of showing manufacturer's name or trademark, mixer model number, drive unit rated horsepower and mixer shaft speed.
K. Bearings
1. Bearings throughout the design shall be anti-friction type of ball, roller, or tapered roller design, Pressed-on type or sliding, journal type bearings are not acceptable. Replacement of any gear drive anti-friction bearing, except the bearing supporting the output shaft, shall not require removal of the speed reducer housing from its foundation.
2. All speed reducer output shaft and independent mixer shaft support
bearings shall have a minimum L-10 life of 100,000 hours as calculated by the latest AFBMA standard. Other bearings shall be of a type appropriate to the nature and size of the torsional, thrust and lateral loads encountered. In addition to the design torsional and thrust loads created by the gearing, bearing life calculations shall include the bending loads caused by the forces acting at the mixing/aeration impeller. The type and magnitude of the forces used in the calculation shall be substantiated by the equipment supplier, on request.
3. The output shaft bearings shall be grease-lubricated with grease inlet and
relief accessible from the mounting surface. In aeration service no bearing may be located within 30 inches of the process liquid.
4. Grease fittings serving the mixer and output shaft bearings are to be
plainly marked and each grease fitting shall be protected with a removable cover.
PART 3 EXECUTION 3.01 GENERAL
A. It is the intent of these Specifications to provide a rapid mix system to adequately dispense all chemicals and a flocculation system to adequately flocculate the chemicals and unwanted materials used for water treatment that are shown on the Drawings and included in these Specifications, in the incoming raw water flow to provide a complete mix. It is intended that the system include
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all necessary equipment, materials and parts to do this, along with the complete installation of all equipment, materials, etc., to perform the specified function.
B. Turbine Mixer
1. A turbine mixer shall be furnished and installed at the 4 locations shown
on the Drawings.
C. Testing
1. All mixers shall be field tested for adequate mixing by the injection of a liquid dye at the point of application of coagulant feed and observed for proper dispersal of the dye in the mixing basin.
2. Failure to completely mix will be cause for rejection of the equipment. 3. The equipment manufacturer or certified manufacturer’s trained
representative shall perform the following start-up commissioning services:
a. Provide hands-on or supervisory assistance in configuring the
equipment for start-up. b. Check power at the equipment to confirm proper operation and
loading. c. Check power at the control room to confirm proper voltage. d. Perform vibration diagnostics to measure unit mounting and
operation limits of the equipment. e. Test external bearing temperatures to ensure proper bearing
performance. f. Check high-speed coupling alignment to ensure conformance to
factory tolerances. g. Measure shaft run-out to ensure conformance to Specifications. h. Visually inspect the equipment for any abnormalities that could
jeopardize optimal equipment performance. i. Complete a comprehensive process equipment services
commissioning checklist to confirm that all equipment specifications are met, and that all manufacturer recommended start-up procedures are completed.
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j. Provide a follow-up commissioning report that captures the equipment’s start-up baseline data and serves as the foundation for the equipment’s ongoing maintenance records.
END OF SECTION
***
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SECTION 11223
VERTICAL FLOCCULATION EQUIPMENT PART 1 GENERAL 1.01 WORK OF THIS SECTION
A. Scope: CONTRACTOR shall furnish all labor, materials, equipment, and incidentals as shown, specified and required to provide vertical paddle wheel flocculators.
B. Each mechanism shall be as specified herein and will be designed for installation in a basin having the dimensions indicated on the drawings.
C. The manufacturer of the flocculation equipment shall be vested with unit responsibility for the proper function of the complete system including the paddle wheel flocculator mixing units, and drive system to include variable speed drives as shown and specified. The equipment covered by this specification is intended to be standard equipment of proven ability as manufactured by reputable concerns having extensive experience in the production of such equipment.
1.02 REFERENCES
A. The following is a list of standards which may be referenced in this section: 1. American Bearing Manufacturers Association (ABMA):
a. 9, Load Ratings and Fatigue Life for Ball Bearings.
b. 11, Load Ratings and Fatigue Life for Roller Bearings. American Gear
2. Manufacturers Association (AGMA):
a. 2004-B89, Gear Materials and Heat Treatment Manual.
b. 6001-097, Design and Selection of Components for Enclosed Gear Drives.
c. 6010-F97, Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives.
3. American Iron and Steel Institute (AISI).
4. American Society of Mechanical Engineers (ASME):
a. B1.20.1, Pipe Threads, General Purpose (Inch).
b. B16.5, Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24.
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5. ASTM International (ASTM)
a. A36/A36M, Standard Specification for Carbon Structural Steel.
b. A276, Standard Specification for Stainless Steel Bars and Shapes.
6. National Electrical Manufacturers Association (NEMA): MG 1, Motors and Generators.
7. The Society for Protective Coatings (SSPC).
1.03 SUBMITTALS
A. Complete shop drawings of the equipment shall be submitted to the ENGINEER in accordance with the requirements of Section 00700/00710. The submittal shall include: 1. Manuals shall be in a white 3-ring binder, and include tabbed sections
defining scope, process calculations, mechanical and structural calculations, catalog cuts, and drawings.
2. All process design calculations (velocity gradient, tip speed, horsepower requirements, and paddle arrangement) shall be prepared by the manufacturer and sealed by a registered professional engineer.
3. Manufacturer’s literature, illustrations, specifications, and engineering data including total weight of each unit, structural loads at supports, connection details, and performance data.
4. Drawings shall show dimensions, overall arrangement of equipment and materials of construction.
5. Control diagrams and panel layout.
B. Operations and maintenance manuals shall be submitted to the ENGINEER in accordance with the requirements of Section 01600. 1. The manual shall include: Equipment Data Pages, Equipment Introduction
and Operation, Warranty, Long Term Storage, Troubleshooting, Maintenance and Lubrication, Spare Parts List, Equipment Listing, Catalog Cuts, and Drawings.
2. Field start-up reports as described in paragraph 3.3 (Manufacturer Services) shall be submitted after start-up for owner’s insertion into approved O&M manual.
1.04 RELATED SECTIONS
A. Electrical is specified in Division 16. Motors are specified in Section 16220.
B. Instrumentation and Controls are specified in Division 17.
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1.05 PERFORMANCE AND DESIGN REQUIREMENTS
A. The equipment shall be designed to accomplish mixing and tapered flocculation in the basins without shearing or destabilizing the agglomerated floc particles.
B. The equipment shall be designed to operate in basins having the dimensions indicated on the drawings.
C. The flocculation equipment shall operate in water having a design pH of 7.2 to 8
and a water temperature range of 35 degrees Fahrenheit to 85 degrees Fahrenheit.
D. The equipment shall be designed in accordance with the following requirements at a design reference water temperature of 35 degrees Fahrenheit.
Number of Basins 3 Design Flow per Basin (mgd) Number of Stages per Basin 3 Number of Drives Required per Basin 3 Flocculator Stage Width (ft) 18 (Approximately) Flocculator Stage Length (ft) 18 (Approximately) Average Side Water Depth (ft) 12 Stage 1: Velocity Gradient (sec-1) 60 Stage 2: Velocity Gradient (sec-1) 45 Stage 3: Maximum Velocity Gradient 30 Stage 1: Minimum Motor Horsepower (hP) 2 Stage 2: Minimum Motor Horsepower (hP) 1 Stage 3: Minimum Motor Horsepower (hP) 1 Design Temperature (ºF) 35 Approximate Diameter of Flocculators (ft) 15 Approximate Size of Blades (in. x in.) 2 x 6 Maximum Tip Speed (fps) 3.0** * Can operate with reduced performance at 2.0 mgd when one basin is off-line and all flow is going through the remaining basin. ** Maximum tip speed per Ten State’s Standards. PART 2 PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. The equipment shall be manufactured by: 1. Jim Myers & Sons, Inc. (JMS), of Charlotte, NC
2. Meurer Research, Inc. (MRI) of Golden, Colorado
3. Amwell, Aurora, Illinois
4. Siemens
5. Walker Process Equipment, McNish Corporation
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6. or equal.
B. The equipment described by this specification defines minimum equipment requirements as supplied by the first listed manufacturer. All unforeseen costs associated with any deviation from this specification shall be the sole responsibility of the Contractor.
C. The equipment shall be the product of a manufacturer engaged in the design and manufacture of similar equipment in successful operation in similar applications. The manufacturer shall have a minimum of 10 years of United States municipal water experience with 10 installations of the same type of equipment as specified herein with documented successful operation.
2.02 SHAFTING SYSTEM
A. Shafts 1. The shafting system for each mechanism shall be sized within stress
limitations at full operating load.
2. The maximum shear stress shall not exceed 6,000 psi at any point in the shaft. The maximum shear will be determined by combining the bending and torsional stresses under full operating load through Mohr's circle stress convention.
3. Type 304L stainless steel hubs shall be ½-inch thick minimum, and welded to the shafts for paddle arm connection. Welds shall be continuous on both sides of the hub plate.
4. The drive shaft shall be adequately sized to transmit the required torque at full speed, manufactured from solid Type 304L stainless steel, and shall be no less that 2-7/16 inch. The drive shaft shall be keyed on one end and flanged on the other end. A minimum of 4 gusset plates shall be installed at the flange to reinforce the connection.
5. The paddle reel shafting shall be Type 304L stainless steel hollow shafting, straight and true. The paddle reel shaft shall have flanges on both ends for a bolted connection between the drive shaft and idle end shaft.
6. The idle tail shaft shall be solid Type 304L stainless steel, and shall be no less than 1-15/16 inch, flanged on one end. A minimum of 4 gusset plates shall be installed at the flange to reinforce the connection.
7. All flanges shall be standard 150lb ANSI flanges shall be used, and manufactured from Type 304L stainless steel. Flange size shall be determined by pipe shaft diameter. A minimum ¼-inch thick neoprene gasket shall be placed between each set of flanges. After fabrication, each shaft assembly’s flange shall be faced to within 0.015-inch of parallel to one another. Solid shaft flanges shall be faced to within 0.015-inch of perpendicular to the axis of the shaft.
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B. Bearings
1. The solid drive shaft shall be connected to the output shaft of the gear reducer by a flexible chain coupling, and shall be supported by a heavy-duty radial thrust roller bearing and thrust collar mounted on the drive support base. The roller bearing will be dynamically self-aligning.
2. The thrust bearing assembly shall be independent of the gear reducer and no external or overhung loads shall be imposed on the gear reducer. Flocculator designs that direct couple the flocculator shaft to the gear reducer without a separate thrust bearing assembly are not acceptable.
C. Bottom Steady Guide
1. The idle tail shaft shall be inserted into a maintenance free guide assembly which attaches to the basin floor.
2. The paddle reel assembly shall be held in position by a water-lubricated steady guide and bracket mounted on the basin floor. The submerged steady guide shall be UHMW-PE and removable without disassembly of the paddle shaft.
D. Flocculation Paddle Assemblies
1. The flocculator paddles shall be nominal 2-inch x 6-inch pultruded fiberglass or 304/304L stainless steel channel manufactured with NSF-61 approved polyester resin. Paddles shall be bolted to paddle arms with two ½-inch bolts and nylon insert lock nuts at each connection. All cut edges and holes in the fiberglass paddles will be properly resin sealed.
2. The paddles shall be held in place and supported by stainless steel angle arms bolted to the fabricated stainless steel shaft hubs with two 5/8-inch bolts and nylon insert locknuts. The paddle arms shall be sized for a tip deflection of no more than l/360, and shall be no smaller than L3 x 3 x ¼-inch angles.
2.03 DRIVE SYSTEM
A. Drive Motor
1. Integral gearmotors shall be NEMA Premium energy efficient squirrel cage, induction type with totally enclosed fan-cooled frames. Insulation shall be class F minimum with thermostat overload protection embedded in the windings. Maximum temperature rise above ambient shall not exceed the value specified for Class B rise.
2. Electrical characteristics shall be 460 volts, 3 phase, 60 Hz. Motors shall be provided with 1.15 service factor.
3. Motors shall be equipped with oil or grease lubricated anti-friction bearings have a minimum of L-10 life of 80,000 hours, as defined by AFBMA.
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4. The rating of motors shall be adequate to continuously drive the flocculators under any condition of operation but shall not be less than specified above.
5. Motors shall be inverted-duty with embedded winding thermostats and shall otherwise comply with Section 16220.
B. Gear Reducers
1. Drive units shall be as manufactured by SEW Eurodrive and contain wash down duty features.
2. Each drive unit shall be constant speed and designed to provide speed and output torque as required by process design. The gearbox will be parallel helical or helical bevel gearing as required by site constraints.
3. Each drive unit shall be designed and arranged for rotation as indicated on the drawings.
4. Each gear reducer shall be a heavy-duty, foot-mounted, concentric gear unit completely enclosed in a housing of cast iron or fabricated steel construction. The gear reducer shall be specifically designed for the application intended and shall be suitable for connection to the output shaft. General maintenance, specifically including motor changes, gear changes, bearing replacement and maintenance of the oil lubricating system shall not require the removal of the gear reducer housing from its mounting base.
5. The gear reducer shall be designed and rated for a minimum of AGMA II with a service factor of 1.4 applied to the motor nameplate rating.
6. All gearing shall be designed, constructed, stamped and rated for the AGMA service factor specified herein. The manufacturer shall certify in writing that all gearing was designed in accordance with AGMA standards.
7. The thermal rating of gear reducer shall exceed the design mechanical rating to preclude the need for external cooling equipment. External cooling devices are not acceptable.
8. The gear reducer output shaft shall be constructed and supported so that the shaft deflection caused by the operating loads does not affect alignment of the reducer bearings or cause misalignment of the gearing during operation of the flocculator. All bearings in the speed reducer shall be anti-friction type and shall have a minimum L-10 life of 80,000 hours. The units shall be oil lubricated. All gears and bearings shall be protected from rusting during storage by the application of a shop-applied protective coating.
C. Drive Stand Assembly
1. The drive stand assembly shall be manufactured from Type 304L stainless steel consisting of a drive stand and drive support plate. The
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drive support plate shall be a minimum of ½-inch thick, and bolts to the drive stand which shall have a minimum material thickness of ¼-inch.
2. The drive stand shall be designed and reinforced to withstand all loads, torsional and vertical, applied by rotating forces of the flocculation equipment operating at full speed.
3. The drive stand shall allow for the mounting of the drive base plate, radial thrust bearing, and thrust collar.
4. Drive stand assembly shall ship fully shop assembled and shop tested including the following components.
a. SEW Eurodrive Gear Reducer per section 2.3 Drive system paragraph C.
b. Complete Type 304 stainless steel structural drive assembly weldment a minimum of 30-inches in height.
c. U.S. Tsubaki, Inc. Roller Chain Coupling for gear reducer to drive shaft attachment.
d. Type 316 stainless steel drive shaft with faced flange and double shear vertical load connection.
e. Thrust collar with double shear bolt arrangement.
f. Radial trust bearing assembly designed to keep all loads from the gear reducer.
2.04 SUPPORT BRIDGE
A. Concrete bridges by CONTRACTOR. 2.05 HARDWARE
A. All field assembly bolts and anchor bolts, nuts, and washers will be Type 316 stainless steel.
B. Submerged connections are to be made with Type 316 stainless steel bolts, washers, and nylon insert locknuts.
2.06 FABRICATION
A. All welded joints that will be fully or partially submerged will be sealed watertight with continuous welds. All welding will be performed in accordance with AWS standards.
B. All parts and components shall be factory-assembled in sections convenient for field handling and installation but requiring the minimum amount of work for field assembly. Any field assembly work shall be bolted. No cutting or welding should be required on either field assembly or erection.
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C. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation.
D. All assembled parts and components ready for shipment shall be securely bundled, coiled, or crated and adequately protected from damage and corrosion during shipment and storage.
2.07 SURFACE PREPARATION
A. Stainless steel, aluminum, fiberglass, and UHMW-PE shall not be painted.
B. All stainless steel surfaces, except in bearing areas, shall be brush blasted in accordance with SSPC-SP7 before shipment.
C. Mechanical components such as drive unit and bearing shall include manufacturer’s standard wash down duty paint system.
PART 3 EXECUTION 3.01 INSTALLATION
A. The CONTRACTOR shall install the flocculation equipment in strict accordance with the manufacturer's drawings and recommendations.
B. Anti-seize thread lubricant, which is NSF-61 approved, shall be applied to the male threads of all stainless steel bolts at the time of the assembly.
3.02 WARRANTY A. The supplier shall guarantee in writing that the equipment furnished is
appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of 1 year after the equipment is satisfactorily placed in service. If the equipment is not placed in service within 6 months of delivery, the 1 year guarantee period shall commence 6 months after delivery.
3.03 MANUFACTURER'S SERVICES
A. Manufacturer’s Field Services: The CONTRACTOR shall provide the following
services in addition to any other services specified herein, and required by these Specifications. 1. A factory trained manufacturer’s representative shall be provided for a
minimum of 2 trips and a minimum of two 8-hour days to provide installation supervision, start-up and field testing services, and O&M training services. The installation services shall be coordinated between the CONTRACTOR and the manufacturer. The start-up and field testing services, and the O&M services shall be coordinated with the ENGINEER.
2. After installation supervision and field testing services by the manufacturer, the CONTRACTOR shall submit to the ENGINEER, a
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certification letter on the manufacturer’s letterhead and signed by the manufacturer certifying that the equipment was installed per the manufacturer’s recommendations.
3. The manufacturer shall provide start-up reports covering both dry and wet start up activities. These reports shall include system voltage and amperage readings at 20 percent and 100 percent speed.
4. The manufacturer shall provide operator training to all required plant personnel.
B. All costs, including travel, lodging, meals and incidentals for manufacturer service shall be included in the CONTRACTOR’S bid.
END OF SECTION
***
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SECTION 11230
SLUDGE COLLECTION EQUIPMENT PART 1 GENERAL 1.01 WORK INCLUDED
A. Under this section of the specification, the sludge collector system shall be installed in the sedimentation basins as shown in the Contract Drawings and as described herein.
B. The sludge collector systems shall include tandem collector assemblies, electric drive assemblies, drive cables, sensors, rigid sludge conduit, cable pulleys, control system for fully automatic operation, and all other miscellaneous accessories and hardware as required for a complete installation. This equipment shall be provided as an integral package, manufactured by a single manufacturer.
C. The sludge collectors shall remove by means of 10 feet of differential head, the settled solids from the basin floor. The solids will be discharged through the rigid or flexible sludge conduits which are connected to fixed piping to exit the basin.
1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Electrical is specified in Division 16. B. Instrumentation and controls are specified in Division 17. C. Valves are specified in Division 15.
D. Pipe is specified in Division 2. E. Control panels are specified in Section 16900.
1.03 SUBMITTALS
A. Product data, installation instructions: Section 00700/00710. B. Operation and Maintenance Manuals: Section 01600.
1.04 STORAGE AND PROTECTION
A. Equipment and accessories shall be stored and protected in accordance with the manufacturer’s recommendations.
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PART 2 PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. The sludge collection system shall be manufactured by Jim Myers & Sons; Meurer Research, Inc. of Golden, Colorado; Roberts Filter Group; Siemens; F.B. Leopold; Monroe Environmental; or equal.
2.02 MATERIALS AND CONSTRUCTION
A. Shared Reel Drive Assembly
1. Each drive assembly shall consist of a 3 Phase 230 Vac minimum 1/4 Hp motor which will be coupled to a rotating drum for manipulation of the cable that is attached to the tandem collector assembly.
2. The cable shall be firmly attached to the rotating drum to prevent slippage. Tensioning the cable between multiple pulleys to prevent slippage will not be allowed.
3. The cable shall store on the reel in a single layer, the placement of which shall be organized by the drive mechanism.
4. The complete drive mechanism shall be packaged on a single base and provided with a safety enclosure.
5. The drive cable shall be Type 304 Stainless Steel with a minimum diameter of 3/16 inch.
6. The drive assembly shall be capable of ceasing operation on an excessive motor load without physical damage to the drive unit. The first mechanical failure point shall be an easily replaceable shear pin, but should alarm from an electrically generated source first.
7. The drive assembly shall have integral position sensors which determine when the collector is at the end of the basin, the beginning of the basin and points in-between. No external or under-water position sensors shall be required or allowed.
8. The drive shall have an emergency disconnect button which shall be a large, red palm operated single button.
B. Hoseless Collector Assembly
1. The hoseless sludge collector assembly shall be manufactured entirely of Type 304 stainless steel, with the exception of non-metallic parts such as casters, bushings, orifices, etc. which will be manufactured of plastic, non-metallic materials.
2. Each hoseless collector assembly shall consist of four sludge collection pipes each equal to half the width of the basin with flow orifices which
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are, in turn, connected to a center pipe which carries the sludge to the horizontal telescoping pipe sludge conduit. No flexible sludge hoses are allowed. The center pipe shall seal against the horizontal telescoping pipe sludge conduit by means of a UHMW seal.
3. Each header pipe will be equipped with a scraper blade which is triangular in shape and is equal in length to the header pipe. These “plows” will remove the settled solids that have accumulated at the ends of the basins.
4. The orifices on the collectors shall be designed to allow the flow to enter tangentially into the pipe for efficient sludge removal.
5. Operation of the sludge collector shall be controlled by a sludge valve as directed by the control panel by an electrically actuated sludge valve. The sludge valve(s) shall be provided by the CONTRACTOR as shown on the drawings.
6. The manufacturer shall determine the proper number, spacing and angle of the orifices for the most efficient removal of solids from the basin.
7. Each Hoseless collector assembly will be complete with polyurethane rolling casters, side casters, and all necessary mounting hardware.
8. All welds shall be continuous and brushed clean.
9. All underwater bearings shall be specifically designed for underwater use.
C. Control System
Each drive unit shall have a dedicated control panel furnished by the manufacturer and compliant with Division 16, including Section 16900, Control Panels.
1. Control Panel
a) The sludge collector system shall include an Allen Bradley CompactLogix PLC based electronic control panel which will automatically control all of the functions and operations of the sludge collector system. The HMI shall have the high-brightness sunlight visible display. The control panel shall be fabricated such that the HMI is not normally exposed to sunlight or rain/weather. The enclosure shall have an outer door that opens with a handle to expose the HMI for viewing/control of the system.
b) Each control panel will arrive to the jobsite internally pre-wired ready to connect to the drive unit at the jobsite by utilizing 11-16 gauge wires.
c) Each local panel will operate by an electrical circuit as indicated on the Drawings, which will be furnished to each panel location.
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d) Each control panel will consist of the following:
1) HMI with real time clock for programmable run initiation, 6-inch minimum color touchscreen with sunlight readable display. Allen-Bradley Panelview Plus, or equal, with Ethernet.
2) Programmable Logic Controller, compact Logix with ethernet.
3) VFD with manual operation keys and speed control. 230VAC 3 phase output, ¼ HP minimum.
4) Power supply with control voltage of 24 VDC.
5) Properly sized protective circuit breakers and terminal blocks.
6) Dry contacts and ethernet for communication with the Plant SCADA system. SCADA integration will be implemented in a future contract.
7) Provide a red NEMA 4X alarm strobe light, one for each control panel, to indicate alarms.
2. The control panel components shall be installed inside a NEMA 4X marine grade stainless steel control panel housing. It shall be the responsibility of the sludge collector manufacturer to provide all of the necessary control hardware, software and components as required for a complete installation. Comply with Section 16900.
3. Sludge collection system shall have hand and automatic modes of operation. The hand mode of operation shall be available at the Sludge collection control panels via hand controls. The automatic mode of operation shall be timer-based per the manufacturer recommendations with adjustability of setpoints.
PART 3 EXECUTION 3.01 INSTALLATION
A. Equipment should be stored indoors in a dry area prior to installation.
B. Install sludge collection equipment as indicated on the contract drawings and in
accordance with the manufacturer’s recommendations.
C. Provide factory certified service technician for 2 days in 2 trips, one day to inspect the installation and supervise start-up and initial operation of the sludge collector system, and the second day as a follow-up startup training 10 months into the warranty period.
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D. Factory certified service technician to provide field report certifying that the equipment is properly installed, fully operational and ready for to the ENGINEER.
END OF SECTION
***
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SECTION 11235
STAINLESS STEEL INCLINED PLATE SETTLERS
PART I GENERAL This Section covers the technical specifications for inclined plate settlers, baffles, flow control deck, effluent troughs and appurtenances for a complete working system. 1.01 Work Included A. Under this section of the specification, the CONTRACTOR shall provide and
install the sedimentation equipment for the pre-treatment facility, including inclined plate settlers, collection troughs and supports as shown in the Contract Drawings and as described herein.
B. The sedimentation equipment shall include, but not be limited to, inclined plate
settlers with integrated side baffles, flow control deck, collection launders, support structures, end baffles, mounting brackets, anchor bolts and fasteners, and related appurtenances. This equipment shall be provided as an integral package by a single manufacturer who shall take responsibility for coordination of all components to assure proper functioning of the sedimentation equipment as a system.
1.02 Related Work
A. Sludge collectors are specified in Section 11230. 1.03 Submittals A. The CONTRACTOR shall provide product data, drawings and calculations in
accordance with Section 00700/00710 and as follows: 1. Basic design, layout, including plates effluent launders, weirs, and
support structures.
2. Design velocities including inlet velocity, velocity at velocity through plates, velocities at flow control points at top of plates and at inlet to trough and velocities in troughs
3. Head loss calculation through plate settling units at maximum/average
design flow. 4. A statement of the terms of the warranties. 5. List of spare parts which should be purchased and kept on hand. 6. All ancillary equipment to be provided by the manufacturer shall be
listed.
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7. Complete shop drawings of all equipment furnished including cut-sheets describing sub-components with the specific components highlighted.
8. Operation and Maintenance Manuals 1.04 Storage Protection A. Equipment shall be stored and protected in accordance with the manufacturer’s
recommendations. 1.05 Delivery A. Plate packs shall be shipped on flat bed trucks to allow access by crane provided
by the CONTRACTOR.
B. If access by crane to the basins is not possible, then the plate settlers shall be shipped as a pack which can be disassembled for individual component installation.
1.06 Skilled Supervision
A. Manufacturer shall have available skilled installation, supervision and start-up services as specified.
1.07 Supplier Qualifications and Experience A. Manufacturer shall have been in continuous business for a period of at least 10
years, engaged in the manufacture of water treatment equipment for municipalities. Said manufacturer shall have at least 10 years experience in the design and building of high rate laminar flow clarification equipment.
B. Prior to bid each manufacturer must provide a list of at least ten (10)
installations of all stainless steel plate settlers used in municipal applications along with names and phone numbers of references to be contacted. A list of FRP plate installations will not be acceptable.
C. Manufacturer must provide a certificate of NSF standard 61 certification of the
proposed stainless steel inclined plate settlers. NSF approval on the material by itself is acceptable. Said certificate must accompany the manufacturer’s bid package to the CONTRACTOR before bid opening.
D. Any manufacturer bidding alternate un-named items of equipment shall provide
a written indemnification against patent infringement to the OWNER. 1.08 Guaranties A. The manufacturer of the plate settler shall guarantee all components provided
by said manufacturer including buy-out items not manufactured by said manufacturer for a period of twelve (12) months, commencing from the date the equipment is put into service, or eighteen (18) months from delivery of the equipment, whichever is shortest.
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1.09 Process Description A. The inclined plate settlers system shall take coagulated and flocculated water
flowing into the basins at a velocity of between 0.5 and 1.5 feet per second through the basin inlet ports, as shown on the drawings, and evenly distribute it to the plates according to the 10 States Standards. The plate settler effluent system shall be designed to handle a varying water level.
PART 2 PLATE SETTLERS This section covers the individual components which make up the plate settler system. 2.01 Design and Scope of the Work A. The work includes the supply, delivery, supervising the installation,
commissioning, and training in use and maintenance of the plate settlers. B. The basins shall be in number and dimension as shown in the contract drawings
and as specified herein. C. The manufacturer shall provide plate settling equipment that will provide the
maximum settling performance. D. The inclined plate settler system shall comprise the following elements: 1. Stainless steel plates and frames with integral side baffles. 2. Stainless steel effluent collection troughs with adjustable weirs. 3. Stainless steel end baffles. 4. Stainless steel support beams which span the basin to support the ends
of the plate packs. Said beams shall be provided by the manufacture of the plate settlers.
5. All wall mounted brackets as required. 2.02 Acceptable Manufacturers A. The plate settler shall be manufactured by Jim Myers and Sons of Charlotte,
North Carolina; Meurer Research, Inc. of Colorado; Roberts Filter Group; Monroe Environmental; or equal.
B. To assure system integrity and responsibility, all items of equipment described
in this section shall be manufactured by a single manufacturer regularly engaged in the production of this equipment.
2.03 Process Requirements/Conditions (Any blanks to be filled in by manufacturer)
A. Number of Basins 3 B. Design flow (process) at design loading 3.5 mgd each C. Maximum flow (Hydraulic) at max loading 4.375 mgd/basin D. Design Influent Turbidity 5-300 E. Maximum Influent Turbidity 1850
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F. Average Influent Turbidity <100 G. Required Effluent Turbidity ≤2 H. Effective Rise Rate (Hazen velocity) 0.28 gpm/ft2 at design
conditions I. Maximum Rise Rate 0.35 gpm/SF J. Allowed Plate Efficiency 80% K. Angle of Inclination 55° L. Design Velocity between plates 0.02 ft/sec M. Design Velocity in Feed Channels 0.5 ft/sec N. Dimension of Basins Per drawings O. Plate Width 4.5 feet P. Number Plates per Row 57 Q. Nominal Plate Length 10 feet R. Minimum Effective Projected Horizontal
Surface Area per Basin 8.681 ft2
2.04 Inlet System A. The plate manufacture shall provide an effective inlet diffusion system to reduce
the velocity to less than 0.5 ft. per second when entering the feed flumes of the plate settlers.
B. The inlet velocity shall not exceed 2 ft/second in order to prevent floc damage. 2.05 Plates A. The plate settling units shall operate in counter-current mode with clarified
water flowing upward while settled solids move down. The incoming water shall be fed near the lower end of the plate from the side to allow the settled solids to fall to the floor of the clarifier without being re-entrained by the incoming flow.
B. The plates shall be arranged in packs. The packs shall be installed on cross
beams provided by the manufacturer. C. The incoming water shall be fed near the lower end of the plate from the side to
allow the settled solids to fall to the floor of the basin while minimizing re-entrainment by the incoming flow.
D. The plates shall be inclined at an angle of 55° from the horizontal. The plate
settlers shall have no moving parts.
E. The effluent flow at the top of the plates shall be removed by a means that provides an even distribution across the full width of the plate.
F. The plates shall be removable individually for inspection or repair and to ease
initial installation. No structures or troughs shall be required to be removed in order to extract the plates. The effluent troughs shall be located to the side of the plate rows.
G. If each plate has a tubular top support structure, the plate shall be
manufactured of 24 gauge (minimum), T-304 stainless steel. If each plate does
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not have a top tube, then plate material shall be 22 gauge, T-304 stainless steel. FRP (fiberglass) will not be accepted.
H. The plate packs shall be self supporting and shall not exceed the maximum allowable deflection limits stipulated below.
I. The plate settlers shall be designed so that an operator may walk out onto the
plates at any time, even during operation, without the need to remove any components. The entire top of each plate settler must be visible for inspection. Local OSHA regulations should be followed.
J. The plates shall be designed structurally for the following conditions:
1. Loading of 30 lbs. per plate live load.
2. A maximum deflection of 1/360 for all structures, troughs, etc. 3. A concentrated load of 250 lbs. anywhere on the flow deck (top tubes) or
edge of plates.
2.06 Effluent Collection Troughs
A. The effluent troughs shall be located to the side of the plate rows. Troughs located over the plate settlers obstructing access to the tops of the plates will not be accepted.
B. The effluent collection troughs shall be manufactured of T-304 stainless steel.
All brackets trough supports, reinforcing sections, stiffeners, flanges, weirs and fasteners shall be of T-304 stainless steel.
2.07 Structural Support System Requirements A. The manufacturer of the plate settlers shall provide stainless steel beams to
support the plate settler packs to insure compatibility. B. Support frames and beams shall be adequately sized to carry the load of the
plate settling system under both wet and dry conditions without exceeding a maximum deflection of L/360 of the span.
C. The manufacturer will be required to coordinate the structural details of the
design with the ENGINEER. This will be required to determine the final location of beams through wall openings, sludge collection mechanism and other design details which may affect the supply of structural support components.
2.08 PASSIVATION A. All completed stainless steel assemblies shall be passivated in accordance with
ASTM A380 at the factory prior to being shipped. Because passivation times may vary depending on the chemical makeup of the passivation solution, treatment temperature, application method, material grade, and other factors, the Shop Drawing for the proposed equipment shall include a complete description of the
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cleaning, passivation and testing procedure to be used and how it meets the requirements of ASTM A380.
B. Pre-cleaning: Parts shall be degreased using alkaline solution spray with cold
water rinse. C. Solution: Nitric 25% +/- 5% by volume at a temperature of ambient. D. Passivation time: 1 hour minimum. E. Method(s): Total immersion or continual spray F. Rinse: Final rinse is done with de-ionized water at ambient temperature. G. Final check: Residual pattern test check after 20 minutes for presence of stains
or water spots. 2.09 HARDWARE A. All field assembly bolts and anchor bolts, nuts, and washers shall be Type 316
stainless steel. B. All submerged connections shall utilize Type 316 stainless steel nylon insert
locknuts. C. Anti-seize compound shall be applied to the threads of all stainless steel bolts
before assembly. 2.10 FABRICATION A. All welded joints that will be fully or partially submerged shall be sealed
watertight with continuous welds. All welding shall be performed in accordance with AWS standards.
PART 3 EXECUTION 3.01 INSTALLATION A. The CONTRACTOR shall install the inclined plate settler equipment in strict
accordance with the manufacturer's recommendations. B. Install and level the plate pack units and troughs in accordance with the
manufacturer's recommendations and the Drawings. All plate settler support’s anchor locations shall be leveled to within +/- 1/8 of an inch. Exercise care in erecting and leveling the plate settlers, troughs, and weir plates so that the units are at the elevations shown on the Drawings or specified herein and have deflections within manufacturer's specified limits.
C. After installation, all v-notch weirs must be leveled to within 1/16 of an inch of
target elevation as shown on manufacturer’s drawings.
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D. Anti-seize thread lubricant, which is NSF-61 approved, shall be applied to the male threads of all stainless steel bolts at the time of the assembly.
3.02 WARRANTY A. The supplier shall guarantee in writing that the equipment furnished is
appropriate for the intended service and shall be free of manufacturing and fabrication defects in material and workmanship for a period of 1 year after the equipment is satisfactorily placed in service. If the equipment is not placed in service within 6 months of delivery, the 1 year guarantee period shall commence 6 months after delivery.
3.03 MANUFACTURER'S SERVICES A. Manufacturer’s Field Services: The CONTRACTOR shall provide the following
services in addition to any other services specified herein, and required by these Specifications.
1. A factory trained manufacturer’s representative shall be provided for a
minimum of 2 trips and a minimum of three 8-hour days to provide installation supervision, start-up and field testing services, and O&M training services. The installation services shall be coordinated between the CONTRACTOR and the manufacturer. The startup and field testing services, and the O&M services shall be coordinated with the ENGINEER.
2. After installation supervision and field testing services by the
manufacturer, the CONTRACTOR shall submit to the ENGINEER, a certification letter on the manufacturer’s letterhead and signed by the manufacturer certifying that the equipment was installed per the manufacturer’s recommendations.
3. The manufacturer shall provide startup reports covering installation
inspection and start up activities. 4. The manufacturer shall provide operator training to all required plant
personnel. B. All costs, including travel, lodging, meals and incidentals for manufacturer
service shall be included in the CONTRACTOR’S bid
END OF SECTION
***
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SECTION 11240
DRY CHEMICAL FEED EQUIPMENT PART 1 GENERAL 1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install dry chemical feed equipment as shown on the Contract Drawings and as specified herein. The chemical to be fed is powdered activated carbon.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Sections 00700/00710 and 01600.
B. Painting is specified in Division 9.
C. Electrical work is specified in Division 16. D. Instrumentation/SCADA is specified in Division 17.
1.03 SYSTEMS DESCRIPTION
A. The carbon feeder is to have a wetting cone eductor system providing pressur-ized feed to the raw water.
B. One feed point is approximately 100 feet from the feeder in the chemical
building raw water pipe trench and another feed point is approximately 250 feet away at the flash mix basin with a third feed point approximately 250 feet away in the flocculation basin inlet flame. Piping will be 2-inch Schedule PVC and HDPE. At the point of application pressure will be approximately 5 psi in the pipe and 3 psi in the basins.
C. The carbon slurry will travel through approximately 250 feet of 2 inch HDPE pipe
and approximately 50 feet of schedule 80 PVC pipe and fittings to the raw water line in the chemical feed manhole. The line pressure in the raw water line at the point of application is approximately 5 psi.
1.04 QUALIFICATIONS
A. The carbon feed equipment shall be furnished by a single manufacturer who is experienced, reputable, and qualified in the manufacture of the equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with best practices and methods. Carbon equipment shall be manufactured by Acrison or equal.
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1.05 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ENGINEER in accordance with Section 01300 - Submittals. Shop Drawings shall include complete electrical wiring diagrams and equipment controls.
B. O&M instructions shall be submitted to the ENGINEER in accordance with Section
01600. 1.06 EQUIPMENT OR SYSTEM WARRANTY
A. Refer to Section 01600 for warranty requirements. PART 2 PRODUCTS 2.01 CARBON FEEDERS
A. General
1. Feeder shall be of the volumetric type, designed to handle and accurately feed powdered or granular, light or dense, chemicals. The carbon feeder shall consist of a wetting cone, feeder assembly and accessories as specified.
2. The units shall be of such a design that flooding or free flowing of
chemicals cannot occur. All parts shall be of corrosion resistant materials and the steel parts and housings shall be Bonderized before painting.
3. Start-stop controls shall be provided at the machine control panel as well
as in the control room.
4. The feeder(s) shall be equal to Acrison or proven equal. 5. All electrical components of the feed system shall be suitable for Class 2,
Division 1, Group F conditions, except for the control panel which shall be located outside of the hazardous area.
B. The feeders shall be equipped as follows:
1. Carbon Feed System
a. The equipment shall be equal to Acrison Model W105Z feeder with
integral carbon steel storage hopper and a screw sized to feed 1.73 to 40 lbs/hr of PAC at 20 lbs/C.F., high gear bead box and SCR control. The feeder shall discharge into a 316 stainless steel wetting cone with a PVC eductor. A converging hopper, dust collector with a bag loading hatch, shut off knife gate, 24-inch diameter extension hopper, pneumatic storage hopper vibrator, storage hopper low level switch, and rotameter shall also be
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furnished. The feeder motors shall be explosion proof. Provide a solenoid valve installed in the carbon system water flush line. The valve shall open for a preset (adjustable) time on shutdown of the feeder to flush the line out. Upon reaching the preset time the valves will close until the next start/stop cycle.”
C. Rate of Feed Range
1. The feeder(s) shall have an accurate SCR variable feed adjustment over a
50 to 1 range.
D. Accuracy
1. Variations shall not exceed plus or minus 2 percent.
E. Motor Drive
1. Each feeder shall be equipped with an SCR variable speed drive. The power to the SCR shall be 115 V, 60 Hz., 1 phase. The d-c motor shall be minimum 1 horsepower. See Division 16 for complete motor and electrical requirements.
2.02 ACCESSORIES
A. Storage Hopper
1. The storage hopper shall be a 3 cubic foot unit with a dust collector mounted on top as shown on the drawings. The storage hopper shall be carbon steel.
B. Dust Collector
1. Provide a hopper mounted dust collector with loading hatch and blower.
The blower motor shall be totally enclosed. The dust collector filter cloth shall be at least 120 square feet. The dust collector shall come with an automatic shaker and loading chute. The dust collector shall be equal to Donaldson-Torit Model UMA150, Donaldson-Torit Model VS-1200, Acrison Model DCBDS-1000, or equal. Dust collectors shall be Class 2, Division 1, Group F, rated by UL, FM or similar testing agency. Provide a dust collector control panel suitable for 120 volt, single phase, 25 amp power supply and compliant with Section 16900.
C. Converging Hopper
1. Position a converging hopper between the storage hopper and the feeder
assembly as shown on the Drawings. The connection just above the feeder shall contain the shutoff gate. All connections shall be dust tight. Vibrators, when required, shall be attached to the converging hopper.
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D. Vibrator
1. Provide a pneumatic vibrator and solenoid valve mounted on the converging hopper.
2. Each vibrator shall be controlled by a timer, operating only when the
feeder screw is turning. The timer shall be equal to General Electric Type TSA-14 Repeat Timer.
E. Shut-off Gate
1. A shut-off gate is not required.
F. Solution Hose and Piping
1. Provide solution hose and piping of the sizes and lengths shown on the
Drawings. Hoses and pipes shall be resistant to the chemical solution they carry.
G. Rotameter
1. A rotameter shall be furnished by the feeder supplier along with a
throttling valve and 3 shutoff valves. The feeder manufacturer shall provide the rotameter(s) as shown on the Drawings.
H. Storage Hopper Low Level Switch
1. A storage hopper low level switch shall be mounted on the hopper to
notify the operator through an audible alarm and panel mounted light that the hopper is running low.
I. Water Supply Booster Pumps 1. If water is needed at a pressure greater than about 65 psig to operate the
system, 1 water supply booster pump and bypass with variable speed drive and a pressure switch shall be supplied. The pump shall take supply water with a pressure of 65 psig and boost it to the needed pressure. The pump speed shall adjust as necessary to maintain the needed pressure at the pressure switch located just before the wetting cone.
2. The booster supply pump system shall be Grundfos Booster Paq series or
equal. 3. Booster pump controls shall be packaged with the carbon feed system
controls. If booster pump controls are packaged separately, CONTRACTOR shall adjust wiring terminations as required and provide a complete and functional system.
J. Provide a control panel compliant with Section 16900. Provide SCADA signals as
indicated on the Contract Drawings.
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2.03 PAINTING AND FINISH
A. The feeder housing and all steel parts shall be Bonderized before painting to insure proper paint bond and to resist corrosion. Immediately after Bonderizing, feeder housing and all steel parts shall be given a priming coat. The equipment shall be finished to the manufacturer's standard color scheme by the equipment supplier.
PART 3 EXECUTION 3.01 INSTALLATION OF DRY CHEMICAL FEEDERS
A. General
1. It is the intent of these Specifications to provide a complete functional and operational dry chemical feed system as planned and specified with all necessary equipment, materials, parts and other components and proper installation of these items of equipment, materials, etc., to perform the functions specified.
2. Installation shall be in strict accordance with the Drawings and Specifica-
tions except where written approval to deviate is obtained by the CON-TRACTOR. Where these Drawings and Specifications conflict with manu-facturer's written instructions, revisions will be made to fit the particular installation after all parties have agreed.
B. Dry Chemical Feeder
1. The feeder shall be mounted on a concrete base as shown on the Draw-
ings. The feeder shall be anchored in place by bolting down using anchors as specified in Section 05520 of these Specifications.
2. Connect the water supply line to the wetting cone as shown on the
Drawings. Provide a union between the feeders and the valves.
3. Install a suitable drain valve and piping from the drain connection and connect a tee to the tank overflow fitting with one line going to a suitable drain, the other line to vent.
4. All tank connections must be suitably supported to avoid straining the
tank.
5. Mount agitator on tank and make electrical connections to agitator motor as shown on inside of motor terminal cover.
6. Vibrator
a. Install and connect the vibrator.
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7. Electrical
a. Connect 120 volt power to the feeder with one motor sentinel switch to serve the feeder drive, one to serve the mixer and one to serve the vibrator. See the Drawings for additional requirements.
8. Testing and Calibration
a. The feeders shall be installed, charged with chemical and tested
for proper operation by a one hour running test.
b. The feeders shall be calibrated by running the unit with the speed control set at five points over the full range of the feeder speeds. The sample shall be captured and weighed at each setting with 2 separate samples being taken and weighed. The test shall be run by the CONTRACTOR in the presence of the ENGINEER and the plant operator. The data shall be turned over to the ENGINEER and plant operator.
3.02 MANUFACTURER’S FIELD SERVICES
A. Provide the following field services by manufacturer=s field representative:
1. Minimum of 1 trip, 2 days on-site for field inspection of the completed installation and field testing prior to initial system startup. Field testing shall include full program verification, with program changes made, if necessary for proper operation of the system
2. Provide operator training services.
END OF SECTION
***
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SECTION 11242 CHEMICAL SYSTEMS EQUIPMENT PART 1 GENERAL 1.01 SUMMARY
A. This section includes providing all materials, services, equipment and incidental as shown, specified and required to assemble, shop test, furnish, field test and place in satisfactory operation, positive displacement peristaltic-type chemical metering pumps, chemical transfer pumps and chemical system mixers, and equipment as shown on the Drawings and as specified herein.
B. Solution feeders shall be positive displacement metering pumps. Their feed rate
adjustment feature(s) shall be such as to result in a minimum accuracy of ±1 percent for mechanical drive over a range of 5.0 to 100 percent of the pump’s maximum rated capacity.
C. For purposes of this Specification there is 1 pump classification, mechanical
motor driven peristaltic (tube) type metering pumps and systems.
D. Feed rate adjustment may be accomplished by a combination of the following as noted in Part 2 Products:
1. Speed adjustment by variable motor speed or variable frequency drive. 2. Changing the tube size.
E. Drive motor speed adjustment must be capable of being made while the pump
is in operation.
F. Where suction pressures exceed or approximate discharge pressures in all mechanically operated peristaltic pump systems where bleed through is possible when the pump is not operating or chemical transfer pump systems, a back pressure valve and a pressure relief valve for installation in the discharge line from each pump, shall be furnished. Pressure relief valves are not required where the chemical transfer pump supplied is a centrifugal type unit.
G. A calibration column shall be provided for each system to calibrate the metering
pumps. 1.02 SECTION INCLUDES
A. This Section includes the following:
1. Mechanical motor driven peristaltic (tube) type metering pumps and systems.
2. Chemical solution transfer pumps. 3. Mechanical mixers for chemical solutions.
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4. Chemical metering system accessories. 1.03 RELATED SECTIONS A. 13200 and 13201 Chemical Storage Tanks B. 02610 Pressure Pipe C. 02614 Double Containment Piping Systems D. 15230 Plastic Process Valves E. Division 17 Instrumentation and Controls F. Division 16 Electrical
1.04 SYSTEM DESCRIPTION A. Design Requirements, Performance Requirements
1. The pumping units shall operate without vibration or excessive noise over
the operating speed range. 2. Pumping system vibration shall not exceed the acceptable field vibration
limits given in the standards of the Hydraulic Institute, where applicable. 3. All wetted surfaces of the diaphragm chemical metering pumps, peristaltic
chemical metering pumps, chemical transfer pumps, mixers, and appurtenances shall be suitable for continuous exposure to the chemical being pumped as specified in Part 2 Products, and as noted in the Drawings.
4. Pumping units shall perform at ambient temperature unless otherwise
specified. 5. The units operating in the new chemical storage and feed area of the
building will operate within the room’s temperature range of 55 degrees Fahrenheit to 105 degrees Fahrenheit. Once the chemical in its line leaves this space the temperatures may be hotter or colder than this depending on location. Inside other buildings or building areas the temperature will range between 55 degrees Fahrenheit and 85degrees Fahrenheit while outside temperature conditions will be ambient, typically 0 degrees Fahrenheit to 105 degrees Fahrenheit.
6. Metering pumps shall be provided as part of a package which includes
motors, controls, piping, valves, calibration columns, stands, etc., as needed for a complete and functional system as specified herein and shown on the Drawings. All controls shall be located so they are easily accessible from across the bulk chemical tank’s containment wall as shown on the Drawings. Chemical metering pump systems shall be designed so that any leakage drains into the surrounding containment sump. Stands shall rest on the containment sump slab or mountable containment well and provide access to the pumps at the top of the
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containment wall or 42 inches above the finished floor, whichever is higher.
7. Transfer pumps shall be provided with motors, controls, base plates,
safety guards and stands, etc., as needed for a complete and functional system as specified herein and shown on the Drawings.
8. Mixers shall be provided with mounting stands, safety guards, etc., as
needed for a complete and functional system as specified herein and shown in the Drawings. Mixers shall be directly mounted to a tank or mounted to a support stand as specified herein or noted on the Drawings.
B. Installation Requirements 1. Pumps shall be installed as shown on the Drawings. They shall be located
just inside the bulk tank chemical containment area unless otherwise shown.
2. Stands shall be designed to allow contained chemicals to freely move
around them, i.e., the stands shall not occupy more space than the material of the stands. This may require cutouts in stands made of sheet or plate material.
3. Equipment shall be installed as specified herein, as shown on the
Drawings and as recommended by the manufacturer.
1.05 SUBMITTALS
A. Submittals are required for all components related to the chemical feed system including material compatibility to the chemical fluid being pumped.
1.06 QUALITY ASSURANCE A. Manufacturer's Qualifications: Manufacturer shall have experience in
manufacturing diaphragm or peristaltic type chemical metering pumps and pump skids of similar installation.
B. All equipment provided under this Section shall be obtained from a single supplier
or manufacturer for a given pump type who, with the vendor, shall assume full responsibility for the completeness and proper operation of the chemical feed system.
C. To insure quality and unit responsibility, the pump skids must be assembled
and tested by the chemical metering pump manufacturer or vendor. The manufacturer or vendor must have technical and design staff, and fabricating personnel to complete the work specified. Components to be included in the skids shall be as specified herein and are shown in the chemical system schematics on the Drawings.
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D. Field Tests on the Drawing 1. Tests shall be conducted on the actual pumps and skids being provided
for the Project.
2. Each system must be tested in the field prior to acceptance. The test shall be performed with the actual chemical being pumped. The system shall be operated throughout the entire operating range of the pumps.
3. All piping shall be hydrostatically tested to a pressure of 150 psig without
leakage. The hydrostatic test may be tested with water. Documented testing results shall be provided.
E. Acceptable Manufacturers 1. Manufacturers shall be Watson-Marlow, MasterFlex, Flomotion, Blue-White
or equal. 1.07 WARRANTY A. In addition to the warranty provisions required by Divisions 0 and 1, the vendor
shall provide a warranty for all diaphragm chemical metering pump skids, controls and appurtenances for a period of one year on the skids, controls and accessories, and 2 years on the chemical metering pumps. Peristaltic pumps shall carry a 2-year warranty on the electronic circuit board and on the mechanical drive.
PART 2 PRODUCTS 2.01 GENERAL A. All metering pumps and transfer pumps shall have either flexible hose, pipe or
expansion joints to connect them to the fixed rigid piping system including connection to the associated bulk and day tanks.
2.02 SKID MOUNTED CHEMICAL METERING PUMP SYSTEM A. Pumps shall be peristaltic (tube) positive displacement metering pumps as
specified herein for all chemical feed systems noted. All pump systems shall consist of duplex or triplex pump systems as shown on the Drawings or specified herein. This specification addresses skid mounted chemical metering pump systems complete with the skid assembly containing chemical metering pumps, all necessary piping, valves, fittings, supports, electrical controls, and accessories as specified herein. The diaphragm metering pump skid shall contain the following items:
1. Skid with drip lip (provide drip lip with all non wall/tubular frame
mounted systems) 2. Metering pumps
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3. Calibration column 4. Pressure gauges 5. Isolation valves 6. Pressure relief valves 7. Backpressure valves, as applicable 8. Pipe line strainer 9. Mounting stand(s) to support pump 10. All piping, valves, gaskets, supports, hardware, wiring, and accessories
necessary for a fully functioning skid. B. Skid shall be specially designed, constructed and installed for the service
intended and shall comply with the requirements listed in Part 2 Products of this specification.
C. The metering pump skid package shall be designed so that the skid containing
the pumps may be placed on a support structure (table, stand, etc.) such that the pumps are located nominally 42 inches above the floor, depending on which chemical is involved per the Drawings, or the skid package may be self-supporting, provided the pumps are nominally 42 inches above the floor, depending on which chemical is involved per the Drawings. The plan dimensions of the skid of a simplex, duplex, or triplex pump package shall be as shown on the Drawings. The pumps shall be located at the top of the secondary containment wall or 42 inches above the floor, whichever is higher.
D. The weight of suction and discharge piping shall not inflict any stress on the
pump. All piping shall be supported by means other than the pump. E. The skid mounting of the metering pumps shall conform to the following
requirements: 1. The skids shall be constructed of fusion welded polypropylene sheets,
FRP, polyethylene or stainless steel sheets, tubes, or struts, etc., as recommended by the pump manufacturer for chemical compatibility. Adequate piping and equipment supports for the system shall be provided. Fork lift truck cut outs shall be provided for skids which will rest on a table, platform or shelf to attain the needed height.
2. All components of the skid-mounted system (pumps, piping and controls)
shall be tested as described in Part 1, 1.06.D. 3. The table, stand, etc., shall be constructed so that if the chemical
containment area becomes flooded the stand will not float or flip over. This may require anchor points, flow paths through the stand, etc.
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2.03 PERISTALTIC (TUBE) TYPE CHEMICAL SOLUTION METERING PUMPS
A. General
1. Chemical solutions to be pumped under this classification are: Sodium hypochlorite, hydrofluosilicic acid, poly-phosphate (sodium
hexametaphosphate), and coagulant, currently DelPac 2500.
2. The pump shall have the capability to be controlled manually at the pump by variable speed drive as specified in Part 2 Products, as well as, remotely as specified in Division 17. The combined turn down ratio shall be as specified under speed controls below.
3. The feed pumps shall be sized such that the feed rates given herein are
70 to 80 percent of the supplied pumps capacity. For example, if the given feed rate is 2.0 gph, the supplied pump shall have a feed rate somewhere between 2.5 gph (2.0/0.8) and 2.86 gph (2.0/0.7).
4. The metering pump shall be placed on a support structure (table, etc.)
such that the pumps are located nominally 42 inches above the floor, depending on which chemical is involved per the Drawings. The pump(s) shall be located at the top of the secondary containment wall or 42 inches above the floor, whichever is higher.
B. Description
1. The chemical metering pump(s) shall be simplex style, shaded pole motor
driven peristaltic tube style. To prevent damage to pump from overheating, the motor shall have automatic reset thermal overload protection.
2. The pump shall have a 3-position power switch capable of 1) stopping the
pump, 2) running the pump continuously in normal operation, and 3) intermittently running the pump only when depressed to facilitate the tube changing process.
3. The pump shall have the ability to operate at flows less than maximum
via a turndown adjustment which provides from 5 percent to 100 percent range in 1 percent increments. The adjustment must be completely electronic and reduce the output by de-energizing the motor for a portion of a 2-second cycle; i.e., 50 percent flow results in 1 second on and 1 second off. No mechanical disengagement (clutches, etc.) are allowed.
4. The system connections shall be made via a dual connection fitting at
both the section and discharge connections. This fitting shall accept 1/4-inch OD tubing, or 3/8-inch NPTF piping fittings.
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5. The pump drive shall be encased in weather-resistant housing constructed of a chemically resistant glass-filled ABS or equal material, and be rated to NEMA 3R specifications.
6. The pump controls must be protected by a see-through polycarbonate
cover which is removable and can be latched in place for operation. 7. The power supply shall be 115 VAC, 60 Hertz, single phase. The drive
system is to automatically compensate for supply voltage variations within 10 percent of the rated voltage such that the frequency of the pump remains constant. Provide a power cord and internal overload protection.
8. The liquid end shall be physically attached to the drive unit by fasteners
which will retain the pump head in place while tube replacement is being performed. The cover plate retention screws shall be capable of being worked by hand, without the use of tools to facilitate tube replacement.
9. The pump head shall contain the roller assembly and the peristaltic pump
tube, which are retained by a cover plate. The head and cover plate shall be see-through to allow for tubing inspection.
10. The liquid end shall contain non-metallic bearings on each side of the
rotor assembly to fully support all generated loading. 11. The roller assembly shall have 3 non-metallic rollers to create pump flow
and pressure, and to prevent siphoning or backflow. 12. The pump shall be listed either directly or via a third party agency to: a. UL778 b. CSA 22.2 c. NSF50 d. NSF61 e. CE f. IP54 g. NEMA 3R Enclosure Rating 13. SCADA signals required are the same as specified in Paragraph 2.03. 14. A flow monitor is required which will annunciate an alarm upon loss of
chemical flow and includes a dry contact output to transmit the alarm to future SCADA system. Refer to Section 17100, Article 2.02.H and 2.02.I for flow switch requirements.
C. Liquid End 1. The liquid end shall be constructed of PVC with the type of tubing needed
for the chemical it will be pumping and be sized to provide the flow and pressure as described herein.
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D. Accessories Required with Pump 1. The pump should be assembled on a wall mount or floor mount in
polypropylene, polyethylene, fiberglass, or stainless steel material. A single pump manufacturer should be responsible for supplying all components of the metering pump system, including:
a. A strainer constructed of materials compatible with chemical being
used shall be provided with each pump. b. A ceramic weight capable of holding the suction tubing at the
bottom of the chemical tank. c. An injector capable of preventing backflow and being installed into
either 3/8-inch NPT or 1/2-inch NPT female connections. d. A minimum of 20 feet of tubing compatible with chemical to be
used shall be provided with each pump, or a minimum of 1 replacement head or the number of heads anticipated to be needed to get the pump through the first 2 years of service.
E. Pump Features
General Treatment Chemical Metering Pumps1,2
Solution to Be Pumped
No. of Pumps Required/ Installed
Max. Discharge Pressure
PSIG5
Suction Lift Capacity
(ft of water)4
12.5% Sodium Hypochlorite pre post
3/3 2/2
20 3
23-25% Hydrofluosilicic Acid 2/2 20 3 Poly-phosphate (sodium hexametaphosphate)
2/2 20 3
Coagulant 100% 3/3 20 3 1 See the schedule on the drawings for design Range @ Maximum Discharge Pressure, GPH,
and chemical characteristics. 2 These are full strength solutions which may come in a range of strengths. What is used will
depend on what the OWNER purchases. 3 The maximum discharge pressure listed is the maximum pressure anticipated in the pump
discharge line because of line losses, elevation changes, and line pressure at the feed points. Actual pressure may vary because of CONTRACTOR pipeline installation location, route, etc.
4 The minimum dry (unprimed) suction lift capability of the pump shall be 3 feet of the
chemical being pumped or 4.5 feet or water whichever is greater. The pumps shall be capable of feeding chemical which has been pulled (unprimed condition) from a nominal level of 6 inches above the bottom of the tank. If the pump cannot pull the suction lift needed, then a tank stand shall be provided for the day tank which lifts the day tank to the height needed so that the metering pump can feed the chemical in an unprimed condition.
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Depending on day tank size and metering pump elevation the metering pumps will often have flooded suction but not always.
2.04 SPARE PARTS
A. Spare Parts, for parts of each pump or model that will most likely require normal maintenance shall be furnished with each pump.
2.05 CHEMICAL SOLUTION TRANSFER AND LARGE CAPACITY FEED PUMPS A. General 1. Transfer pumps shall be platform/shelf/stand mounted. Pumps will be
located as shown on the Drawings. 2. Pumps shall be placed at or near the top of the chemical containment
sump wall on a platform/shelf/stand and be of 316L stainless steel, FRP, or other suitable material able to handle the pumps weight along with the chemical filled piping, etc.
3. The pumps are to be used to pump full strength chemicals from a bulk
storage tank to chemical dilution or day tank and shall be suitable for the installation considering chemical compatibility.
4. The pump shall have the capability to be controlled manually, as
indicated in the Drawings. 5. The pump shall be mag-drive, self-priming, centrifugal pump; mag-drive,
positive displacement-type pump; or peristaltic (tube) type pump, or progressive cavity.
B. Self-Priming Chemical Transfer Pumps 1. The chemical transfer pumps shall be provided as scheduled below and
installed as shown on the Drawings.
2. The transfer pumps shall be capable of pumping chemical as noted below and in the Drawings. They shall have a flooded suction or a maximum unbound suction lift as specified below or as shown on the Drawings for the installation considering the specific gravity of the chemical being transferred. Mag-drive type, positive displacement pumps shall be Pulsafeeder Eclipse series or equal. Peristaltic-type, positive displacement pumps shall be Watson-Marlow, Thermo Scientific B/T or I/P series or equal. Centrifugal-type, mag-drive pumps shall be Finish Thompson, Inc., SP Series Magnetic Drive Pump, Hayward Flow Control Systems, Walden Typhoon, Met-Pro, Goulds, or equal. Progressive cavity pumps shall be Seepex, Mayno, or equal.
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3. The coagulant transfer pump shall be a positive displacement unit capable of handling chemicals with viscosities of 3000 cp. The other pumps can be positive displacement or centrifugal.
C. List of Chemicals to be Pumped from Bulk Tank(s) to Day Tank(s) No. Solution to be Percent Min. Capacity Max. Suction Max. Discharge Required Pumped Solution GPM Lift (FT) of Chemical Pressure (FT) 1 Coagulant- DelPac 2500 100 40.0 3 10 1 Sodium hypochlorite 12.5 7.5 3 10 1. Hydrofluosilicic acid (HFS) 22-25 0.5 3 10 1 Polyphosphate 100 1.20 3 10 3. Pumps shall be field tested to verify that they meet the specified design
conditions. The chemical for which they are supplied will be used to perform the field tests.
4. The pumps shall carry a minimum 3-year warranty from the
manufacturer. 5. See Division 16 for motor and electrical requirements. 6. Pumps shall be sized to fill chemical day tanks in less than 20 minutes. 7. Where suction pressures exceed or approximate discharge pressures, a
backpressure valve shall be installed on the discharge line from each pump equal to Chemlines Series SB10 with an adjustment range of 3 to 60 psi or an outside lever and weight/spring check valve which allows for adjustment of the closing force.
2.06 ACCESSORIES
A. General
1. Accessories shall be provided as specified in Section 2.02. B. Calibration Chamber: Provide one, clear plastic calibration chamber with vent for
each chemical system for use in calibrating the peristaltic metering pumps. The chamber shall be sized to give adequate capacity for a minimum 60 second draw down test. The scale shall give direct readings in GPH without the need for calculations. The calibration chamber shall be piped and valved so that each pump shall be able to utilize the calibration chamber without interfering with the operation of the other pumps. The top of the chamber shall have a threaded fitting to allow for piping to a common vent.
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C. Piping, Valves and Appurtenances 1. Pipe and accessories used on the skids shall be Schedule 80 PVC, CPVC or
PVDF, or as recommended by the pump manufacturer for chemical compatibility with plain and socket ends and unions for easy disassembly.
2. Cement shall be as recommended by the pipe manufacturer for the
service outlined in this Section. The calibration column shall be clear material construction.
3. True-union ball or diaphragm valves shall be utilized. Isolation valves
shall be provided at all equipment connections. Seals shall be compatible with the chemical being pumped. Valves used for sodium hypochlorite and hydrogen peroxide systems shall be vented ball valves or other valves designed for chemicals which gas off.
D. Back Pressure and Pressure Relief Valves 1. Provide one pressure relief valve for each metering pump and a back
pressure valve for each diaphragm metering pump. 2. Valves shall be spring-loaded, diaphragm-type, with materials of
construction compatible with chemical service. PART 3 EXECUTION 3.01 INSTALLATION
A. Installation shall be per manufacturer's recommendations.
3.02 INSTALLATION AND START-UP SERVICES A. The chemical metering pump supplier shall provide a minimum of 0.5 days
installation and start-up services for each chemical system/metering pump skid provided to aid the CONTRACTOR in proper installation of the equipment and for equipment start-up. The installation and start-up services provided shall occur in a minimum of 2 trips. In addition the supplier or his factory trained representative shall provide a minimum of 2 days training to the operators for the equipment provided, 1 day of initial training and 1 day of refresher training approximately 8-10 months into the warranty period or as requested by the OWNER.
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B. The chemical transfer pump and mixer supplier’s shall provide a minimum of 1 days installation and start-up services for their equipment to aid the CONTRACTOR in proper installation of the equipment and for equipment start-up. The installation and start-up services provided shall occur in a minimum of 1 trip. In addition the supplier or his factory trained representative shall provide a minimum of 1 days training to the operators for the equipment provided.
END OF SECTION
***
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SECTION 11243
BULK LIME SLURRY SYSTEM PART 1 GENERAL 1.01 SUMMARY A. The manufacturer shall furnish and install one complete bulk lime slurry storage
and feed system as specified herein and as shown on the Drawings. The equipment shall be fabricated, erected, assembled and placed in proper operating condition in full conformity with the drawings, specifications, instructions and recommendations of the equipment manufacturer.
B. The entire bulk slurry chemical system will be designed, coordinated and
supplied by one manufacturer. The system manufacturer shall furnish all equipment to complete a functioning, integrated package. The system manufacturer shall take sole responsibility for the products incorporated in the package. Basis of design is Burnett Lime Company, 7095 South Carolina 11, Campobello, South Carolina 29322.
C. The system shall be complete and operable as installed by the manufacturer.
Without exception, the contract price is to include all royalties and costs arising from patents and licenses associated with furnishing the specified equipment. All materials shall be designed to withstand stresses encountered in operation, fabrication, and erection. The CONTRACTOR shall financially reimburse the ENGINEER completely for any and all redesign work resulting from a proposal to substitute equipment of a different configuration or design from that specified, as noted in the instructions to Bidders and detailed in the General Conditions.
1.02 RELATED WORK A. Special requirements for materials and equipment are given in Sections
00700/00710 and 01600. B. Pressure pipe is specified in Division 2. C. Grout is specified in Division 3. D. Painting is specified in Division 9. E. Electrical work is specified in Division 16. F. Instrumentation is specified in Division 17. 1.03 REFERENCES A. Where standards for materials or construction of equipment, etc., are noted
such as ANSI, AWWA, ASTM, etc., the standard to be used shall be the latest in effect as of February 2011, unless a specific year’s standard is noted.
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1.04 SYSTEM DESCRIPTION A. Bulk Lime Slurry System 1. The bulk lime slurry system shall consist of a bulk storage tank and a
feed pump enclosure. Thirty percent lime slurry will be delivered to the bulk storage system, and then diluted in the tank to 20 percent. The feed pump enclosure will include 4 slurry pumps. Primary feed will be to the raw water main in the chemical building. Piping shall be arranged so that each pump can be a backup for another pump. Slurry pumps shall be able to feed a minimum of 3 mg/l (dry equivalent) at a 4 mgd rate up to 30 mg/l (dry equivalent) at a 9.9 mgd rate. A second pump will feed chemical to the raw water flash mix inlet flume. A third pump will feed chemical to the finished water pipe in the filter pipe gallery and the fourth pump will be able to feed chemicals to either the raw water pipe in the chemical building or the finished main in the pipe gallery.
B. Slurry System Operation 1. Normal Operation a. Normal startup, control, and shut down will be through the plant
SCADA system for the raw water and finished water lines. 2. Alternate Operation a. All systems may be operated from the control panel, bypassing the
SCADA system. C. Monitoring and Controls 1. Equipment for control, monitoring and operation of the equipment shall
be as shown in these specifications or on the Drawings. 2. All systems monitored or controlled in the control panel shall also be
monitored or controlled by the plant SCADA system. 1.05 QUALIFICATIONS A. The manufacturer of the slurry system shall have at least 10 years experience in
the design and manufacture of the type proposed and must be able to refer to at least 10 similar installations.
1.06 SUBMITTALS A. The manufacturer shall complete a plant scale trial of his equipment of at last 1
week duration prior to the bid for his system to be considered. All costs shall be borne by the manufacturer. A report shall be written and submitted prior to bidding. All costs associated with change to the design shall be borne by the manufacturer.
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B. Prebid submittals are required only if called for in Section 00300-Form of Proposal, and shall be in accordance with Section 00820 – Special Conditions and Section 00700/00710 – Standard General Conditions.
C. Shop drawings and other items needed to establish compliance with the
Drawings and these Specifications for all products in this Section shall be submitted to the ENGINEER in accordance with Section 00700/00710.
D. The supplier shall provide complete installation details for the system furnished,
as well as layout drawings and all necessary installation hardware. E. O&M instructions shall be submitted to the ENGINEER in accordance with Section
1600. 1.07 EQUIPMENT OR SYSTEM WARRANTY A. Refer to Section 01600 to warranty requirements. 1.08 DELIVERY, STORAGE, AND HANDLING A. The manufacturer shall be responsible for receiving all components, delivering
to the site, and setting in place on concrete pads provided by the CONTRACTOR. B. The manufacturer’s installation and startup technicians shall provide final
terminations and system extensions. 1.09 SEQUENCING AND SCHEDULING A. Requirements for coordinating this work in sequence are found in Section
01010 – Summary of Work and Section 00700/00710 – Standard General Conditions.
1.10 QUALITY ASSURANCE A. The manufacturer shall preassemble and factory-test the system, operating the
system at both the minimum and maximum dosages. The manufacturer shall certify the results in a report to the ENGINEER prior to the shipping.
PART 2 PRODUCTS
2.01 LIME SLURRY TANK
A. Tank shall be single compartment, welded steel reinforced top, having a nominal
capacity of 20,000-gallons and a maximum diameter of 12 feet.
B. Tank shall be fabricated using steel as specified by ASTM A36 C. Tank design shall be in accordance with AWWA D100 with minimum top and
bottom plate thickness of ¼-inch and minimum wall plate thickness of 3/16-inch. D. Tank appurtenances shall be as follows: (Reference to tank drawings for
preliminary orientation)
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1. 12-inch mixer mounting nozzle (top)
2. 24-inch atmospheric manhole/inspection port (top)
3. 24-inch manhole (3-1/2 feet above bottom)
4. 6-inch nozzle (pump suction, 9-inches above bottom)
5. 6-inch nozzle (pump suction, 9-inches above bottom)
6. 3-inch nozzle (drain, 2-inches above bottom)
7. 4-inch nozzle (overflow, 6-inches below top)
8. 2-inch nozzle (spare, top)
9. 6-inch nozzle (level sensor – 18-inches off wall, top)
10. 2-inch nozzle (water fill, top)
11. 2-inch nozzle (slurry fill, top)
12. 3-inch nozzle (recirculation)
13. Four 10-inch wide by 23 feet long gusseted baffles fabricated from ¼-inch
plate positioned 1-inch off the wall
14. Anchor lugs (4)
15. Ladder, ladder cage and full tank perimeter handrail shall be of carbon steel.
16. Standoff pipe supports and clamps (maximum 8 feet on center for overflow, slurry and water lines).
17. Lift lugs (2).
18. Fill pipe (2-inch), overflow pipe (4-inch), with quick-connects.
19. 4 - ¾” x 16” stainless anchor furnished and installed by Burnett Lime Company.
E. Surface Preparation and Painting
1. The tank dome, wall exterior and appurtenances shall be prepared by SP-6 commercial sandblast followed by one coat of time-Lock Mopoxy IR High Solids Epoxy Coating of #41 Series. Field painting by CONTRACTOR, of dome and wall exterior shall be one coat of Rus-Kil H20 Acrylic DTM Coating #310-09 and one finish coat of Rus-Kil H20 Acrylic DTM Coating #310-16
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2. The bottom of the tank shall be coated with coal tar epoxy by manufacturer.
2.02 FEED PUMP ENCLOSURE
A. The pump enclosures shall be a nominal 10’ x 8’, minimum metal building with the tank shell forming 2 walls. The minimum clear height of the enclosure shall be 7 feet. Enclosure shall be compliant with the KY Building Code. The enclosure shall be designed to handle a second future storage tank.
B. The enclosure building shall be Stainless Steel Frame (1 ¼” Stainless Steel Tube)
with 3” vinyl backed insulation. The 26 gauge exterior wall panels, roof panels and flashings shall be coated with a factory finish of Valspar Corporation Polar White PMW1614 minimum .8 mil over a minimum .2 mil Valspar Corporation Dynaprime PMY0154 primer.
C. The enclosures accessories shall include:
1. One 36-inch by 78-inch access door with stainless steel hardware.
2. One Dayton Model 5ZK52D 1500-watt UL-listed heater with thermostat/on-off switch. Basis of design is Dayton Model 5ZK52D.
3. One Dayton Model 1HLA1 120-volt fan having minimum free air capacity of 580 CFM. The fan shall be thermostatically controlled with a set point of 85 degrees Fahrenheit. The fan shall be fitted with a wire guard and removable interior vent door. Provide manually adjustable, FRP air intake vent with FRP screen. Basis of design is Dayton Model 1HLA1.
4. Interior lighting shall be by one, 4-foot long, 2-lamp, surface-mounted, fluorescent fixture controlled by weatherproof interior switch.
5. Provide one 120-volt interior GFI Type outlet.
6. All lighting, heater, ventilation, switches and outlets shall be prewired using 3-wire, color-coded, #12 THHN, copper wire in conduit.
7. Provide lime system tank and pump enclosure with grounding lugs.
2.03 CONTROLS A. Lime Control Panel
1. All motor starters, relays, timers and devices for the control and operation of the equipment shall be housed in a control panel. Terminal strips for remote signal/equipment interface within the panel will be provided. The control panel shall be compliant with Section 16900. Provide all SCADA signals indicated in the I/O Table on the Drawings.
2. Power Supply: The CONTRACTOR shall provide a 480V power feed to the flange mounted circuit breaker located in the lime system control panel. All controls shall operate on 120 VAC maximum. A 3000 VA control power
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transformer with primary and secondary over current protection shall be provided by the manufacturer.
3. Enclosure: NEMA 12, bottom entry, flange-mounted disconnect. A grounding lug shall be provided within the panel to assure positive system ground.
4. Components
a. Circuit Breaker: Isolation breaker for the panel shall be a 60 Amp Type M breaker. Basis of design is /ITED 43B060L
b. Starters and motor protection: Pump motor shall be controlled and protected by Allan Bradley 100C and 140MC2, Type E self-protected manual combination starter with adjustable amperage breaker. Basis of design is Allan Bradley 100C and 140MC2. Motor protection shall conform to IEC Circuit Breaker requirements as defined by IEC 947-2 and UL/CSA listed.
c. Relays: Relays shall be general purpose control type, 10 amps, 600-volt reversible contacts. Basis of design is Allen-Bradley 700 Type H.
d. Selectors: 30.5 mm, NEMA 4X rated; contacts shall be rated 10 amps continuous, 6 amps breakers at 120 VAC. Basis of design is Allen-Bradley, Type 800H.
e. Weatherproof Horn: Horn shall generate a loud audible alarm when activated by 115 VAC power. The horn shall surface mount with sealable side conduit entry and shall be rated for NEMA 4. Basis of design is Federal, Model 350W.
f. Running Lights: Provide GREEN Run 30.5 mm full voltage LED type indicator lights. Basis of design is Allen-Bradley type 800H.
g. Level Alarm and Reorder Light: Provide Red 30.5 mm full voltage type LED indicator lights. Basis of design is Allen-Bradley type 800H.
5. Panel Construction: All wiring across panel hinges shall be protected by a plastic enclosure. Terminal strips will be numbered for all field-wiring terminations.
6. Engraved Nameplates: Engraved nameplates with white background and black letters on all front panel-mounted devices.
7. External Interface: A Normally open contact for mixer failure.
8. Surge Protection: All analog signal wiring and AC power wiring shall be
protected against lightning spikes and other transient surges at all control panel termination points. Basis of design is Siemens TPS series.
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9. Cater pump control shall be provided for managing the high and low-pressure status of the lime slurry pumps MP-1, MP-2 and MP-3. A red light for both high and low pressure alarm and the Red Lion digital readout are located on the door the Lime Control Panel. Terminals shall be provided for remote connections to auxiliary panel.
B. Lime Tank Level Panel
1. Lime level control panel shall house the level transmitter and tank level
indicator. Basis of the design is Siemens Sitrans L Milltronics MultiRanger. The level indicator shall produce a high level alarm (located on the exterior of the Pump Enclosure) and a re-order alarm light (located on the door of the Lime Control Panel). Additional contact is available for remote monitoring.
2. Panel enclosure shall be a polycarbonate enclosure rated NEMA 4.
3. Terminals shall be provided for remote connections to auxiliary panel
2.04 TANK MIXER
A. The tank mixer shall be vertical, flange mounted with two axial flow, and one radial flow impeller sized and positioned to maintain a homogenous mixture of up to 20% Lime Slurry at ambient temperature. Mixer shall be suitable for operation in a 12’ diameter by 19’ straight shell atmospheric tank.
B. The motor shall be furnished specifically for direct mounting to gear reducer.
Motor shall be a TEFC, Frame DV13S4, with a severe duty canopy with the following characteristics:
Horsepower: 7.5 Maximum Speed: 1750 rpm 460 volt, 3-phase, 60 Hz Continuous Duty TEFC Basis of design is SEW-Euro Drive
C. A local mixer disconnect switch is located within visible sight of the mixer motor and entrance manway to the tank. All tank-mounted conduit shall be compliant with Section 16130.
D. The speed reducer shall be designated for mixing service and operation in an
outdoor environment. The rating of the speed reducer shall adhere to appropriate AGMA standards and the reducer shall bear an AGMA nameplate.
E. The speed reducer shall be constructed and supported so that the shaft deflection,
caused by operation loads, does not affect alignment of the anti-friction bearings or cause misalignment of gearing during mixer operation.
F. All reducer bearings shall be severe duty, anti-friction type, oil or grease-
lubricated. The speed reducer shall be splash lubricated, by means of gears or a
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slinger rotating on a horizontal shaft in an oil bath, to ensure positive displacement of the oil upward for lubrication of critical bearings. A single oil drain shall be provided at the low point of the speed reducer to allow oil drainage and leave a maximum residual of oil of no more than ¼-inch in the drive housing.
G. The shaft and impellers shall be carbon steel. The maximum operating speed of
the unit shall be 0.5 times the natural frequency of the shaft and impeller assembly. The shaft diameter shall be determined by an analysis of torque and bending moment as well as critical speed. Minimum shaft diameter shall be 2.75 inches. The shaft supporting the turbine shall be removable from the speed reducer without disturbing the gears of the speed reducer using a rigid flange coupling on the impeller shaft.
H. The basis of design is Tesco Model LSM-16-20 with motor and Eurodrive F series gear reducer.
2.05 SLURRY FEED PUMPS
A. Four feed pumps shall be tubular diaphragm type, each with a maximum rated delivery capacity of 78 gph at 40 psig while operating at a service speed of 175 spm. Pump shall have a minimum turndown ratio of 10 to 1 by variation of the stroke of the pump. Capacity shall be adjusted by manually changing piston stroke length or by automatic stroke adjustment. Remote connection by others.
B. The motor shall have the following characteristics:
Horsepower: ½ or ¾ as sized by Pump Manufacturer 460 volt, 3-phase, 60 Hz TEFC: Continuous Duty Service Factor 1.15
C. Pumps shall be mounted on a steel base plate and secured to the floor of the enclosure.
D. Basis of design on the pumps is Pulsafeeder Model 7120 with a Baldor Model
M8001 or M8002.
2.06 CHEMICAL FEED LINES
A. The slurry feed lines shall be accessible in a PVC conduit (conduit provided by CONTRACTOR). The feed tubing shall be either ¼, 3/8, ½, 5/8 or 3/4-inch ID clear flexible reinforced PVC hose (as determined by manufacturer). Basis of design is Kuri Tec Series #K3150.
2.07 VALVES AND APPURTENANCES
A. Water isolation valves and flush valves shall be true union PVC Ball Valves. B. Provide one 3/4-inch hose bibb on water supply header. C. Isolation valves for liquid lime service shall be 2-inch flanged, pinch valves, ONYX
Controls basis of design. There are two limit switches on all pinch valves. One limit
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switch is interlocked in the pump run circuit to assure positive position of the valve for pump protection. The second limit switch is to provide a water flush on system shutdown.
D. Water meter shall be 2-inch, positive displacement AWWA approved water meter
with indicator and a maximum range of 170 gpm. Basis of design is Badger.
2.08 INSTRUMENTATION
A. Level transducer shall be a 6-inch flange mounted transducer. The basis of design is Milltronics Model XPS15. The level transmitter shall be wall mounted near the control panel. The basis of design is Milltronics MultiRanger 100.
B. A pressure transducer shall be NEMA 4X. Basis of design (Endress & Hauser)
provided for each pump discharge line. Indicators by Red Lion (basis of design) shall be panel mounted on the door of the lime control panel.
PART 3 EXECUTION
3.01 INSTALLATION
A. All installation shall be in strict compliance with the manufacturer’s written
instructions. All anchor bolts and other items placed in the concrete structure shall be located according to certified prints furnished by the manufacturer, as approved by the ENGINEER. All electrical connections shall be made in accordance with the National Electric Code (NEC).
3.02 MANUFACTURER’S SERVICE A. Furnish the services of a factory representative for one 8-hour day during the
installation phase of the equipment. The factory representative shall have full knowledge and experience in the installation of the type of equipment being installed.
B. Furnish the services of a factory representative, having complete knowledge of
proper operation start-up procedure and maintenance requirements, for one 8-hour day, to inspect the final installation, supervise a test run of the equipment and instruct the owner’s personnel in the proper operation of the system.
3.03 CLEANING A. All reactors shall be cleaned of all debris prior to factory test. The manufacturer
shall clean and remove from site all excess construction material utilized in the installation of the system.
3.04 STARTUP A. The manufacturer shall conduct a site acceptance test upon the completion of the
installation. Tests shall be conducted using water as the testing media. CONTRACTOR shall be responsible for the providing and disposal of the water, and the providing of the power from either the permanent or temporary source.
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3.05 WORK BY CONTRACTOR A. Foundations, floor slabs, trenching, grating and electrical conduit in slab. B. Grounding for the pump enclosure and tank. C. All drainage from floor drains. D. Curbs and containment structures. E. 480/3/60 power to the power panel and terminating in the power panel. F. Two-inch valve service water connection including backflow preventer and
customer service connection within the pump enclosure building. G. All trenching, open trenching, wall sleeves, coring, feed line conduit and
tapping. H. Final painting of tank. I. Service water pressure not to exceed 70 psi to the system.
END OF SECTION
***
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SECTION 11244
POTASSIUM PERMANGANATE LOADING, STORAGE AND FEED SYSTEM PART 1 GENERAL INFORMATION 1.01 SCOPE OF WORK A. The contractor shall provide a complete potassium permanganate feed system
consisting of, but not limited to, the following components: drum loading and inverting system, transition hopper, shut-off gate, helix feeder with flow proportional controls, scale weighing system, wetting cone with dissolver or vortex mixer.
B. The intent of this specification is to have one manufacturer supply and take
responsibility for the entire potassium permanganate feed system. C. The following standards are minimum required and revisions in effect at time of
bid shall apply. 1.02 DESCRIPTION OF RELATED WORK SPECIFIED ELSEWHERE A. Section 09900 Field Painting B. Division 17 Instrumentation/SCADA C. Division 16 Electrical D. Scales are specified in Section 11251. 1.03 SUBMITTALS A. Shop drawings, catalog cuts, wiring diagrams, descriptive data shall be in
conformance with Section 00700/00710 of the Specification. B. Operations and Maintenance Manuals shall be furnished to the engineer in
accordance with Section 01600 of the Specification. C. Warranties shall be provided per Section 01600. 1.04 QUALITY ASSURANCE A. The equipment described shall be a Merrick Industries, Inc. VOLUMERIK® Model
100-V1 Helix Type Volumetric Feeder, Acrison, or equal. B. The manufacturer of equipment shall have a minimum of 10 years experience in
the manufacturing of this equipment and be able to provide 10 reference installations.
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PART 2 EQUIPMENT 2.01 VOLUMETRIC HELIX FEEDER
A. The CONTRACTOR shall supply a volumetric feeder capable of feeding potassium permanganate at a volumetric rate from 2.5 cubic feet per hour (250 lbs/hr) to 0.05 cubic feet per hour (0.5 lbs/hr). The chemical shall be supplied with anticipated nominal bulk density of 100 lbs per cubic foot.
B. The feeder shall operate over a 50:1 range, from maximum feedrate, without
shutting off the system.
C. The feeder shall have an open progressive pitched spiral helix that provides uniform filling and consistent feed characteristics.
D. The feeder shall have a 1.0 cubic foot integral hopper.
E. The feeder shall be equipped with an electro-mechanical vibrator with a cycle
timer control to precondition the chemical being fed.
F. The feeder shall not use any chains, sprockets or belt drives for speed reduction. The helix shall be supported by the speed reducer quill without the use of external bearings.
.2.02 MOTOR DRIVE TRAIN A. The feeder motor shall be PWM rated, 0.5 HP, variable speed DC motor, 1750
RPM, TEFC. The motor shall be direct coupled to a speed reducer. B. Material feed mechanism shall be equipped with an adjustable current overload
limiting device that shuts down the feeder to protect the helix and gearbox in the event of jamming due to foreign material.
2.03 MATERIALS OF CONSTRUCTION
A. The feeder shall be fabricated from 316 stainless steel. The housing shall be fabricated from 11 gauge stainless steel with 7 gauge stainless steel end plates and base. The integral hopper shall be constructed from 14 gauge stainless steel.
B. Feed helix and discharge spout shall be stainless steel 316 and Teflon coated.
2.04 CONTROLS A. The chemical feed system supplier shall be responsible for providing a complete
integrated pre-wired factory assembled and tested control system. The controls shall be housed in a NEMA 4X enclosure.
B. Motor control shall be a variable speed DC motor controller with 50:1 turndown,
full torque over entire turndown range, continuous operation at full turndown and on/off/auto selector switch, 0-100 percent speed potentiometer and signal
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isolator for 4-20 mA input control and vibrator timer with on-off switch dual 0-100 percent potentiometers for speed and dosage.
C. The control panel shall be designed to operate on a 115V, 1PH, 60 Hz power
supply. See Section 16900 for control panel requirements.
D. Controls shall be feeder mounted.
E. The feeder system shall include a weight scale and touchscreen NEMA 4X process controller. The controller shall adjust system federate to maintain the setpoint at a steady-state accuracy of 1 percent or better. Weight scale accuracy shall be 0.5 percent or better. See Section 1251 for scale requirements.
F. Provide the following status and control signals for external connection to the
SCADA system: 1. Refill required 2. Feeder running 3. General alarm 4. High weight 5. Low weight 6. Empty hopper 7. High feed rate 8. Low feed rate 9. In-control 10. Material fed totalizer (pulse output) 11. Feed rate (4-20 mA) 12. Net weight (4-20 mA) 13. Feed rate setpoint (4-20 mA input) 14. Run permission 15. Start refill 16. Stop refill
2.05 WASHDOWN DISSOLVER A. The chemical system supplier will be responsible for providing a vortex type
wetting chamber complete with ejector to ensure complete chemical wetting prior to delivery to application point.
B. The vortex mixer wetting chamber will be able to operate effectively between
water supply pressures of 75 psig through 100 psig.
C. The mixer shall be constructed on cast iron and be epoxy painted or be of stainless steel.
2.06 DRUM INVERSION SYSTEM AND TRANSITION ADAPTER
A. The transition hopper shall be capable of mounting securely to a full permanganate drum, and be suitable for inversion without discharging chemical into the environment. The transition device shall be manufactured of 316 stainless steel and be easily mounted to the drum of permanganate by one person. The transition
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valve assembly shall be constructed to open easily with the full weight of material present, and to automatically lock in both the full open or full closed positions.
B. The inversion system shall be fully portable and automatic allowing a hydraulic
motor to lift and invert the drum. The system shall include as an integral component a 12V rechargeable marine battery and charger. The hydraulic system shall incorporate a non-flammable hydraulic fluid suitable for use with the permanganate. The hydraulic system shall include pressure relief valves to prevent damage to the hydraulic pump or feed equipment.
C. The system shall have a built in control panel with the necessary switches to
operate the system.
D. The system shall be a Merrick Industries, Inc. DRUMINVERTR model 82-50, Acrison, or equal.
PART 3 EXECUTION 3.01 Preparation
A. CONTRACTOR shall remove equipment from protective shipping packing and install in accordance with manufacturers’ instructions and specification guidelines.
3.02 Installation A. Installation shall be in strict accordance with the manufacturer’s instructions and
recommendations at the location shown on drawings. 3.03 Field Testing A. The manufacturer shall furnish the services of a factory trained representative
for a period of not less than 1 day in 1 visit for installation inspection and start-up commissioning service. The representative shall inspect, calibrate, and place the system into operation.
END OF SECTION
***
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SECTION 11251
TANK LEVEL MONITORING SYSTEMS PART 1 GENERAL 1.01 GENERAL REQUIREMENTS
A. A tank level monitoring system shall be provided for each chemical system, as shown on the drawings, whether the system is specified here or in other specification sections. The system shall consist of a scale or level gauge and an indicator. The scales shall be electronic chemical tank scales. The level gauge shall be a pressure cell/transmitter with diaphragm seal. See Sheet I-1 Instrumentation Schedule for additional requirements. See Section 17100 for pressure cell/transmitter requirements.
1.02 SUBMITTALS
A. Submittals are required for all products in this section and shall be in accordance with Section 00700/00710.
1.03 RELATED WORK
A. Chemical solution feed equipment specified in Section 11242.
B. Storage tanks are specified in Division 13. C. Electrical requirements are specified in Division 16. D. Instrumentation is specified in Division 17. E. Piping and accessories are specified in Division 15. PART 2 PRODUCTS 2.01 TANK LEVEL MONITORING AND AUTO REFILL EQUIPMENT A. Electronic Chemical Tank Scales—Day Tanks
1. One electronic chemical tank scale shall be provided for each chemical noted below. The scale’s minimum capacity, display increments and tank size requirements are also noted.
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Chemical
Minimum
Scale Capacity (Pounds)
Display
Increments (Pounds)
Nominal Tank
Diameter (Inches)
Coagulant-DelPac 2500 17,000 1 64
Polyphosphate--totes 4,000 0.2 44
Sodium Hypochlorite 5,000 1 53
Potassium Permanganate 3,000 0.5 44
Hydrofluosilicic Acid 1,000 0.1 33
2. Platform scale shall be of the electronic shear beam load cell type. The
platform shall have 4 adjustable lateral tank restraint brackets for securing the tank to the platform. Platform scale coating system shall be a minimum dry thickness of 80 mils and be resistant to moisture, chemicals, abrasion, impact and UV light. Flexible cable shall connect load cell to indicator to allow easy remote installation of the readout. Cable length shall be as required. The scale shall carry a full 5 year factory warranty and shall have an accuracy of better than 1/4 of 1 percent.
3. The scale shall be CHEM-SCALE™ or Drumm-Scale, with TUF-COAT™
Environmental Armor, as manufactured by FORCE FLOW, 1150-D Burnett Avenue, Concord, California 94520 USA (www.forceflow.com) or equal.
4. The potassium permanganate scale shall be for a volumetric feeder
feeding dry crystalline chemical. The scale shall come with the volumetric feeder. Size shall be by the feeder company. See Section 11244.
B. Indicator 1. The chemical indicator shall provide both manual and automatic control
for chemical transfer pump, valve or feeder to transfer chemical from bulk storage supply to a day tank or hopper. This control shall be accomplished by monitoring the weight (level) of the day tank/hopper on a scale platform connected to a local weight controller with an integrated Hand-Off-Auto Switch (HOA Switch).
2. Controller shall carry CE marking and shall be housed in a NEMA 4X, UL
approved enclosure. Operator shall be able to monitor chemical by weight, volume or percent full. Controller shall display NET REMAINING, FEED RATE, DAILY USAGE, TOTAL AMOUNT USED and DAYS UNTIL EMPTY. A data log function shall store the DAILY USAGE for each of the previous 31 days. An integrated Hand-Off-Auto switch shall be provided with spring return from the Hand position. An adjacent green indicator lamp shall be illuminated when refilling the day tank. In order to preserve accurate chemical usage data in the automatic mode, usage accumulator shall automatically “Pause and Project” chemical usage during the refilling process.
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3. Outputs and alarms shall include 7 process alarms: Low and high level, low and high feed rate, slow refill (bulk supply empty), and min and max daily use. A 4-20 mA output of the net chemical weight shall also be provided. The controller shall provide 1.5 amp solid state relay outputs for operation of the chemical transfer device and 1.5 amp dry contacts for the chemical process alarms.
4. The controller/indicator shall carry a full 5 year factory warranty and shall
be WIZARD® ARC Controller, Model 4000-ARC, as manufactured by FORCE FLOW, 1150-D Burnett Avenue, Concord, CA 94520 USA (www.forceflow.com) or equal.
PART 3 EXECUTION 3.01 INSTALLATION
A. Installation shall be per manufacturer's recommendations.
END OF SECTION
***
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SECTION 11285 SLUICE AND SLIDE GATES PART 1 GENERAL 1.01 SUMMARY
This section covers metallic sluice gates and appurtenances used to isolate pipelines, basins, etc., and/or modulate flow in pipelines, or basins.
A. Section Includes Furnish all labor, materials, equipment, and incidentals required to provide
sluice gates complete and operational with all appurtenances as shown on the Contract Drawings and specified herein.
The CONTRACTOR shall furnish all labor, materials, equipment and incidentals
required to install the gates and appurtenances as shown on the Contract Drawings and specified herein.
The equipment shall include but not be limited to, the following:
1. Sluice Gates
2. Gate Actuators B. Related Work
1. Piping is included in Division 2.
2. Painting is in Division 9.
3. Special sequence or schedule requirements (if any) are specified in Section 01010 - Summary of Work.
4. Valves are included in Division 15.
5. Mechanical identification markers, tags and plates are included in Section
15190. 1.02 REFERENCES A. Comply with applicable provisions and recommendations of the following
standards as of July 2007 except as otherwise shown or specified. Metal Slide Gates ANSI/AWWA C540, Power Actuating Devices for Valves and Slide Gates ANSI/AWWA C561, Fabricated Stainless Steel Slide Gates ASTM A48, Gray Iron Castings ASTM A126, Gray Iron Castings for Valves, Flanges, and Pipe Fittings
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ASTM A167, Stainless and Heat Resisting Chromium-Nickel Steel Plate, Sheet, and Strip ASTM A240, Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications ASTM A249, Welded Austenitic Steel Boiler, Super heater, Heat Exchanger and Condenser Tubes, ASTM A269, Seamless and Welded Austenitic Stainless Steel Tubing for General Service
ASTM A276, Stainless and Heat Resisting Steel Bars and Shapes ASTM A312, Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes ASTM A356, Steel Castings, Carbon, Low Alloy, and Stainless Steel, Heavy Walled for Steam Turbines ASTM A376, Seamless Austenitic Steel Pipe for High Temperature Central Station Service
ASTM A536, Ductile Iron Castings ASTM A582, Free Machining Stainless Steel Bars
ASTM A743, Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant for General Application
ASTM D4020, U.H.M.W. Polyethylene Molding and Extrusion Material ASTM D2000, Standard Classification System for Rubber Products in Automotive Applications
ASTM B98/B98M, Copper-Silicon Alloy Rod, Bar, and Shapes ASTM B139, Standard Specification for Phosphor Bronze Rod, Bar and Shapes ASTM B505, Copper Base Alloy Continuous Castings ASTM B584, Copper Alloy Sand Castings for General Applications ASTM F593, Stainless Steel Bolts, Hex Cap Screws and Studs ASTM F594, Stainless Steel Nuts AISI 1117, Covers 1117 Standard for Resulfured Carbon Steel AISI 4140, Covers 4140 Alloy Steels in All Forms AISI 8620, Covers 8620 Alloy Steels in All Forms 1.03 DEFINITIONS A. See the definitions in the respectful ANSI/AWWA specification section and the
following definitions shall also apply in this section. Fps: Feet per second IOM: Installation, Operation and Maintenance NPS: Nominal pipe size NSF: National Sanitation Foundation PE – Polyethylene SS – Stainless Steel UHMW (PE) – Ultra High Molecular Weight (Polyethylene) 1.04 SYSTEM DESCRIPTIONS
A. All of the equipment and materials specified herein is intended to be standard for use in controlling the flow of water.
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B. See the gate schedule in this section for gate sizes, quantities, connections, class, pressure ratings, type of actuator and location.
C. Design Requirements, Performance Requirements
1. All stainless steel and aluminum gates are intended to provide shutoff with leakage limited to 0.05 gpm per linear foot of perimeter when closed.
2. All gates shall be designed and manufactured according to the referenced
standard unless an exception is noted herein. Where major components of gates have multiple materials of construction to choose from, the acceptable materials are noted in this specification. Any material noted, is acceptable for that component. If a material is noted as acceptable in the referenced standard but not listed in the table of materials for that component, that material shall not be used.
1.05 SUBMITTALS
A. Complete shop drawings of all gates and appurtenances shall be submitted to the ENGINEER in accordance with the requirements of Section 00700/00710.
B. The ENGINEER shall be furnished 2 certified copies of reports covering the
required leakages, hydrostatic and proof-of-design tests on the sluice (slide) gates.
C. The ENGINEER shall be furnished 2 copies of an affidavit of compliance stating
that the gates and materials used in their construction conform to the applicable requirements of the latest version of the following ANSI/AWWA specifications, except as noted herein, and that all tests specified therein have been made and that the test requirements have been met. This applies to the following:
ANSI/AWWA C561, Fabricated Stainless Steel Slide Gates, 1.06 QUALITY ASSURANCE A. Qualifications
1. All of the types of gates and appurtenances shall be products of well established firms who are fully experienced, reputable and qualified in the manufacture of the particular equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these specifications as applicable.
B. Regulatory Requirements
1. The Kentucky Division of Water requires that all gates used in potable water applications be certified by NSF 61.
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C. Certifications
1. All gates to be used in potable water applications or their materials of construction have been certified by the National Sanitation Foundation (NSF) as meeting standard 61, as acceptable for being in contact with potable water and therefore, carry NSF 61 approval.
2. The manufacturer shall provide the ENGINEER with at least 2 copies of an
affidavit of compliance with all applicable provisions of the latest edition of AWWA Specification C561 and AWWA Specification C540 except as noted below, and these Specifications.
1.07 DELIVERY, STORAGE, AND HANDLING A. Packing and Shipping
1. All gates shall be fully assembled, complete with all accessories and appurtenances when shipped. The units shall be carefully prepared and packaged so that no damage is caused in handling or transit. Any component needing to be shipped unattached to the main body shall be properly protected and clearly marked for easy identification and field assembly. Slide gates 24 inch and larger shall be physically attached via bolts, etc., to their skid. Gates should be in the closed position when shipped. All unpainted steel or machined iron surfaces shall be coated with a corrosion inhibitor.
B. Acceptance at Site
1. All gates shall be inspected at the time of receipt for damage caused during shipment. Included in the inspection should be verification that the gates comply with the specifications with regard to size, opening direction, type of end connections, actuator type, number of turns full open to close or vise versa. Gates should be operated through one complete open and closing cycle in the position it will be installed to verify its operation.
C. Storage and Protection
1. Gates should be stored indoors. In the event that outdoor storage is required, the units shall be protected from the weather, especially the possibility of water getting into the gate and freezing. All power actuators and controls shall have the electrical components energized or otherwise protected to prevent corrosion due to condensation caused by temperature variation. Also, see the manufacturer’s storage instructions.
1.08 MAINTENANCE A. Installation, Operation and Maintenance Instructions
1. Manufacturer's installation, operation and maintenance instructions shall be furnished to the ENGINEER as set forth in Section 01600.
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B. Extra Materials
1. Lubricants, spare parts and special tools needed for the equipment shall be furnished to the ENGINEER as set forth in Section 01600.
2. All special tools required for normal operation and maintenance shall be
furnished by the valve manufacturer. PART 2 PRODUCTS 2.01 MANUFACTURERS
A. Acceptable Manufacturers 1. Sluice gates –Waterman, Fontaine, Whipps, Golden Harvest, Hydrogate, or
equal. 2.02 MANUFACTURED UNITS A. General
1. All gates shall be furnished in the number, size and actuator type shown on the Drawings or listed in the gate schedule and as far as possible all equipment of the same type shall be from one manufacturer.
2. All gates shall have the name of the maker, model and the rated seating
and unseating head for which they are designed cast in raised letters or on an attached nameplate on some appropriate part of the body.
3. Whenever possible the stems of all gates shall turn left (counter
clockwise) to open the gate. The stems shall be of the type, rising stem or non-rising stem, as called for in the valve or gate schedule.
4. All gates must be provided with suitable operating devices and adapted
for operation in the position in which they are shown on the Drawings.
5. All gates shall be of the frame type, self contained or non-self contained, as called for in the valve or gate schedule.
6. End connections will be type shown on the Drawings and/or as called for
in the gate or valve schedule. 7. All gates shall be painted or coated according to Part 3 Execution and as
listed in Specification Section 09900 Painting.
8. All bolts, studs and nuts shall be stainless steel.
a. All bolts delivered to the job shall be free of dirt and mill scale and shall be stored in a manner to protect them from dirt and damage. All bolts shall be tightened to the proper torque. They shall be of
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the size recommended for the pipe, fittings and gates that they are to be used on and shall be in the recommended quantity. Tightening of bolts shall be alternated, so as to not produce undue stress on the gates and fittings.
b. The threads of all stainless steel bolts shall be coated with a layer
of anti-seize before the nuts are attached. Any bolts in potable water applications which are submerged or where something falling off the bolt would fall into the flow stream shall be covered with food grade anti-seize.
9. All materials used in the construction of the sluice or slide gates and their
accessories shall comply with the “Requirements” section of AWWA Specification(s) C561, related to materials, except that materials subject to dealuminization and dezincification shall not be used and that stainless steel is not acceptable for seat facings, wedges and other rubbing surfaces.
10. All gates shall be wall thimble or flange pipe mounted, vertical sluice or
slide gates designed for seating or unseating head, of square, rectangular or round openings, and shall be of the conventional closure or flush bottom closure type as shown and/or indicated on the Drawings.
B. Fabricated Stainless Steel Slide Gates
1. General a. The sluice gates to be furnished under this Specification shall be in
full compliance with the latest edition of ANSI/AWWA C561.
2. Design and Construction
a. Gate design and materials of construction shall be as noted below.
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Fabricated Stainless Steel Slide Gates
Item Material or Characteristic
Thimble, frame, guides, slide, yoke and stem guides
Stainless steel ASTM A167, ASTM A240, ASTM A249, ASTM A269, type 304, and 304L or type 316 and 316L – “L” grades shall be used for all welded components
Floor and Bench Stand (Actuator pedestal and gear housing)
Cast iron ASTM A126 class B or ASTM A48 class 30; or Stainless steel ASTM A276 type 304 or 316 or ASTM A312 or ASTM A376; or Ductile iron ASTM A536 grade 65-45-12
Gears Steel AISI 8620, AISI 4140 or AISI 1117
Thrust nut – rising stems
Stainless steel ASTM A276, type 304 or 316 or ASTM A743 grade CF8 or CF8M
Thrust nut – non-rising stems
Bronze ASTM B584
Stem couplings Stainless steel ASTM A276 type 304 or 316 or bronze ASTM B584 (CA 863, CA 865, or CA873)
Gate actuator lift nut Bronze ASTM B584 (CA 865 or CA 863) or ASTM B505 (C95800)
Seats UHME PE – ASTM D4020
Seals Neoprene, EPDM or polyethylene
Stem guide bushings UHMW PE – ASTM D4020; stainless steel A276 type 304 or 316; or bronze ASTM B584 (CA932 or CA 873), ASTM B98/B98M (CA 651 or CA 655), or ASTM B139 (CA510)
Stems Stainless steel ASTM A276 type 304 or 316
Stem Cover Galvanized pipe, stainless steel pipe, clear plastic pipe
Anchor bolts and fasteners
Stainless steel ASTM F593 or ASTMF594 alloy group 1 or group 2, or ASTM A276 type 304 or 316
Flush bottom sill Extruded or molded neoprene
Flush bottom sill retainer
Stainless steel ASTM A276 type 304 or 316
Wedges and pressure pads
Stainless steel ASTM A276 type 304 or 316; or ASTM A743 type CF8 or CF8M; or UHMW PE – ASTM D4020
Stem guides Stainless steel or cast iron, bronze bushed Maximum spacing 10 feet
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C. Accessories
1. Slide And Sluice Gate Actuators
a. General
(1) Gate actuators shall be of the type called for in the gate schedule. They shall be equipped with adjustable mechanical stop limiting devices to prevent over travel of the gate disc where applicable. Actuator housings, supports, and connections to the gate shall be designed with a minimum safety factor of 5, based on the ultimate strength, or 3, based on the yield strength of the materials used.
(2) Manual gate actuation, bench stand or floor stand with
crank or handwheel, or self contained gates with manual crank or handwheel, shall be as shown on the Drawings or as listed in the valve or gate schedule.
(3) Certification for the proof of design test of the gate actuator
shall be submitted in accordance with Section 00700/00710.
b. Gate Floor Stands and Extension Stems
(1) Each manual actuator shall be designed to operate the gate
under the maximum seating and unseating head by using a maximum effort of 40 pound on the crank or handwheel and be able to handle without damage efforts of at least twice this. Gearboxes shall be provided when needed to keep the necessary force below 40 pounds. All bearings and gears shall be enclosed in a weather tight housing.
(2) Floor or bench stand stems shall be of stainless steel and
run in adequately designed and lubricated anti-friction roller bearings. The hoist nut shall be of manganese bronze and be supported on roller bearings.
(3) Extension stems shall be of bronze or stainless steel.
Adjustable cast iron stem brackets with bronze bushings shall be provided at 10 foot intervals on all extension stems in excess of 10 foot in length. They shall be furnished with the stand.
(4) All extension stems shall be connected by bolted couplings
for connection to and removal from the gates and stands. Nuts and bolts in connections shall be stainless steel. All extension stem connecting pins shall be stainless steel.
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(5) Gate floor and bench stands shall be high strength heavy pattern at least 32 inches high. They shall be bronze mounted, handwheel or crank operated on roller bearings. Gate stand handwheels shall be between 15 and 24 inches in diameter, hand cranks shall have a radius of 12 to 15 inches. The operating shaft shall be fitted with a (2 inch square operating nut for a removable) (fixed) corrosion resistant crank handle. Non-rising stem stands shall have gate position indicators. Rising stem stands may be furnished without gate position indicators.
(6) For non-geared actuators mechanical seals shall be used
above and below the operating nut. For geared actuators mechanical seals shall be provided on top and bottom of the actuator housing and pinion shaft.
c. Marking
(1) In addition to gate marking as specified in AWWA C540
Section 6, paragraph 6.1 Marking, each gate shall be given a tag number which will correspond to the gate locations shown on the Drawings. Tags shall be of durable material and markings and shall be secured to the gate by pliable steel wire.
d. Portable Electric Actuator (1) A portable electric actuator shall be provided to operate all
slide/sluice dates, both new and existing gates. The number of actuators provided will be as needed to operate all gates, both new and existing. Existing gates shall be modified as necessary to be operated with the portable electric actuator. The portable electric actuator shall be E.H. Wachs, Rodney Hunt, or equal.
2. Wall Thimbles a. Wall thimbles shall be fabricated of or created of cast iron, ductile
iron or stainless steel as shown on the drawings. Wall thimbles shall be of the type shown on the drawings. All wall thimble bolt holes shall be supplied with plastic caps to prevent thread corrosion and prevent concrete from entering the holes. Wall thimbles embedded in concrete walls shall be supplied by the gate manufacturer. Where gates are attached to sections of flanged pipe the pipe may be supplied by the pipe supplier.
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D. Slide/Sluice Gate Schedule Marking1 Gate Type Seating Head
(ft) Unseating Head (ft)
Frame Type Stem Type Actuator Type2
MIG 1 & 2 AWWA C561 6 6 Self Contained Upward Opening
Rising Stem Handwheel
MEG 1 & 2 AWWA C561 10 10 Self Contained Upward Opening
Rising Stem Handwheel
FIG 1 & 2 AWWA C561 6 6 Self Contained Upward Opening
Rising Stem Handwheel
FEG 1 & 2 AWWA C561 10 10 Self Contained Upward Opening
Rising Stem Handwheel
SBIGT1 - 1 & 2 AWWA C561 5 5 Self Contained Downward Opening
Rising Stem/Falling Stem
Handwheel
SBIGT2 - 1 & 2 AWWA C561 5 5 Self Contained Downward Opening
Rising Stem/Falling Stem
Handwheel
SBIGT3 - 1 & 2 AWWA C561 5 5 Self Contained Downward Opening
Rising Stem/Falling Stem
Handwheel
CEG – 1 & 2 AWWA C561 5 5 Self Contained Downward Opening
Rising Stem/Falling Stem
Handwheel
PWG1 AWWA C561 10 10 Self Contained Upward Opening
Rising Stem Handwheel
PWG – 2 & 3 AWWA C561 10 10 Self Contained Upward Opening
Rising Stem Handwheel
PWG 4 AWWA C561 25 25 Self Contained Upward Opening
Rising Stem Handwheel
1 - M = Mixer; F = Flocculation; S = Settling; I = Influent; E = Effluent; SC = Screen; G = Gate; C = Clearwell; PW = Pump Well; Numbers are Train or Gate numbers 2 – All gates shall have actuators which can be opened and closed with a portable electric actuator.
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2.03 FABRICATION A. Shop Assembly 1. All gate actuators shall be fully shop assembled prior to shipment.
Actuator placement on the gate shall occur in the field. Gates shall have their disc and frames fully shop assembled and secured in place ready for shipment. Gate stems, and actuators shall be assembled in the field.
B. Shop/Factory Finishing
1. The exterior surface of various parts of gates, operators, floor stands and miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease, and other foreign matter and thereafter 1 shop coat of an approved rust inhibitive primer in accordance with AWWA C540 Section 4.5, such as specified in Section 09900 shall be applied in accordance with the instructions of the paint manufacturer.
2.04 SOURCE QUALITY CONTROL A. Tests, Inspection 1. Gates a. Shop testing gates for leakage is not required. 2. Actuators a. Actuators shall undergo a proof of design test and a performance
test in accordance with AWWA C540 Section 5. B. Verification of Performance 1. Actuators a. The manufacturer shall provide the ENGINEER with at least 2 copies
of certification of actuator Proof-of-Design tests and Performance Tests in accordance with AWWA Specification C540 and Sections 00820 and 00700/00710 of these specifications.
PART 3 EXECUTION 3.01 EXAMINATION A. Verification of Conditions 1. Prior to installation of a gate the installation area shall be visually and
mechanically inspected or checked for cleanliness, levelness and alignment. If any of these conditions are not according to the gate manufacturer’s requirements the CONTRACTOR shall fix the situation by
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removing concrete spatter, leveling uneven locations and filling all honeycombing. The gate location shall be smooth and clean prior to gate installation.
3.02 PREPARATION A. Protection 1. All gates and wall thimble mounting faces shall be protected from
concrete spatter by covering them with plastic or other material. All wall thimble bolt holes shall be plugged with plastic caps or equal prior to pouring concrete.
B. Surface Preparation 1. All materials used to protect wall thimble faces and bolt holes shall be
removed and the faces wiped clean. The surrounding wall area shall also be wiped clean of any concrete spatter of dust left over from wall repair or leveling work.
2. All concrete spatters shall be removed from around the gate location. All
uneven locations or honeycombing shall be leveled by filling voids or grinding down high spots. Where a gate is being installed on an existing pipe the pipe end shall be adjusted as necessary to mount the gate. This may include grinding it down to make it flush with the surrounding wall, squaring off edges, adding a flange, etc.
3.03 ERECTION, INSTALLATION APPLICATION A. Special Techniques
1. Interior
a. All gates and appurtenances shall be installed at the locations shown on the Drawings. All necessary materials, parts, operators and gaskets shall be furnished and installed under this Contract.
b. All gates, gate stands, extension stems, and floor boxes, on or in
structures, shall be installed as shown on the Drawings. Gate stands shall be set plumb and level and shall be anchored as shown on the Drawings. Stands shall be properly centered over gate stems or operating mechanisms. Any gate or stand found to be binding unduly shall be made to operate freely.
c. Gate boxes shall be accurately centered over gate operating nuts.
Tops of boxes shall be flush with floors.
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d. Tops of operating nuts shall be not more than 30 inches below the surface. Where gate operating nuts are more than 30 inches below tops of valve boxes, extension stems shall be provided to bring the operating nut to within 12 to 24 inches of box tops.
e. All gates shall be installed with their operators located in such a
location that it will not interfere with pedestrian traffic.
f. Particular attention shall be paid to the location and orientation of all gate operators to provide an accessible installation. Should any gate be located with the operator inaccessible and simple reorientation of the operator would make it accessible, the operator shall be moved at no cost the OWNER.
g. The CONTRACTOR shall thoroughly clean the gates before starting
erection. All scale, rust and dirt shall be removed by power brushing and/or solvent cleaning.
h. Field painting is specified in Section 09900. The CONTRACTOR and
the gate manufacturer shall coordinate shop paint and field paint to assure compatibility, in accordance with Section 09900.
B. Tolerances 1. Gate locations shall only be altered with written approval of the ENGINEER
unless noted otherwise. Dimensions of components, when noted, shall be as noted or unless larger or thicker components may cause operational problems.
3.04 FIELD QUALITY CONTROL A. Tests 1. After installation is complete the gate shall be tested for leakage in
accordance with the appropriate ANSI/AWWA specification. If the gate does not pass the leakage test the CONTRACTOR shall take whatever steps are necessary, including adjustment and removal and replacement, to repair the situation and the gates shall be tested again. The gate will be tested until, in the ENGINEERS opinion, the gate passes the leakage test and will not be a problem to operate or maintain as a result of the repairs.
2. After installation is complete the gate’s actuator shall be tested for
proper operation in accordance with ANSI/AWWA C540. Any deficiencies shall be corrected or the device replaced or otherwise made acceptable to the ENGINEER.
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B. Manufacturer’s Field Service 1. The equipment manufacturer or a certified manufacturer’s trained
representative shall perform the following installation and start-up commissioning services:
a. Verify alignment and proper installation of all gates and gate
components. b. Checking power to electric actuators or electric actuator
components. c. Verifying that the proper tolerances have been met. d. Complete and submit an equipment services checklist to confirm
that all specification and manufacturer requirements have been met and that all important data, such as critical tolerances, have been recorded.
e. Provide start-up and a minimum of 2 hours training to the plant
operators. 3.05 ADJUSTING and CLEANING A. Lubricate all threaded shafts, gears, bearings, and the like prior to the unit
being placed in service. Make all final adjustments to wedges, actuators, etc. 3.06 DEMONSTRATION A. Remove the line plugs, or fill the basin or pipe when the gate is closed to
demonstrate that the gate meets the leakage requirement when the maximum seating or unseating head is pressing on the gate. In cases where the gate is controlling water in a lake, river or stream perform the tests when it is expected to see the maximum seating or unseating head during that time of season.
3.07 PROTECTION A. In instances where the gate is installed in a lake, river or stream provide barriers
or deflectors around the gate to protect it from damage until it or the main structure are ready to be placed into operation. In basins, tanks, etc., cover the gate, its actuators, etc., with plastic or other means to protect it from concrete spatter, dust, etc., until the unit is ready to be place into operation.
END OF SECTION
***
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SECTION 11312
SUBMERSIBLE PLANT DECANT PUMPS AND ACCESSORIES PART 1 GENERAL 1.01 SUMMARY
A. Provide all labor, materials, equipment and services required to furnish and install the submersible plant wastewater pumps as shown on the Drawings and specified herein.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Section 01600.
B. Painting is included in Section 09900.
C. Motors and electrical work are specified in Division 16. 1.03 REFERENCES
A. Where referenced specifications (ASTM, ACI, PCI, etc.), are mentioned, these standards are deemed to be the minimum standard of quality of materials or methods to apply to this project.
1.04 SUBMITTALS
A. Shop drawings, control drawings, and operation and maintenance instructions shall be submitted in accordance with Section 00700 (00710). Refer to Section 01600 for additional requirements.
1.05 QUALITY ASSURANCE
A. The pump manufacturer shall have a minimum number of not less than 50 units of the type specified and required installed and in operation handling plant wastewater or sewage for no less than 2 years in North America.
1.06 SYSTEM DESCRIPTION
A. This specification refers to the decant pumps which will pump decant water from the basins to the head of the plant. The pump discharge line will tie-in to a line with approximately 5 psi of pressure.
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PART 2 PRODUCTS 2.01 PUMPS AND MOTORS
A. The pumps shall be capable of handling decant from floc or settling basing sludge, and waste filter backwash water. The design of the connection between the pumps and the discharge piping shall be such that the pumps will be automatically connected to the discharge piping when lowered into place. The pumps shall be easily removable for servicing or inspection, requiring no bolts, nuts or other fasteners to be removed for this purpose, or need for personnel to enter the wet well. The pumps shall be fitted with a stainless steel chain for each pump, of adequate strength and length to permit raising the pump for inspection and removal.
B. Casing and Impeller
1. The stator casing, oil casing and impeller shall be of grey iron
construction, with all parts coming in contact with sewage being protected by a coat of rubber-asphalt paint. All external bolts and nuts shall be of stainless steel. The wear ring between impeller and pump housing shall be of stainless steel or bronze with vitrile rubber O-ring or neoprene O-ring at the inlet of the pump. The impeller shall be of nonclog design, capable of passing solids, fibrous material, and heavy sludge, and constructed with long throughway with no acute turns.
C. Shaft Seal
1. Each pump shall be provided with a tandem double mechanical seal
running in an oil reservoir, composed of two separate lapped face seals, each consisting of one stationary and one rotating ring with each pair held in contact by a separate spring. The lower seal shall be tungsten-carbide on tungsten-carbide or silicon carbide on silicon carbide. The upper seal shall be either tungsten carbide, silicon carbide or tool steel on carbon. The compression spring shall be protected against exposure to the pumped liquid. All elastomeric components of the seal shall be fabricated using Viton.
2. The pumped liquid shall be sealed from the oil reservoir by one face seal
and the oil reservoir from the motor chamber by the other. The seals shall require neither maintenance nor adjustment, and shall be easily replaced.
3. Seal failure detection shall be provided and wired to an indicator light in
the control panel.
D. Pump Mounting and Removal Facilities
1. A sliding guide bracket shall be an integral part of the pumping unit. The pump casing shall have a machined connection with yoke to connect with the cast iron discharge connection, which shall be bolted to the floor of
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the sump and so designed as to receive the pump connection without the need of any bolts or nuts.
2. Sealing of the pumping unit to the discharge connection shall be accom-
plished by a simple linear downward motion of the pump with the entire weight of the pumping unit guided to and wedging tightly against the discharge connection.
E. Motors
1. Pump motor shall be housed in an oil or air-filled watertight casing and
shall have Class F insulated windings which shall be moisture resistant. All 3 phase motors shall be dual voltage. Pump motors shall have cooling characteristics suitable to permit continuous operation in a totally, partially or nonsubmerged condition.
2. Motors shall not be overloaded under any condition of operation. Motor
service factor shall not be used to prevent overloading. See Division 16 - Electrical for detailed motor specifications.
3. Motors shall be furnished with extra hard usage flexible power cables,
length as required. The cable entry into the motor housing shall be equipped with integral strain relief or an external strain relief device installed to prevent cable pullout.
4. Each submersible pump shall be equipped with a power cable of sufficient
length to reach to the disconnect switch or control panel without splicing.
F. Pump Warranty 1. The pump manufacturer shall warrant the pumps being supplied to the
OWNER against defects in workmanship and materials for a period of 5 years under normal use, operation and service. In addition, the manufac-turer shall replace certain parts which become defective through normal use and wear on a progressive schedule of cost for a period of 5 years. Parts included are the mechanical seal, impeller, pump housing, wear ring, and ball bearings. The warranty shall be in published form and apply to all similar units.
2.02 PUMP AND MOTOR CHARACTERISTICS
A. The service conditions, size and characteristics of the pumps and motors shall be as shown in Table 1.
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1. Table 1 -- Decant Pumps
Item Unit Quantity
Number of Units Required -- 2 Minimum Static Head Feet 20 Average Static Head Feet 27.5 Maximum Static Head Feet 29.5 Capacity Requirement @ Avg. Static Head gpm 687 Total Head @ Capacity Requirement & Avg. Static Head Feet 36 Pump Efficiency @ Capacity Required & Avg. Static Head Percent 70 Capacity Requirement @ Maximum Static Head gpm 650 Total Head @ Capacity Required and Maximum Static Head Feet 38 Minimum Shutoff Head Feet 55 Minimum Suction Size, Diameter Inches 4 Minimum Discharge Size, Diameter Inches 4 Diameter of Solids Passed Inches 3 Maximum Motor Size Hp 10 Maximum Allowable Pump and Motor Speed rpm 1800 Motor Phase -- 3 Motor Voltage V, 460 230/460
2. The basis for design is the Myers 4VC, Grundfos.
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2.03 ACCESS FRAME AND GUIDES
A. A complete access frame and guides for each pump shall be furnished complete with hinged and hasp-equipped cover(s), stainless steel upper guide holder and level sensor cable holder. Frame shall be securely mounted above the pumps. Each door shall have safety locking handle in open position. Doors shall be of checkered aluminum plate, aluminum frame and all stainless steel hardware.
B. Lower guide holders shall be an integral part of the discharge connection. Guide
bars shall be of Schedule 80 galvanized steel pipe of the size indicated on Drawings or required by the pump manufacturer.
C. Safety Device 1. The pump access frame shall include a Hatch Net 120 or equal, which is a
fall through prevention system. The net is to be factory installed. The net is to be easily retractable within the inside opening of the aluminum access frame. When access to the wetwell is required, the net can be slid to one side to facilitate full access. The Hatch Net 120 is manufactured by Safe Approach, Inc. and must meet all OSHA safety standards.
2. Dual safety grates shall be furnished at each wetwell hatch opening as a
fall prevention system and shall consist of 2 aluminum grates attached on opposite sides of the wetwell hatch frame under the cover. Both grates shall smoothly pivot on hinges 90 degrees upward and lock in place by hold open rods. The grate shall be designed to withstand a minimum pedestrian load of 300 pounds per square foot. The aluminum grates shall have an OSHA safety yellow (or orange) finish. Hardware components shall be made of 316 stainless steel to withstand corrosive wastewater environments. The system shall be a Dual Safety Grate as manufactured by U.S.F. Fabrication, Inc., Hialeah, Florida, or equal.
2.04 CONTROLS
A. The pumps shall be controlled as indicated on the Drawings or in the Specifications.”
PART 3 EXECUTION 3.01 DELIVERY, STORAGE AND HANDLING
A. Store indoors.
B. Pumps and motors shall not be stored on vibrating bases or floors. Any motor so stored should be disassembled and inspected for bearing damage, prior to service. If bearing damage is evident, replace bearing.
C. Check the rust preventative coating on external machined surfaces (including
shaft extension) for damage. If necessary, recoat the surfaces with Rust Veto No. 342 (Manufactured by E.F. Houghton Co.) or equivalent. The condition of the
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rust preventative coating shall be checked periodically and surfaces should be recoated as recommended by the coating manufacturer.
D. Oil lubricated bearings - drain oil from bearing housing and refill, to maximum
level, with a circulating type oil. Oil should be changed every 12 months while motor is in storage.
E. Grease lubricated bearings - once a month, inject a small quantity of grease into
the grease fill such that grease is purged from the drain. Inspect purged greases for water condensation or oxidation. If water condensation or oxidation is evident, the motor shall be disassembled and contaminated grease removed, and replaced with new grease.
F. Take precautions as necessary to prevent rodents, snakes or other small animals
from nesting inside pump.
G. Prevent moisture or condensation from accumulating by energizing motor space heaters if provided, or applying reduced voltage to one phase of motor windings (trickle-voltage-heating). Request percent of rated voltage and transformer capacity to be used from manufacturer. The winding should be maintained 5° degrees Celsius minimum above ambient temperature (some locations require a higher temperature above ambient) to prevent condensation.
H. If pump and motor are covered by plastic or similar material, additional
precautions such as heated or circulating air and silica gel may be necessary, to protect against moisture or condensation.
I. Rotate pump and motor shaft several revolutions by hand once every two weeks
while in storage to insure a protective oil film on bearing surfaces.
J. Start-up preparation after storage:
1. Thoroughly clean and inspect motor. 2. Change oil or grease in bearing housing. 3. Secure all plugs, fittings, etc., to prevent leakage. 4. Check insulation resistance.
3.02 INSTALLATION
A. Submersible pumps shall be shipped to the job completely assembled with the power cable attached. The unit must be properly stored and special care given to the protection of the power cable to protect it from mechanical damage and protect the cut end of the cable from the intrusion of moisture. The cable will act like a wick if the cut is allowed to lay in a pool of water. Should this condition be allowed to occur, the unit shall be shipped back to the manufac-turer for complete drying out and testing. A test report from the manufacturer shall be required before any payment for unit is made.
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B. It is important that the discharge connection is attached to the bottom slab level and at the exact location required relative to the access cover. Suggested procedure:
1. Install access cover.
2. Attach upper guide bracket(s). 3. Put discharge connection(s) on bottom slab. 4. Cut to length and install guide bars between upper guide bracket(s) and
discharge connection(s). 5. Put check with level (shim, if necessary) and anchor discharge connec-
tion(s) exactly where position will result in guide bars being parallel and vertical.
C. Use proper gaskets, tighten bolts gradually and evenly. In deep stations install
discharge pipe brackets to relieve discharge connections from overload and intermediate guide bar brackets to prevent guide bars from bending when pumps are pulled.
D. Lower pump units into place along guide bars. Check visually metal-to-metal
contact between volute flange and discharge connection. If necessary, re-check and re-align discharge connection(s) and guide bars with pumps in place.
E. After proper alignment of all components, including metal-to-metal connection
of pump flange is established, grout access cover, discharge connection(s) and pipe thrulets. Build up and shape slopes at pump bottom in accordance with Drawings.
F. As a part of the final inspection each pump shall be pulled to verify trueness of
alignment of guide rails, in the presence of the OWNER and the ENGINEER.
G. All motors and controls shall be connected and the motor operated while disconnected from the pump to determine proper rotation and to observe for vibration or motor defects. Disconnecting of the pump and motor on certain factory assembled units may be waived by the ENGINEER.
3.03 TESTING OF PUMPS
A. All pumps shall be tested to verify performance data submitted. When possible, pumps shall be tested by pumping down a basin or by filling a basin. All pumps shall be tested for capacity at a minimum of 3 points on the pump curve. The motor full load amperage and voltage shall be checked and must fall within the rated values of the motor tested. Failure to perform can result in having the unit removed and replaced.
B. All tests shall be performed by the CONTRACTOR in the presence of the
ENGINEER. All equipment needed for the pump tests, rulers, stopwatch, gauges, volt meter and ammeter shall be provided by the CONTRACTOR.
C. All motors shall be megged with the winding resistance recorded. Motor voltage
and amperage shall also be measured and recorded.
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D. All test data shall be reported to the ENGINEER in writing. 3.04 SPARE PARTS
A. Spare parts shall be furnished for all pumping equipment. All spare parts shall be boxed and tagged with positive identification, including part number, description and the particular pump to which it applies.
B. The required spare parts shall include the following items as a minimum for
each different size or model pumping unit:
One complete set of mechanical seals
One set of impeller adjustment washers
One set of O-rings
Wear ring
Impeller screw 3.05 PAYMENT
A. Payment for the complete system shall be included in the lump sum bid for the project and shall include the furnishing of materials, equipment and parts and installation of all components to provide a completely functional and operational system.
END OF SECTION
***
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SECTION 11313
SUBMERSIBLE SLUDGE PUMPS AND ACCESSORIES
PART 1 GENERAL
1.01 SUMMARY
A. Provide all labor, materials, equipment and services required to furnish and install the submersible sewage pumps as shown on the Drawings and specified herein.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Section 01600.
B. Painting is included in Section 09900.
C. Motors and electrical work are specified in Division 16.
1.03 REFERENCES
A. Where referenced specifications (ASTM, ACI, PCI, etc.), are mentioned, these standards are deemed to be the minimum standard of quality of materials or methods to apply to this project.
1.04 SUBMITTALS
A. Shop drawings, control drawings, and operation and maintenance instructions shall be submitted in accordance with Section 00700 (00710). Refer to Section 01600 for additional requirements.
1.05 QUALITY ASSURANCE
A. The pump manufacturer shall have a minimum number of not less than 50 units of the type specified and required installed and in operation handling sewage for no less than 2 years in North America.
PART 2 PRODUCTS
2.01 PUMPS AND MOTORS
A. The pumps shall be capable of handling raw, unscreened sewage. The design of the connection between the pumps and the discharge piping shall be such that the pumps will be automatically connected to the discharge piping when lowered into place. The pumps shall be easily removable for servicing or inspection, requiring no bolts, nuts or other fasteners to be removed for this purpose, or need for personnel to enter the wet well. The pumps shall be fitted with a stainless steel chain for each pump, of adequate strength and length to permit raising the pump for inspection and removal.
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B. Casing and Impeller
1. The stator casing, oil casing and impeller shall be of grey iron construction, with all parts coming in contact with sewage being protected by a coat of rubber-asphalt paint. All external bolts and nuts shall be of stainless steel. The wear ring between impeller and pump housing shall be of stainless steel or bronze with vitrile rubber O-ring or neoprene O-ring at the inlet of the pump. The impeller shall be of nonclog design, capable of passing solids, fibrous material, and heavy sludge, and constructed with long throughway with no acute turns.
C. Shaft Seal
1. Each pump shall be provided with a tandem double mechanical seal running in an oil reservoir, composed of two separate lapped face seals, each consisting of one stationary and one rotating ring with each pair held in contact by a separate spring. The lower seal shall be tungsten carbide on tungsten-carbide or silicon carbide on silicon carbide. The upper seal shall be either tungsten-carbide, silicon carbide or tool steel on carbon. The compression spring shall be protected against exposure to the pumped liquid. All elastomeric components of the seal shall be fabricated using Viton.
2. The pumped liquid shall be sealed from the oil reservoir by one face seal and the oil reservoir from the motor chamber by the other. The seals shall require neither maintenance nor adjustment, and shall be easily replaced.
3. Seal failure detection shall be provided and wired to an indicator light in the control panel.
D. Pump Mounting and Removal Facilities
1. A sliding guide bracket shall be an integral part of the pumping unit. The pump casing shall have a machined connection with yoke to connect with the cast iron discharge connection, which shall be bolted to the floor of the sump and so designed as to receive the pump connection without the need of any bolts or nuts.
2. Sealing of the pumping unit to the discharge connection shall be accomplished by a simple linear downward motion of the pump with the entire weight of the pumping unit guided to and wedging tightly against the discharge connection.
3. Guide rails and all accessories shall be non-sparking.
E. Motors
1. Pump motor shall be housed in an oil or air-filled watertight casing and shall have Class F insulated windings which shall be moisture resistant. All 3 phase motors shall be dual voltage. Pump motors shall have cooling
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characteristics suitable to permit continuous operation in a totally, partially or nonsubmerged condition.
2. Motors shall not be overloaded under any condition of operation. Motor service factor shall not be used to prevent overloading. See Division 16 - Electrical for detailed motor specifications.
3. Motors shall be furnished with extra hard usage flexible power cables, length as required. The cable entry into the motor housing shall be equipped with integral strain relief or an external strain relief device installed to prevent cable pullout.
4. Each submersible pump shall be equipped with a power cable of sufficient length to reach to the disconnect switch or control panel without splicing.
5. The pump/motor assembly shall be suitable for use in hazardous locations. The assembly shall be rated or certified for use in NEC Class 1, Group D, Division 1 hazardous locations.
F. Pump Warranty
1. The pump manufacturer shall warrant the pumps being supplied to the OWNER against defects in workmanship and materials for a period of 5 years under normal use, operation and service. In addition, the manufacturer shall replace certain parts which become defective through normal use and wear on a progressive schedule of cost for a period of 5 years. Parts included are the mechanical seal, impeller, pump housing, wear ring, and ball bearings. The warranty shall be in published form and apply to all similar units.
2.02 PUMP AND MOTOR CHARACTERISTICS
A. The service conditions, size and characteristics of the pumps and motors shall be as shown in Table 1.
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1. Table 1
Item
Unit Quantity
Number of Units Required
-- 3
Minimum Static Head
Feet 35
Average Static Head
Feet 39
Maximum Static Head System Head @ 750 gpm
Feet 43
& Avg. Static Head System Head @ 2000 gpm
Feet 48
& Avg. Static Head
Feet 79
Capacity Requirement (2 pumps in parallel) Total Head @ Capacity Required and
gpm 1750 (each pump at 875 gpm)
Maximum Static Head
Feet 71
Pump Efficiency @ Capacity Required
Percent 67
Minimum Shutoff Head
Feet 105
Minimum Suction Size, Diameter
Inches 4
Minimum Discharge Size, Diameter
Inches 4
Diameter of Solids Passed
Inches 3
Maximum Motor Size Maximum Allowable Pump and
Hp 25
Motor Speed
rpm 1783
Motor Phase
-- 3
Motor Voltage V, 230/460
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2. The sludge pumps shall be Grundfos SL1.85.100.180.4.52H.S.N.61G or equal.
2.03 ACCESS FRAME AND GUIDES
A. A complete access frame and guides for each pump shall be furnished complete with hinged and hasp-equipped cover(s), stainless steel upper guide holder and level sensor cable holder. Frame shall be securely mounted above the pumps.
B. Each door shall have safety locking handle in open position. Doors shall be of checkered aluminum plate, aluminum frame and all stainless steel hardware.
C. Lower guide holders shall be an integral part of the discharge connection. Guide bars shall be of Schedule 80 galvanized steel pipe of the size indicated on Drawings or required by the pump manufacturer.
D. Dual safety grates shall be furnished at each wet well hatch opening as a fall prevention system and shall consist of 2 aluminum grates attached on opposite sides of the wet well hatch frame under the cover. Both grates shall smoothly pivot on hinges 90 degrees upward and lock in place by hold open rods. The grate shall be designed to withstand a minimum pedestrian load of 300 pounds per square foot. The aluminum grates shall have an OSHA safety yellow (or orange) finish. Hardware components shall be made of 316 stainless steel to withstand corrosive wastewater environments. The system shall be a Dual Safety Grate as manufactured by U.S.F. Fabrication, Inc., Hialeah, FL, or equal.
2.04 CONTROLS
A. The pumps shall be furnished with a control panel as specified in Division 16. The pumps shall operate by liquid level sensors (Flygt Model ENH-10 or equal), which shall be furnished with the pumps. Four sensors are required, three normally open for stop, start lead, and start backup, and one normally closed for the alarm level. See the control circuit on the drawings and sequence of operation in Division 16 of these specifications for complete control requirements. The controls for the pumps shall be provided by the pump manufacturer.
B. Each submersible pump shall be furnished with seal leak detection. Extra hard usage power cable shall also be furnished with each pump, and a power cable support/mounting bracket. All cables shall be of adequate length to remove pumps and set wet well pump control elevations as necessary.
C. The pump control panel shall be NEMA 4X enclosed, with necessary intrinsic safety barriers, sealing fittings, etc. to interface correctly with the Class 1, Division 1, Group D classified wetwell atmosphere.
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PART 3 EXECUTION
3.01 DELIVERY, STORAGE AND HANDLING
A. Store indoors.
B. Pumps and motors shall not be stored on vibrating bases or floors. Any motor so stored should be disassembled and inspected for bearing damage, prior to service. If bearing damage is evident, replace bearing.
C. Check the rust preventative coating on external machined surfaces (including shaft extension) for damage. If necessary, recoat the surfaces with Rust Veto No. 342 (Manufactured by E.F. Houghton Co.) or equivalent. The condition of the rust preventative coating shall be checked periodically and surfaces should be recoated as recommended by the coating manufacturer.
D. Oil lubricated bearings - drain oil from bearing housing and refill, to maximum level, with a circulating type oil. Oil should be changed every 12 months while motor is in storage.
E. Grease lubricated bearings - once a month, inject a small quantity of grease into the grease fill such that grease is purged from the drain. Inspect purged greases for water condensation or oxidation. If water condensation or oxidation is evident, the motor shall be disassembled and contaminated grease removed, and replaced with new grease.
F. Take precautions as necessary to prevent rodents, snakes or other small animals from nesting inside pump.
G. Prevent moisture or condensation from accumulating by energizing motor space heaters if provided, or applying reduced voltage to one phase of motor windings (trickle-voltage-heating). Request percent of rated voltage and transformer capacity to be used from manufacturer. The winding should be maintained 5° degrees Celsius minimum above ambient temperature (some locations require a higher temperature above ambient) to prevent condensation.
H. If pump and motor are covered by plastic or similar material, additional precautions such as heated or circulating air and silica gel may be necessary, to protect against moisture or condensation.
I. Rotate pump and motor shaft several revolutions by hand once every two weeks while in storage to insure a protective oil film on bearing surfaces.
J. Start-up preparation after storage:
1. Thoroughly clean and inspect motor.
2. Change oil or grease in bearing housing.
3. Secure all plugs, fittings, etc., to prevent leakage.
4. Check insulation resistance.
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3.02 INSTALLATION
A. Submersible pumps shall be shipped to the job completely assembled with the power cable attached. The unit must be properly stored and special care given to the protection of the power cable to protect it from mechanical damage and protect the cut end of the cable from the intrusion of moisture. The cable will act like a wick if the cut is allowed to lay in a pool of water. Should this condition be allowed to occur, the unit shall be shipped back to the manufacturer for complete drying out and testing. A test report from the manufacturer shall be required before any payment for unit is made.
B. It is important that the discharge connection is attached to the bottom slab level and at the exact location required relative to the access cover. Suggested procedure:
1. Install access cover.
2. Attach upper guide bracket(s).
3. Put discharge connection(s) on bottom slab.
4. Cut to length and install guide bars between upper guide bracket(s) and discharge connection(s).
5. Put check with level (shim, if necessary) and anchor discharge connection(s) exactly where position will result in guide bars being parallel and vertical.
C. Use proper gaskets, tighten bolts gradually and evenly. In deep stations install discharge pipe brackets to relieve discharge connections from overload and intermediate guide bar brackets to prevent guide bars from bending when pumps are pulled.
D. Lower pump units into place along guide bars. Check visually metal-to-metal contact between volute flange and discharge connection. If necessary, re-check and re-align discharge connection(s) and guide bars with pumps in place.
E. After proper alignment of all components, including metal-to-metal connection of pump flange is established, grout access cover, discharge connection(s) and pipe thrulets. Build up and shape slopes at pump bottom in accordance with Drawings.
F. As a part of the final inspection each pump shall be pulled to verify trueness of alignment of guide rails, in the presence of the OWNER and the ENGINEER.
G. All motors and controls shall be connected and the motor operated while disconnected from the pump to determine proper rotation and to observe for vibration or motor defects. Disconnecting of the pump and motor on certain factory assembled units may be waived by the ENGINEER.
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3.03 TESTING OF PUMPS
A. All pumps shall be tested to verify performance data submitted. When possible, pumps shall be tested by pumping down a basin or by filling a basin. All pumps shall be tested for capacity at a minimum of 3 points on the pump curve. The motor full load amperage and voltage shall be checked and must fall within the rated values of the motor tested. Failure to perform can result in having the unit removed and replaced.
B. All tests shall be performed by the CONTRACTOR in the presence of the ENGINEER. All equipment needed for the pump tests, rulers, stopwatch, gauges, volt meter and ammeter shall be provided by the CONTRACTOR.
C. All motors shall be megged with the winding resistance recorded. Motor voltage and amperage shall also be measured and recorded.
D. All test data shall be reported to the ENGINEER in writing.
3.04 SPARE PARTS
A. Spare parts shall be furnished for all pumping equipment. All spare parts shall be boxed and tagged with positive identification, including part number, description and the particular pump to which it applies.
B. The required spare parts shall include the following items as a minimum for each different size or model pumping unit:
C. One complete set of mechanical seals
D. One set of impeller adjustment washers
E. One set of O-rings
F. Wear ring
G. Impeller screw
3.05 PAYMENT
A. Payment for the complete system shall be included in the lump sum bid for the project and shall include the furnishing of materials, equipment and parts and installation of all components to provide a completely functional and operational system.
END OF SECTION
***
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SECTION 11319
SUMP PUMPS PART 1 GENERAL 1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to install, complete and make ready for operation, a portable positive displacement sump pump as shown on the Drawings and specified herein.
1.02 RELATED WORK
A. Painting is included in Division 9.
B. Instrumentation/SCADA is included in Division 17.
C. Piping is included in Division 2. D. Valves are included in Division 15.
E. Electrical work is included in Division 16.
1.03 DESCRIPTION OF THE SYSTEM
A. The equipment specified herein for the chemical area sumps is intended to be a positive displacement pump(s) mounted on a wheeled portable stand which can be easily moved to where it is needed. The number of new sump pumps and accessories shall be furnished and installed as follows:
New or No. of Pumps Location Replacement Required/Installed
Chemical Building New 1/1
1.04 SUBMITTALS
A. Furnish to the ENGINEER for review, as required in Division 0, Section 00700/00710, shop drawings and technical literature covering details of all equipment, fixtures and accessories being furnished under this Section prior to fabrication, assembly or shipment.
1.05 OPERATING INSTRUCTIONS
A. Operating and maintenance instructions for each type of equipment shall be furnished to the ENGINEER as required for in Division 1, Section 01600.
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PART 2 PRODUCTS 2.01 PUMPS
A. The pumps shall be heavy duty pumps designed for industrial use.
B. The pumps shall be a peristaltic, diaphragm, progressive cavity, gear, etc.
C. The pumps shall be able to handle chemicals with the following characteristics. The fluid in each area may be full strength, less than full strength or just water. The characteristics of each chemical at 68 degrees Fahrenheit are noted below:
Possible Sump Pump Chemicals to be Handled
Solution to Be Pumped1
Suction Lift Ft of Chemical
Hydrofluosilicic acid 3 Sodium hypochlorite 5 2Coagulant DelPac 2500 5 Carbon slurry - 17% 5 Potassium permanganate 3 Polyphosphate (sodium hexametaphosphate)
3
1 See the chemical schedules of the Drawings from chemical characteristics. 2 The initial chemical being used is DelPac 2500, a polyaluminum chloride, but any of several other coagulants may be used, including but not limited to aluminum sulfate (alum), aluminum chlorohydrate, etc. The characteristics given may cover any one or more of these chemicals.
D. See Division 16 for complete motor specifications. The motor shall be 1.0 horsepower or less and be TEFC and be rated for continuous duty. The sump pump shall have integral overload protection for the motors.
E. The sump pump shall be able to pump at least 8 gpm at 50 feet TDH.
F. The pump shall come with a portable wheeled stand, a motor, minimum 10 feet
of appropriately sized reinforced PVC, Teflon, PVDF suction and discharge hose. The discharge hose shall connect the pump discharge to the fixed rigid discharge piping mounted nearby or to other piping to a portable tank, truck, etc.
G. The units shall be ThermoFisher/Masterflex, Watson-Marlow, Seepex, ARO,
Wilden, Moyno, Flomation Systems, Pulsafeeder, or equal.
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H. The pumps shall include an integral cooling fan and 12-foot power cord for 120 V operation.
2.02 SUMP COVER
A. Sump covers, if shown on the Drawings, shall be provided and installed to fit the sumps. Otherwise, sump covers are not required.
2.03 DISCHARGE PIPING
A. A minimum of 50 feet of discharge tubing/hose shall be provided if no rigid piping is shown on the Drawings. Rigid discharge piping shall be installed as shown on the Drawings.
2.04 CONTROLS
A. The pumps shall have an integral OFF/ON switch and thermal overload protection with manual reset.
PART 3 EXECUTION 3.01 SUMP PUMP
A. Sump pumps shall be installed as shown on the Drawings and as specified herein.
B. Sump pump controls shall be installed as shown on the Drawings and as
specified in Division 16. 3.02 PERFORMANCE TESTS
A. After the sump pumps have been installed, performance tests shall be conducted. The purpose of these performance tests shall be to demonstrate that the units have been properly installed and that they and their appurtenant equipment will operate satisfactorily and meet the specified conditions.
B. For the purpose of these tests, the CONTRACTOR shall furnish the water. The
CONTRACTOR shall provide and install temporary pressure gauges on the discharge of each pump for testing purposes.
C. The performance tests shall be conducted in the presence of the ENGINEER with
the cooperation of the manufacturer's factory representative. It is intended that these tests shall be carried out by operating each pumping unit through the range specified for a continuous period of at least 1 hour, or until it is shown that all of the equipment is in acceptable condition and will meet the specified requirements.
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D. Throughout these tests of the pumping equipment, the motors and pumps must run smoothly without vibration or excessive heating, otherwise the test shall be stopped and not undertaken again until the unit shall have been put into condition to comply with the requirements for smoothness of operation.
END OF SECTION
***
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SECTION 11375
POSITIVE DISPLACEMENT BLOWERS PART 1 GENERAL 1.01 SCOPE OF WORK
A. Provide all materials and equipment required for the supply of positive displacement blowers, and all services needed for installation inspection, startup and training for same, as specified herein and as applicable for the filter system manufacturer’s equipment package as specified.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Sections 00700/00710 and 01600.
B. Electrical work is specified in Division 16.
C. Valves are specified in Division 15.
D. Hangers and supports are specified in Division 15. E. Piping is specified in Division 2.
F. Special sequence or schedule requirements (if any) are specified in Section 01010 - Summary of Work.
1.03 SYSTEMS DESCRIPTION
A. Positive displacement blowers shall be provided to supply air induced turbulence to aid in filter cleaning. The number of blowers supplied shall provide for a minimum of 1 spare unit.
B. The blower will take air in from the outdoors, through a pipe to the compressor,
compress it and send it to the filter system which will be in another room. C. The positive displacement blower packages shall include an inlet filter and
silencer or combination filter/silencer, discharge unloading and relief valve, discharge silencer, check valves, expansion joints in both the suction and discharge piping, pressure gauges on the discharge piping with shutoff valve, mounting frame, vibration isolation mounting hardware, safety guards and instrumentation.
1.04 QUALIFICATIONS
A. The blower(s) shall be furnished by a manufacturer who is experienced, reputable, and qualified in the manufacturer of the equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with
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best practices and methods. The blower(s) shall be oil free, rotary lobe, positive displacement units as manufactured by Aerzen, Kaeser, or equal.
B. The blower manufacturer shall have and be able to document a minimum
number of not less than 50 units in operation for no less than 5 years in North America, of the type specified and required. The submission of a bond or deposit equal to the total price of the equipment and accessories and for the same time period will be permitted in lieu of experience clause.
C. The blower manufacturer shall have ISO 9001 certification and provide proof of
certification. The ISO 9001 certification shall be held by the manufacturer of the blower and not a parent company.
1.05 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ENGINEER in accordance with Section 00700/00710 - Submittals.
B. O&M instructions shall be submitted to the ENGINEER in accordance with Section
01600. The O&M shall be provided in both hard copy and electronic copy.
C. Provide manufacturer's certified performance curves showing discharge pressure, capacity, brake horsepower and speed; along with dba noise pressure level at 1 motor, with and without the sound enclosure; descriptive brochures; valve data; and ISO 1217 performance test results
1.06 EQUIPMENT OR SYSTEM WARRANTY
A. The manufacturer shall warrant the blower to the OWNER against all defects in materials and workmanship for a period of 60 months from date of shipment or 54 months from substantial completion. In addition the manufacturer shall warrant all other blower system components to the OWNER against all defects in materials and workmanship for a period of 12 months from substantial completion or 18 months from shipment. Also see additional warranty requirements in Section 01600.
PART 2 PRODUCTS 2.01 BLOWERS – POSITIVE DISPLACEMENT A. General 1. The blower shall be an oil free 3 lobe rotary positive displacement type as
manufactured by Aerzen, Kaeser, or equal. 2. The blower speed range shall be nominal 2500 to 4000 rpm with a
minimum speed of 2450 rpm.
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3. The blower manufacturer, not the parent company, shall have ISO 9001 certification and provide proof of certification.
4. The maximum gear tip speed shall be selected so that the noise level at
the required pressure shall not exceed 95 dB(A) at 1 meter, free field conditions, from the unit over the entire range of frequencies (30 to 8000 hertz) without the use of a sound isolation hood. The packaged unit shall be able to achieve a noise level of 80 dB(A) or less at 1 meter, free field conditions, over the entire range of frequencies (30 to 8000 hertz) with the use of a sound isolation/reduction enclosure or hood. A sound isolation/reduction enclosure shall be provided for each blower.
5. The unit shall have easy access to the oil fill and drain plugs. 6. Blower packages shall be designed to minimize the life-cycle costs and
maximize plant reliability. The design and the selection of the components shall be based on a minimum useful life to 20 years and a mean time between overhauls of 5 years of continuous operation.
7. No special foundations shall be required. The blower packages will be
installed directly on a concrete slab without grouting the base frame. There shall be only 4 easily accessible anchor points.
8. Blowers shall have the following capacities, characteristics and
performance requirements: Number of Units: 2 Capacity: 1920 SCFM Maximum speed: 4400 rpm Maximum motor size: 100 hp Inlet pressure: atmospheric @ 915 ft elevation Inlet temperature: 105oF maximum Discharge pressure: 7 psig1 Max. Blower Op. Pressure: 8.3 psig 1 – This discharge pressure does not include losses through the
equipment in the blower package including blowers, filters or silencers, etc. This added loss must be added to the discharge pressure noted here. This pressure assumes losses through 8-inch schedule 10S stainless steel pipe.
B. Blower Design 1. Housing a. The housing head plates, gear house and end cover shall be
constructed of heavy, close-grained, high strength cast iron ASTM A48 ribbed as required for rigidity. Minimum blower casing pressure rating shall be 36 psig. The cylinder shall be constructed in one piece. The design of the blower shall be such that the rotors
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may be easily removed from the housing for maintenance. The housing shall come with ANSI 125 pound flanges, or the DIN equivalent flanges, for suction and discharge connections.
2. Rotors a. The blower rotors shall be rigid and constructed of either ductile
iron connected to forged alloy steel shafts or be a single common piece of drop forged AISI 1043, or equal, carbon steel. All rotor clearances shall be set to accommodate the direction of rotation of the drive shaft. The rotors shall be statically and dynamically balanced per ISO 1940/ANSI 52.19 G.6.3. Cast, hollow rotors shall be capped and dust tight. Open rotors are not acceptable.
3. Timing Gears a. The timing gears shall be spur type and made to AGMA 12
standards with hardened and ground teeth. The gears shall have a minimum 1.7 service factor per AGMA. The gears shall be accurately machined case hardened alloy steel, and mounted on the rotor shafts via a heavy tapered interference fit and secured by a lockout. The gears shall operate in an oil bath.
4. Bearings a. The unit shall be equipped with anti-friction type ball or roller
bearings. The bearings shall have a minimum expected“B10” life of 43,000 hours operating continuously and at design full load and pressure. Inboard bearings shall be furnished with the blower to prevent any deflection of the blower shafts. All shafts shall be supported by heavy duty antifriction bearings.
5. Lubrication a. All bearings and gears shall be splash oil lubrication via slingers at
both the drive and gear ends of the unit. The unit shall have visible oil level gauges. Grease lubrication is not acceptable.
6. Seals a. Seals shall be designed to prevent lubricant from leaking into the
air stream as well as to prevent oil from leaking out of the machine.
b. The rotor chamber seals shall be non-contacting, vented labyrinth
seals containing 4 piston ring seals. The drive shaft seal shall be a radial lip seal riding on a replaceable shaft sleeve. The impeller side of the oil seal shall be vented to atmosphere to prevent carryover of oil into the air stream.
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7. Flow Direction a. The units shall have flow traveling from the top to the bottom of
the unit through the various filters and silencers as noted below. 8. Testing a. Each unit shall be tested under full load conditions according to
ISO 1217 to verify flow and brake horsepower at blower maximum conditions. A slip test is not acceptable. The acceptance criteria shall be +5 percent tolerance on power and -5s percent tolerance on flow regardless of machine size.
C. Blower Drive 1. The blower shall be arranged to be driven through a V-belt drive of the
high capacity type, oil and heat resistant. The v-belt drive shall have an automatic tensioning system to automatically tension belts to the desired tension.
2. The drive motor for the blower shall be constant torque, have a maximum
speed of 3600 rpm and be a 3/60/230/460 TEFC motor. Embedded winding thermostats are required.
3. The motors shall be horizontally mounted on an adjustable slide base for
maintaining rated speeds, belt adjustment and future capacity changes. 2.02 BLOWER ACCESSORIES A. General 1. The accessories noted below shall be provided for each blower package.
Where an accessory’s design is different for a positive displacement blower versus a centrifugal blower the appropriate design shall be provided for the blower being provided.
B. Silencers 1. The silencers shall be constructed of cast iron or welded heavy gauge
steel and be equipped with ANSI 125 lb flanges. They shall be designed so as to offer the minimum of resistance to the air flow and yet effectively eliminate roar and other noises inherent to the operation of positive displacement type air blowers.
2. The blower shall have a combination inlet filter silencer which shall
contain an easily removable and washable filter element and a filter maintenance indicator. The filter media shall meet efficiency requirements of ASHRAE 52.2 MERV7 50-70 percent at 3-10 microns corresponding to EN79 GY. The unit shall be similar to Universal Silencer, Stoughton, WI, or equal. The inlet filter silencer shall be mounted directly
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to the inlet flange of the blower. The silencer portion shall be located upstream of the inlet filter. Filter and silencer performance losses shall be included in the blower performance calculation.
3. A silencer shall be installed in the discharge of the blower and shall be a
combination base frame/discharge silencer. It shall be a distortion resistant cylindrical vessel having a low pressure drop and which meets or exceeds API 619 for the residual pulsation being lower than 2 percent peak to peak of the discharge pressure. The unit shall be similar to Universal Silencer or equal.
4. The discharge silencer shall be fabricated of a single shell of pressure
vessel quality steel with continuous welds. The silencer must be subject to a pressure test for tightness and strength at a minimum of 1.65 times the maximum blower operating pressure. The silencer shall have a machined inlet connection where the discharge flange of the blower stage bolts directly to, with no intermediary pieces. Discharge silencer performance losses shall be included by the blower vendor in the blower performance calculation.
5. The base frame is to be constructed from welded carbon steel or cast iron
that shall be designed to maintain alignment of the blower internal components and the drive during operation. It shall be designed to resist distortion while being installed on vibration isolating mounts. The blower manufacturer shall supply a stainless steel grounding lug fully welded to the base.
C. Valves 1. Each package shall have a single pressure safety/relief valve which shall
be of the spring-loaded, adjustable in the field, unloading type on the discharge side of the blower downstream of the silencer and upstream of the check valve design flow. The valve shall be field adjustable, spring-loaded, and have a certificate of conformity to PED. The valve shall be manufactured by Aerzen. If the blower package is supplied with a sound enclosure, the pressure relief valve shall also be housed by the sound enclosure and shall relieve into a segmented section of the sound enclosure. It shall be of the size and type recommended by the blower manufacturer for his equipment. It shall be designed to release the full flow of air.
2. The check valves shall be of a type particularly suited for positive
displacement blower operation and installation in either vertical or horizontal runs of piping. They shall be lightweight swinging discs. The check valves shall be designed so that they operate without chatter. Pressure losses produced by the check valve shall be indicated in the blower performance calculation.
3. The shutoff valves shall be flanged or lug wafer butterfly valves. The
butterfly valves shall be cast iron body, stainless steel shaft, and bronze
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vane. The shaft shall be supported by and operated in glass filled Teflon bearings with Buna N liners. The valves shall be operated by a hand wheel and shall have a position indicator.
4. The unit shall also have an automatic start mechanical unloading valve
which is self actuated, adjustable in the field and is attached to the discharge manifold. Suppliers proposing an electrical unloading valve must provide complete costs of electrical in their package, including power supply, conduit, wiring, and control integration.
D. Expansion Joints 1. The expansion joints in the blower discharge and suction lines shall be
flanged or stainless steel strapped rubber spool pieces as manufactured by Red Valve, Carnegie, Pennsylvania, U. S. Rubber Company, Long Island, NY; Flexicraft; Proco Style FS-111; or equal. If strapped units are supplied they shall be held in place by a minimum of 2 straps. The suction line expansion joint shall be between the outside air inlet pipe and the blower package of equipment. The discharge unit shall be located after the discharge silencer to connect the package to the main discharge piping.
E. Vibration Isolation Mounts 1. The blower package shall come with rubber type vibration isolation
mounts to absorb a minimum of 80 percent of the vibration (both high and low frequencies) at operating speeds.
F. Safety Devices 1. The blower package shall come complete with all necessary safety guards
including a belt guard to bring the system in compliance with OSHA. The belt guard shall be designed to allow easy access to the belts and be of corrosion resistant material.
G. Instrumentation 1. The blower package shall come with an inlet air pressure/vacuum gauge,
a discharge air pressure gauge, a suction pressure switch, a discharge air pressure switch and a discharge air temperature gauge/switch. See Division 17 for information on instrumentation requirements.
H. Each package shall be supplied with a sound enclosure covering the entire
blower package. The enclosure shall provide suitable protection for outdoor installation. The enclosure shall be designed so as to be able to install them side-by-side with all maintenance done from the front or back of the package. Details are as follows:
1. Panels shall be made of galvanized steel sheet, powder coated in a light
reflecting color per RAL 5001 or of aluminum. The skid shall be of the
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same color. Sound enclosure acoustic material shall comply with UL 94 - HF1 for fire-retardant, self-extinguishing, non-dripping materials.
2. The enclosure and the blower package must be both mounted on a skid/
oil-drip pan designed for meeting environment protection standards. Fork lift channels shall be included to allow for easy transportation and installation.
3. A grounding strap shall be installed between the blower base and the
package skid to bypass any vibration isolating mounts. 4. Quick release panels, each less than 50 lb (as mandated by MSHA), must
provide easy and quick access for routine maintenance of the blower and the package components.
5. A high efficiency blower shaft driven ventilation fan or electric fan shall
provide ventilation and cooling integral to the sound enclosure. Cooling fan shall be sized for sufficient heat removal from the sound enclosure, even when the blower is operated with a VFD.
6. Electrical components, instrumentation and instrument connections shall
not be mounted or interface with moving panels of the sound enclosure. 7. Both blower oil sumps shall be piped to a common fill and drain, located
at the front of the package for easy maintenance. An oil level indicator shall be mounted on the outside of the enclosure, which gives an accurate oil level indication while the blower is in operation. All oil lines to be hydraulic hose with fittings. No plastic tubing with compression fittings are allowed.
I. Coatings or Finishes
1. Only ferrous metals shall be painted. 2. All ferrous metals shall be painted in accordance with the manufacturer’s
standard painting system and color for the intended service. When the manufacturer has more than one color available as a standard color, color available at no additional cost, the OWNER shall choose the final color in the shop drawing submittal.
3. The equipment manufacturer shall coordinate shop paint and
CONTRACTOR field paint to assure compatibility. 4. All stainless steel components shall be passivated prior to assembly. 5. All stainless steel, aluminum, and brass shall not be painted.
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2.03 CONTROLS
A. Controls shall be as specified herein and in Division 16. See the blower control circuit on the Drawings.
PART 3 EXECUTION 3.01 FACTORY TESTING
A. Each blower and vacuum pump shall be given a factory mechanical test to assure mechanical integrity and a performance test to confirm capacity. If the tests indicate that adjustments are necessary to insure conformance to the manufacturer's standards, such adjustments shall be made prior to shipment. A certificate of successful performance test shall be submitted with the shop drawings.
FIELD TESTING & TRAINING
A. After installation of all equipment has been completed and as soon as conditions permit, the manufacturer shall verify the installation and conduct an acceptance test under actual operating conditions. Each blower shall a field test performed where the test shall consist of air washing 3 filters under expected operating conditions with readings taken and recorded at 1-minute intervals. Each test shall be performed for at least 5 minutes.
B. If required, CONTRACTOR shall make any changes, at his own expense, to the
installation that may be necessary to assure satisfactory operation. CONTRACTOR shall be held liable for changes needed in the installation.
C. A minimum of 2 days in 1 or 2 trips at 8 hours per day shall be provided for
field testing and training. Training shall not be performed until the blowers have undergone field testing and the filters for which they will be providing air for have been field tested.
3.02 TOOLS AND SPARE PARTS
A. All special tools required for normal operation and maintenance shall be furnished by the equipment manufacturer.
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B. Spare parts shall be furnished for the blower and vacuum pump equipment. All spare parts shall be boxed and tagged with positive identification, including part number, description and the particular blower to which it applies. The minimum spare parts to be provided are:
Inlet Filter Element 1 per blower model Blower Bearings 1 set per blower model Seals 1 set per blower model All Gaskets 1 set per blower model Lubricants 1 years supply V-belts 1 set each blower model
END OF SECTION
***
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SECTION 11445
JET AERATION AND MIXING SYSTEMS
PART 1 GENERAL
1.01 THE REQUIREMENT
A. The Contractor shall furnish all labor, materials, tools, and equipment necessary for installation, testing, and placing into satisfactory operation all jet aeration equipment, suction manifolds, discharge manifolds, associated piping, and flushout system piping with valves and operators, supports, anchor bolts, anchoring accessories and other appurtenances required for satisfactory installation and operation, as shown on the Contract Drawings and specified herein.
1.02 OPERATING CONDITIONS AND PERFORMANCE REQUIREMENTS
A. Jet Mixing Performance
1. The jet aeration equipment shall be capable of providing complete mixing in the anaerobic zones within the aeration tanks through liquid recirculation alone.
2. The jet mixing equipment manufacturer shall guarantee that mixing energy equal to or greater than 100 HP per million gallons (HP/MG) of mixed liquor is delivered to the aeration basin compartments through liquid recirculation alone. Calculations shall be provided with the Shop Drawings to verify mixing energy. Mixing energy shall be calculated based upon the energy of the jet as it leaves the nozzle, not upon mixing pump horsepower. Mixing energy calculations shall be based on the following:
Tank Liquid Flow (gpm) x Nozzle Headloss (feet) 3960 x Tank Volume1 (MG) 1 Tank volume approximately 0.15 MG
B. Jet Aeration Performance
1. The jet aeration equipment shall have the capability of transferring oxygen to the mixed liquor. The jet aeration system manufacturer shall unconditionally guarantee system performance for the specified transfer efficiency at the submergence and liquid flow per nozzle stated below.
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Airflow (scfm/nozzle)
Minimum Clean Water Transfer Efficiency
25 27%
50 22%
80 20%
100 19%
2. Clean water transfer efficiency shall be based on a liquid temperature of
20°C, oxygen saturation value and transfer characteristic (KLa) equal to that of clean tap water at 20°C, and initial dissolved oxygen concentration of zero mg/l, an alpha factor of 1.0, a beta factor of 1.0, and a temperature correction factor (theta) of 1.024.
3. In the event that the equipment fails to meet the minimum oxygen transfer efficiency requirements, the manufacturer shall alter or replace the equipment as necessary to meet specified requirements at no additional cost to the Owner.
C. Equipment Summary
Jet Mixing/Aeration Manifolds Minimum Mixing Energy 100 HP/MG Number Manifolds Required 1 Liquid Header Diameter 12 in Liquid Header Minimum Wall Thickness 0.188 in Air Header Diameter 6 in Air Header Minimum Wall Thickness 0.146 in Backflush Pipe Diameter 8 in Minimum Number of Jet Nozzles per Header 8 Nozzle Opening 2.125 in Elevation of Nozzle Centerline above Slab 2.5 ft Nozzle Angle 30 degrees
downward Tank Water Surface Level 13 ft 3 in Tank Dimensions 32 ft 11 in x 46 ft 0
in Minimum Tank Liquid Flow 3,200 gpm Liquid Flow per Jet Nozzle 400 gpm Design System Head Loss at 3,200 gpm including all piping
24.4 ft
Design Nozzle Headloss only at 400 gpm each 20.3 ft Tank Air Flow 391 scfm
See Drawings for additional information
1.03 SUBMITTALS
A. Submittals shall be in accordance with Specification 00700, Submittals.
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B. In addition, the following items shall be submitted with the Shop Drawings:
1. Performance Affidavit
2. Certified oxygen transfer efficiency curves shall be submitted based on previous testing for the design submergence and range of operating airflows specified herein.
3. Installation instructions shall be complete including anchoring, leveling, fastening, inspection, provisions for expansion/contraction, etc. The Manufacturer's installation instructions shall be submitted prior to shipment of the jet aeration equipment.
4. The Manufacturer shall submit certifications from the pipe manufacturer stating that the FRP pipe used for the jet manifolds and suction and discharge manifolds has been tested according to ASTM D-2996.
5. Calculations shall be provided with the Shop Drawings to verify mixing energy as described above.
1.04 QUALITY ASSURANCE
A. The materials covered by these Specifications are intended to be equipment of proven reliability, and as manufactured by reputable manufacturers having experience in the production of such equipment. The Contractor shall furnish the names of not less than 5 successful installations with over 1 year of operation of the manufacturer's equipment of the same size and model of that offered under this contract. Manufacturer shall have at least 10 years experience in design, application and supply of jet mixing equipment as specified herein.
1.05 WARRANTY AND GUARANTEE
A. Warranty and Guarantee shall be as specified in Specification 00700.
PART 2 EQUIPMENT
2.01 ACCEPTABLE MANUFACTURERS
A. The materials covered by these Specifications are intended to be standard equipment of proven reliability and as manufactured by reputable manufacturers having experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practices and methods and shall operate satisfactorily when installed as shown on the Contract Drawings and operated per manufacturers recommendations. See Bid Form for acceptable manufacturers.
2.02 GENERAL
A. Jet Mixing/Aeration Manifolds
1. Jet aeration equipment shall be of duplex jet manifold design, comprised of a liquid header, an air header, and air/liquid jet nozzles integrally
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fabricated to form a single unit. The jet nozzles shall be duplex (or bi-directional) manifolds mounted on both sides of the liquid header directly opposing one another. The jet nozzles shall be equally spaced along the length of the manifold and shall be aligned on a horizontal plane or at an angle slightly below horizontal. All manifolds shall be aligned identically. The jet manifold shall be designed to provide uniform distribution of the liquid phase and air phase to each jet nozzle. The recirculated liquid and low pressure air shall be combined in the jet nozzle and the resultant fine bubble stream shall be discharged as a high energy jet in the lower regions of the basin.
2. Liquid headers shall be cylindrical members and shall be internally smooth and free from protrusions which might collect stringy material. The air header shall be a cylindrical member and shall be located above and parallel to the liquid header. The jet aerator assembly shall be joined to the liquid header and the air header and laminated for strength to form a single integrated unit Additional air header supports shall be provided as necessary. The liquid and air headers shall be fabricated of machine filament wound, fiberglass reinforced thermosetting resin pipe conforming to ASTM D-2996 and classified according to ASTM D-2310. The pipe shall be classified RTRP-12EZ and shall be rated at 75 psig with a minimum service factor of 10. The air feed for each jet nozzle shall be fabricated from structurally sound fiberglass reinforced plastic and shall be molded to the air and liquid headers in accordance with NBS Specifications PS-15-69. Individual feeds shall ensure uniform air distribution to each jet.
3. Each jet nozzle shall consist of an inner liquid nozzle and outer air/liquid discharge nozzle fabricated from fiberglass reinforced plastic in accordance with NBS Specifications PS-15-69. The mating surface of the liquid nozzle shall match the contour of the liquid header and shall provide a smooth contoured flow path into the nozzle. No portion of the liquid nozzle or aerator assembly shall protrude into the liquid header.
4. The minimum nozzle thickness shall be 0.31 inches including a minimum 20 mil interior and exterior resin rich liner. The interior and exterior liner shall be of Nexus reinforcement material or isophthalic resin with silicone carbide abrasion resistant additive throughout the laminate. The jets shall be molded and assembled to be concentric with the inner liquid and outer air/liquid discharge nozzle in axial alignment. The air/liquid discharge nozzles shall be of constantly decreasing cross-sectional area so as to increase the velocity of the air/liquid mixture originating from the liquid nozzle and the air chamber. The outlets of both the inner and outer nozzles shall be circular and shall be capable of passing a 2.125 inch spherical solid and be free from all protrusions which may collect stringy material. The inner liquid nozzle shall have a diameter of 2.125 inches. The air/liquid secondary discharge nozzle shall have a circular orifice outlet with cross-sectional area of at least 2.5 times that of the liquid nozzle. The diameter of the secondary nozzle shall increase in the direction of the inner liquid nozzle with an included angle which shall be
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greater than 10 degrees and less than 30 degrees for at least 6" along the horizontal flow path of the secondary nozzle.
5. Liquid and air headers shall be provided with flanged connections (150 lb. drilling) for connection to pump discharge lines and air downcomers unless otherwise shown on the Contract Drawings. The manufacturer shall supply all hardware required to connect the jet aeration system to piping installed by the Contractor.
6. Supply all system components downstream of the butterfly valves on the air blower discharge pipes serving each manifold including supports and expansion/contraction provisions for the drop pipes. Drop pipes/downcomers shall be stainless steel to within one foot of the fiberglass manifold. Fiberglass manifold shall be extended to top of tank unless otherwise noted on Drawings.
B. Supports
1. All necessary in-basin supports for the jet aeration equipment, suction/discharge manifolds, and flushout system shall be provided by the jet aeration vendor. Supports shall be spaced on maximum 10 feet. centers. All supports shall be fabricated of Type 316 stainless steel. The support system shall be designed to withstand a force equal to 10 times the buoyant force of the duplex manifold when the liquid and air headers are filled with air and also to withstand all forces reasonably anticipated including thrust forces.
2. Support systems shall be designed for thermal expansion and contraction of the piping over a temperature range of 10°F to a maximum of 110°F.
3. Each pipe and manifold support shall consist of:
a. Contoured saddle 6" wide by 3/16" thick welded to a single pipe leg of 2" Schedule 40.
b. Pipe cup of 2-1/2", Schedule 40 pipe welded to a 6" x 6" x 3/8" baseplate.
c. Contoured clamp 6" wide by 3/16" thick.
d. Four 1/2" x 4" anchor stud assemblies.
e. Four 3/8" x 2-1/2" clamp hardware assemblies
f. Neoprene clamp liner 6" wide by 3/16" thickness
4. All hardware assemblies and anchor bolts shall be Type 316 stainless steel. All hardware assemblies shall be supplied with lock washers. The support saddle/leg assembly shall be shipped unattached from the cup/baseplate assembly for field height adjustment. The location of the supports shall be as determined by the jet aeration vendor and approved by the Engineer.
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C. Flushout System
1. Each jet manifold shall be equipped with a positive pneumatic flushout system. The system shall be an air-lift type activated by turning off the recirculation pump and opening the extended operator plug valve flushout valve. The flushout plug valve shall be provided by the jet aeration equipment manufacturer. Nozzles shall be oriented so that the air-lift will draw air and liquid in reverse direction through the inner liquid nozzle in sufficient quantity to completely flush the nozzles and liquid header and so that liquid will not be drawn into the air header during the flushout operation.
2. All flushout system piping shall be provided as part of the jet system. All flushout valve supports shall be furnished and shall be located above the water level. The sizing of flushout system components shall be as determined by the jet aeration vendor and approved by the Engineer.
2.03 SPARE PARTS
A. Spare parts shall be provided in accordance with Specification 00700.
PART 3 EXECUTION
3.01 MANUFACTURER’S FIELD SERVICES
A. The services of a qualified manufacturer's technical representative shall be provided in accordance with Specification 00700, and shall include the following site visits:
Service Number of Trips Number of Days/Trip Installation and Testing 1 1 Startup and Training 1 1 Services after Startup 1 1
3.02 HANDLING AND STORAGE
A. Special care shall be exercised during delivery, handling, and storage of equipment and material to prevent damage, degradation of materials, and fouling. Delivery, handling, and storage of the piping and equipment shall be in accordance with manufacturer's recommendations and as specified in Specification 00700 and Division 1.
B. All parts of the jet aeration equipment shall be shipped to the jobsite adequately palletized and protected from breakage and dirt. Jet aeration headers shall be shipped in no more than 2 sections. Flanged connections shall be provided to join the two sections. All loose fittings, pipe supports, etc., shall be adequately boxed and palletized. All equipment shall remain palletized and boxed until the time of installation.
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3.03 INSTALLATION
A. The Contractor shall install all jet aeration equipment as shown on the Contract Drawings and described in Specification 00700 and these Specifications. The equipment shall be erected by the Contractor in accordance with the manufacturer's instruction and checked by the manufacturer in conformity with the applicable Section of this Specification.
B. The Contractor shall replace any equipment which is broken or damaged in shipment or during installation at no additional cost to the Owner. The Contractor shall also be responsible for providing proper storage at no additional cost to the Owner.
C. All field joints in FRP piping shall be flanged connections. No laminated field joints shall be permitted.
3.04 SHOP TESTING
A. Shop testing shall be as specified in Specification 00700.
3.05 FIELD TESTS
A. After installation and prior to acceptance by the Owner, the Contractor shall perform and the Equipment Manufacturer shall supervise field tests on the aeration equipment supplied under Specification 00700 and this Section of the Specifications. Details of the test procedure shall be submitted to the Engineer for approval. The field test shall consist of, but not be limited to, the following:
1. Guaranteed Uniform Air Distribution - An air distribution test shall be performed on the aeration equipment supplied. The aeration tanks shall be filled to a depth above the air manifold as approved by the Engineer. The system shall be operated at the design condition with airflow uniformity being verified by means of visual inspection. If, in the opinion of the Engineer, there are areas of consistent low or high air quantity release, the Contractor shall make all necessary adjustments to correct these deficiencies.
2. Field Leakage Tests - Field leakage tests shall be performed by the Contractor for all submerged air and liquid piping. The procedure shall consist of filling the system with air under pressure and performing a visual inspection to determine whether any leaks exist. For this testing, all liquid shall be purged from the piping and all nozzles shall be temporarily plugged, then the piping shall be submerged under water. All piping shall be installed without leaks and shall remain leak free. Field leakage tests shall be witnessed by the Engineer. Any leaks shall be repaired or piping or nozzles replaced and field leakage test repeated.
3. Flushout System Tests - A test of the air-lift flushout system shall be performed on the jet aeration equipment. If the Contractor cannot make the flushout system perform as specified, the Contractor shall modify or
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replace the system with equipment which will so perform at no expense to the Owner.
3.06 PAINTING
A. Painting shall be as specified in Specification 09900, Painting.
END OF SECTION
***
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SECTION 12345
INSET STEEL LABORATORY CASEWORK
PART 1 GENERAL 1.01 SUMMARY A. Section Includes 1. Steel casework. 2. Table frames. 3. Work surfaces. 4. Sinks and outlets. 5. Service fittings. 6. Accessory equipment. B. Related Sections 1. Small plumbing valves and accessories are specified in Section 15100. 2. Electrical is specified in Division 16. 1.02 CASEWORK SCOPE OF SUPPLY DESCRIPTIONS A. Casework and accessories shall be provided as shown on the drawings and as
specified herein. It is intended that in locations shown on the drawings for items such as dishwashers, etc., which are not being provided now but may be provided in the future and where otherwise shown or noted, that the space be filled with a mobile cabinet, cart or table, a cabinet, cart or table on wheels. The mobile cabinet, cart or table may be stored in these locations or elsewhere in the building and moved around the structure to collect samples, provide portable work surfaces, etc.
B. The mobile cabinet, cart or table shall be manufactured by the same supplier as
that for the lab casework. The OWNER may or may not chose to purchase a mobile cabinet, cart or table at this time but if he does it shall be paid for from money in the allowance noted in Section 01020.
C. All casework shall be installed by the casework supplier who shall be factory
trained in the proper installation of the casework, including countertops, and accessories. The installer shall have the tools needed to make any and all field adjustments required.
1.03 CASEWORK DESIGN REQUIREMENTS A. Flush construction: Surfaces of doors, drawers and panel faces shall align with
cabinet fronts without overlap of case ends, top or bottom rails. Horizontal and vertical case shell members (panels, top rails and bottoms) shall meet in the same plane without overlap, cracks or crevices.
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B. Slim-line styling: Front width of end panels 3/4-inch and front height of top and bottom members 1-inch.
C. Self-supporting units: Completely welded shell assembly without applied panels
at ends, backs or bottoms, so that cases can be used interchangeably or as a single, stand-alone unit.
D. Interior of case units: Easily cleanable, flush interior. Base cabinets, 30-inch
and wider, with double swinging doors shall provide full access to complete interior without center vertical post.
E. Drawers: Sized on a modular basis for interchange to meet varying storage
needs, and designed to be easily removable in field without the use of special tools.
F. Case openings: Rabbited-like joints all 4 sides of case opening for hinged doors
and 2 sides for sliding doors in order to provide dust resistant case. G. Framed glazed doors: Identical in construction, hardware and installation to
solid panel doors. Design frame glazed doors to be removable for glass replacement.
1.04 CASEWORK PERFORMANCE REQUIREMENTS A. Structural performance requirements: Casework components shall withstand the
following minimum loads without damage or permanent deformation to the component or to the casework operation:
1. Steel base unit load capacity: 500 lbs. per lineal foot. 2. Suspended units: 300 lbs. 3. Drawers in a cabinet: 150 lbs. 4. Utility tables (4 legged): 300 lbs. 5. Hanging wall cases: 300 lbs. 6. Load capacity for shelves of base units, wall cases and tall cases: 40 lbs.
per square foot, up to 200 lbs. B. Metal Finish Performance Requirements 1. Abrasion resistance: Maximum weight loss of 5.5 mg per 100 cycle when
tested on a Taber Abrasion Tester #E40101 with 1000 gm wheel pressure and Calibrase #CS10 wheel.
2. Hardness: Surface hardness equivalent to 4H pencil. 3. Humidity resistance: Withstand 1000 hour exposure in saturated
humidity at 100 degrees Fahrenheit. 4. Moisture Resistance a. No visible effect to surface finish after boiling water trickled over
test panel inclined at 45 degrees Fahrenheit for 5 minutes.
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b. No visible effect to surface finish following 100 hour continuous application of a water soaked cellulose sponge, maintained in a wet condition throughout the test period.
5. Adhesion: Score finish surface of test panel with razor blade into 100
squares, 1/16" x 1/16", cutting completely through the finish but with minimum penetration of the substrate, and brush away particles with soft brush. Minimum 95 squares shall maintain their finish.
6. Salt spray: Withstand minimum 200 hour salt spray test. 1.05 WORK SURFACE PERFORMANCE REQUIREMENTS A. Test procedure: Apply five drops of each reagent to surface and cover with
25mm watch glass, convex side down; test volatiles using one ounce bottle stuffed with saturated cotton. After 24 hour exposure flush surface, clean, rinse and wipe dry.
B. Evaluation ratings: Change in surface finish and function shall be described by
the following ratings: 1. No Effect: No detectable change in surface material. 2. Excellent: Slight detectable change in color or gloss, but no change to
the function or life of the work surface material. 3. Good: Clearly discernible change in color or gloss, but no significant
impairment of work surface function or life. 4. Fair: Objectionable change in appearance due to surface discoloration or
etch, possibly resulting in deterioration of function over an extended period.
5. Poor: Pitting, cratering or permanently etching of work surface material;
obvious and significant deterioration. C. Test Results - Epoxy Resin Work Surface (Black): CHEMICAL - ACIDS RATING 1. Hydrochloric Acid 20% No Effect 2. Hydrochloric Acid 37% No Effect 3. Nitric Acid 20% Excellent 4. Nitric Acid 70% Good 5. Sulfuric Acid 25% Poor 6. Sulfuric Acid 85% Poor 7. Sulfuric Acid 96% Poor 8. Phosphoric Acid 85% No Effect 9. Perchloric Acid 60% No Effect 10. Aqua Regia -- No Effect 11. Chromic Acid 60% Good 12. Acetic Acid 98% No Effect 13. Formic Acid 90% No Effect
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14. Boric Acid Sat. No Effect 15. Citric Acid Sat. No Effect 16. Oxalic Acid Sat. No Effect 17. Hydrobromic Acid 48% No Effect 18. Hydroflouric Acid 48% Good 19. Vinegar -- No Effect CHEMICAL – BASES 20. Ammonium Hydroxide 28% No Effect 21. Sodium Hydroxide 10% No Effect 22. Sodium Hydroxide 40% No Effect 23. Sodium Hydroxide Flake No Effect 24. Potassium Hydroxide 10% No Effect CHEMICAL – SALTS 25. Zinc Chloride Sat. No Effect 26. Calcium Hypochlorite Sat. No Effect 27. Clorox Bleach -- No Effect 28. Silver Nitrate 10% No Effect 29. Sodium Sulfide Sat. No Effect 30. Sodium Chloride Sat. No Effect 31. Iodine, Tincture -- No Effect 32. Hydrogen Peroxide -- No Effect 33. Phenol 80% No Effect 34. Cresol -- No Effect 35. Formaldehyde 40% No Effect 36. Mineral Oil 100% No Effect 37. Glycerin 100% No Effect CHEMICAL – SOLVENTS 38. Methyl Alcohol 100% No Effect 39. Ethyl Alcohol 100% No Effect 40. Buty Alcohol 100% No Effect 41. Naphtha 100% No Effect 42. Turpentine 100% No Effect 43. Kerosene 100% No Effect 44. Heptane 100% No Effect 45. Gasoline 100% No Effect 46. Benzene 100% No Effect 47. Toluene 100% No Effect 48. Xylene 100% No Effect 49. Acetone 100% No Effect 50. Methyl Ethyl Ketone 100% No Effect 51. Methyl Isobutyl Ketone 100% No Effect 52. Ethyl Acetate 100% No Effect 53. Ethyl Ether 100% No Effect 54. Chloroform 100% No Effect 55. Methyl Chloride 100% No Effect 56. Trichlorethylene 100% No Effect
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57. Carbon Tetrachloride 100% Excellent 58. Monochloro Benzene 100% No Effect 59. Dioxane 100% No Effect 60. Furfural -- No Effect CHEMICAL – DYES 61. Congo Red 1% No Effect 62. Eosin Y 0.5% No Effect 63. Gentian Violet 1% No Effect 64. Indigo Carmen 0.5% No Effect 65. Methyl Green 0.5% No Effect 66. Wrights Blood Stain 0.35% No Effect 1.06 SUBMITTALS A. Shop Drawings: Provide 1/4" = 1'-0" or ½” = 1’-0” scale elevations of casework
units, cross sections, rough-in and anchor placements, tolerances and clearances. Indicate relation of units to surrounding walls, windows, doors and other building components. Provide 1/4" = 1'-0" rough-in plan drawings for coordination with trades. Rough-in shall show free area.
B. Product Data: Submit manufacturer's data for each component and item of
laboratory equipment specified. Include component dimensions, configurations, construction details, joint details, and attachments, utility and service requirements and locations. Provide information on what is available regarding mobile inset steel cabinets, carts and instrument carts, and tables.
C. Test Reports: Submit independent laboratory certified test reports verifying
conformance to test performance specified. D. Samples for initial selection purposes in the form of manufacturer’s color charts
consisting of sections of units showing the full range of colors, textures, and patterns available for each type of material indicated or exposed to view. Provide 3-inch x 5-inch painted steel samples of each color of finish for casework.
E. Submit evidence of the installers being factory-trained and certified by the
manufacturer of the equipment being provided. 1.07 QUALITY ASSURANCE A. Single source responsibility: Casework, work surfaces, laboratory fume hood
and equipment and accessories shall be manufactured or furnished by a single laboratory furniture company.
B. All casework construction and performance characteristics shall be in full
compliance with SEFA 8 standards. An independent, third party testing report must be submitted validating compliance to the SEFA 8 standards.
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C. Manufacturer's qualifications: Modern plant with proper tools, dies, fixtures and skilled workmen to produce high quality laboratory casework and equipment, and shall meet the following minimum requirements:
1. Ten years or more experience in manufacture of laboratory casework and
equipment of type specified. 2. Ten installations of equal or larger size and requirements. D. Installer's qualifications: Factory-trained and certified by the manufacturer of
the equipment being provided. E. Cabinet identification: Cabinets are identified on Drawings by manufacturer's
catalog numbers. Unless otherwise modified on Drawings or in specifications, catalog description constitutes specific requirements for each type of cabinet.
1.07 REFERENCE STANDARDS A. All casework, worksurface and service fixture construction and performance
characteristics shall be in full compliance with SEFA (Scientific Equipment and Furniture Association) standards. At the OWNER’S request, independent, third party testing must be submitted validating compliance and adheres to the architectural specifications.
1. SEFA 1.2 – Laboratory Fume Hoods 2. SEFA 2.3 – Installation of Scientific Laboratory Furniture and Equipment 3. SEFA 3 – Work Surfaces 4. SEFA 7 – Laboratory and Hospital Fixtures 5. SEFA 8 – Laboratory Furniture 1.08 DELIVERY, STORAGE AND HANDLING A. Schedule delivery of casework and equipment so that spaces are sufficiently
complete that material can be installed immediately following delivery. B. Protect finished surfaces from soiling or damage during handling and
installation. Keep covered with polyethylene film or other protective coating. C. Protect all work surfaces throughout construction period with 1/4-inch
corrugated cardboard completely covering the top and securely taped to edges. Mark cardboard in large lettering "No Standing."
1.09 PROJECT CONDITIONS A. Do not deliver or install equipment until the following conditions have been met: 1. Windows and doors are installed and the building is secure and weather
tight. 2. Ceiling, overhead ductwork and lighting are installed. 3. All painting is completed and floor tile is installed.
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PART 2 PRODUCTS 2.01 MANUFACTURER A. Design, materials, construction and finish of casework specified are the
minimum acceptable standard of quality for inset steel laboratory casework. The casework shall be and the basis of this product specification is Mott Manufacturing; or equal.
2.02 CASEWORK MATERIALS A. Sheet steel: Mild, cold rolled and leveled unfinished steel. B. Minimum Gauges 1. 20 gauge: Solid door interior panels, drawer fronts, scribing strips, filler
panels, enclosures, drawer bodies, shelves, security panels and sloping tops.
2. 18 gauge: Case tops, ends, bottoms, bases, backs, vertical posts,
uprights, glazed door members, door exterior panels and access panels. 3. 16 gauge: Top front rails, top rear gussets, intermediate horizontal rails,
table legs and frames, leg rails and stretchers. 4. 14 gauge: Drawer suspensions, door and case hinge reinforcements and
front corner reinforcements. 5. 11 gauge: Table leg corner brackets and gussets for leveling screws. C. Glass for glazed swinging and sliding doors and/or unframed doors: 6 mm
Clear Float Glass (unframed) or 6 mm Safety Glass, laminated (framed). 2.03 CASEWORK FABRICATION A. Base Units and Cases 1. Base units and 25-inch, 31-inch and 37-inch high wall cases: End panels
and back reinforced with internal reinforcing front and rear posts. 2. 49-inch and 84-inch high cases: Formed end panels with front and rear
reinforcing post channels; back shall be formed steel panel, recessed 3/4" for mounting purposes.
3. Posts: Front post fully closed with full height reinforcing upright. Shelf
adjustment holes in front and rear posts shall be perfectly aligned for level setting, adjustable to 1/2" o.c.
4. Secure intersection of case members with spot and arc welds. Provide
gusset reinforcement at front corners.
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5. Base unit backs: Provide drawer units without backs and cupboard units
with removable backs for access to services behind units. 6. Bottoms: Base units and 25-inch, 31-inch, 37-inch and 49-inch high wall
cases shall have one piece bottom with front edge formed into front rail, rabbeted as required for swinging doors and drawers and flush design for sliding doors.
7. Top rail for base units: Interlock with end panels, flush with front of unit. 8. Base for base units: 4-inch high x 3-inch deep with formed steel base and
11 gauge die formed steel gussets at corners. Provide 3/8-inch diameter leveling screw with integral bottom flange of minimum 0.56 sq. in. area at each corner, accessible through openings in toe space.
9. Tops of wall cases: One piece, with front edge formed into front rail. B. Drawers, Steel 1. Drawer fronts: ¾-inch thick, double wall construction, pre-painted prior to
assembly and sound deadened. 2. Drawer bodies: Bottom and sides formed into one piece center section
with bottom and sides coved and formed top edges. Front and back panels spot welded to center section.
3. Drawer suspension: Heavy duty coved raceways for both case and drawer
with nylon tired, ball bearing rollers; self-centering and self-closing when open to within 3-inch of the closed position.
4. Provide drawer with rubber bumpers. Friction centering devices are not
acceptable. 5. Provide security panels for drawers with keyed different locks. 6. File drawers: Provide with 150 lbs. full extension slides for full access and
operation. C. Doors, Steel 1. Solid panel doors: ¾-inch thick, double wall, telescoping box steel
construction with interior prepainted and sound deadened. Reinforce interior of front panel with welded steel hat channels. Hinges with screws to internal 14 gauge reinforcing in case and door. Hinges shall be removable; welding of hinges not acceptable. Doors shall close against rubber bumpers.
2. Frame glazed doors: Outer head to be one piece construction. Inner head
to consist of top, bottom and side framing members which are removable for installation or replacement of glass. Provide continuous vinyl glazing
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retainer to receive glass. In all other respects, framed glazed door construction and quality shall match solid panel doors.
3. Sliding doors – solid or framed glazed: Design for tilt-out removal after
removal of bottom guide. Doors shall be hung with nylon tired sleeve bearing rollers in formed steel top hung track and shall close against rubber bumpers.
4. Unframed sliding glass doors: Glass with edges ground set in extruded
aluminum shoe with integral pulls, wheel assemblies and top and bottom extruded aluminum track. Provide rubber bumpers at fully opened and closed door position.
D. Shelves 1. Form front and back edges down and back ¾-inch. Form ends down
¾-inch. 2. Reinforce shelves over 36-inch long with welded hat channel
reinforcement the full width of shelf. 3. Pull out shelves: Same suspension as specified for drawers. E. Corner base guards: 4" high #304 stainless steel corner guards. F. Base molding: 4-inches high, to be furnished and installed by flooring
contractor. G. Hardware 1. Drawer and hinged door pulls: Clear anodized extruded aluminum, screw
attached on 4" centers. Pull Location: Horizontal at drawers, vertical at doors Pull type: Brushed aluminum rectangular style finger pull
2. Sliding door pulls: Recessed stainless steel, styled and sized to harmonize with drawer pulls.
3. Hinges: Institutional type, five knuckle projecting barrel hinges,
minimum 2-1/2 inches long, type 302 or 304 stainless steel. Provide 2 hinges for doors up to 36 inches high; 3 hinges for doors over 36 inches high. Drill each leaf for 3 screw attachment to door and frame.
4. Door catches: Adjustable type, spring actuated nylon roller catches. Non-
metallic plunger catch for acid storage only. 5. Elbow catches: Spring type of cadmium plated steel, with strike of
suitable design.
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6. Locks: National Lock Remove-A-Core 5-disc tumbler, heavy duty cylinder type. Exposed lock noses shall be dull nickel (satin) plated and stamped with identifying numbers.
7. Keying: Locks (location shown on Drawings) or, if not shown, provide 6
keyed locks with location to be marked in shop drawings, shall have capacity for 225 primary key changes. Master key one level with the potential of 40 different, non-interchangeable master key groups.
8. Keys: Stamped brass available from manufacturer or local locksmith, and
supplied in the following quantities unless otherwise specified. a. Two (2) for each keyed different lock. b. Three (3) for each group keyed alike locks. c. Two (2) for master keys for each system. 9. Label holders (locations shown on Drawings): Formed steel with satin
chrome finish, 1-inch x 1 ½-inch, screw installed. 10. Shelf clips: Die formed steel, zinc plated, designed to engage in shelf
adjustment holes. 11. File followers: Metal backs engaging in steel bottom channel, with spring
positioning lock. 2.04 TABLE FRAMES A. Table frames: 4 ½-inch high "C" channel front and back aprons, end rails and
cross rails. B. Table drawers: Provide front and back rails; drawer unit, hardware and
suspension same as specified for base unit drawers. C. Legs: 2-inch x 2-inch steel tube legs with welded leg bracket. Attach legs with
two bolts to front and back aprons and weld to end rails. Each leg shall have a recessed leveling screw and a black, coved vinyl or rubber leg shoe, 2 inches in height.
2.05 METAL FINISH A. Metal Finish 1. Preparation: Spray clean metal with a heated cleaner/phosphate solution,
pre-treat with iron phosphate spray, water rinse, and neutral final seal. Immediately dry in heated ovens, gradually cooled, prior to application of finish
2. Application: Electrostatically apply urethane powder coat of selected
color and bake in controlled high temperature oven to assure a smooth, hard satin finish. Surfaces shall have a chemical resistant, high grade laboratory furniture quality finish of the following thickness: Liquid dipped, solvent based finishes are not and will not be acceptable.
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a. Exterior and interior exposed surfaces: 1.5 mil average and 1.2
mil min. b. Backs of cabinets and other surfaces not exposed to view: 1.2 mil
average. B. Cabinet Surface Finish Tests 1. All casework construction and performance characteristics shall be in
full compliance with SEFA 8 – 2010 standards. Provide a copy of the independent, third party performance testing which validates compliance and adherence to the finish specifications.
2. Chemical Spot Test a. Purpose of Test (1) The purpose of the chemical spot test is to evaluate the
resistance a finish has to chemical spills. Note: Many organic solvents are suspected carcinogens, toxic
and/or flammable. Great care should be exercised to protect personnel and the environment from exposure to harmful levels of these materials.
b. Test Procedure (1) Obtain one sample panel measuring 14" x 24" (355.6mm x
609.6mm). The received sample to be tested for chemical resistance as described herein.
(2) Place panel on a flat surface, clean with soap and water and
blot dry. Condition the panel for 48-hours at 73±3°F / 23±2°C and 50±5% relative humidity. Test the panel for chemical resistance using forty-nine different chemical reagents by one of the following methods:
(a) Method A – Test volatile chemicals by placing a
cotton ball saturated with reagent in the mouth of a one-ounce (29.574cc) bottle and inverting the bottle on the surface of the panel.
(b) Method B – Test volatile chemicals by placing five
drops of the reagent on the surface of the panel and covering with a 24mm watch glass, convex side down.
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(c) For both of the above methods, leave the reagents on the panel for a period of one hour. Wash off the panel with water, clean with detergent and naphtha, and rinse with deionized water. Dry with a towel and evaluate after 24-hours at 73±3°F / 23°±2°C and 50±5% relative humidity using the following rating system:
Level 0: No detectable change. Level 1: Slight change in color or gloss. Level 2: Slight surface etching or severe staining. Level 3: Pitting, cratering, swelling, or erosion of
coating. Obvious and significant deterioration.
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Test # Chemical Reagent Test Method 1. Acetate, Amyl A 2. Acetate, Ethyl A 3. Acetic Acid, 98% B 4. Acetone A 5. Acid Dichromate, 5% B 6. Alcohol, Butyl A 7. Alcohol, Ethyl A 8. Alcohol, Methyl A 9. Ammonium Hydroxide, 28% B 10. Benzene A 11. Carbon Tetrachloride A 12. Chloroform A 13. Chromic Acid, 60% B 14. Cresol A 15. Dichlor Acetic Acid A 16. Dimethylformanide A 17. Dioxane A 18. Ethyl Ether A 19. Formaldehyde, 37% A 20. Formic Acid, 90% B 21. Furfural A 22. Gasoline A 23. Hydrochloric Acid, 37% B 24. Hydrochloric Acid, 48% B 25. Hydrogen Peroxide, 3% B 26. Iodine, Tincture of B 27. Methyl Ethyl Ketone A 28. Methylene Chloride A 29. Mono Chlorobenzene A 30. Naphthalene A 31. Nitric Acid, 20% B 32. Nitric Acid, 30% B 33. Nitric Acid, 70% B 34. Phenol, 90% A 35. Phosphoric Acid, 85% B 36. Silver Nitrate, Saturated B 37. Sodium Hydroxide, 10% B 38. Sodium Hydroxide, 20% B 39. Sodium Hydroxide, 40% B 40. Sodium Hydroxide, Flake B 41. Sodium Hydroxide, Saturated B 42. Sulfuric Acid, 33% B 43. Sulfuric Acid, 77% B 44. Sulfuric Acid, 96% B 45. Sulfuric Acid, 77% and Nitric Acid, 70% equal parts B 46. Toluene A 47. Trichloroethylene A 48. Xylene A 49. Zinc Chloride, Saturated B
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c. Acceptance Level (1) Results will vary from manufacturer to manufacturer.
Laboratory grade finishes should result in no more than four Level 3 conditions. Suitability for a given application is dependent upon the chemicals used in a given laboratory.
2. Hot Water Test a. Purpose of Test (1) The purpose of this test is to insure the coating is resistant
to hot water. b. Test Procedure (1) Hot water, 190 degrees Fahrenheit to 205 degrees
Fahrenheit (88 degrees Celsius to 96 degrees Celsius), shall be allowed to trickle (with a steady stream and at a rate of not less than 6 ounces (177.44 cc) per minute on the surface, which shall be set at an angle of 45° for a period of 5 minutes.
c. Acceptance Level (1) After cooling and wiping dry, the finish shall show no visible
effect from the hot water. 3. Impact Test a. Purpose of Test (1) The purpose of this test is to evaluate the ductility of the
coating. b. Test Procedure (1) A one-pound ball approximately 2" (50.8mm) in diameter
shall be dropped from a distance of 12" (304.8mm) onto a flat horizontal surface, coated to manufacturer’s standard manufacturing method.
c. Acceptance Level (1) There shall be no visible evidence to the naked eye of cracks
or checks in the finish due to impact.
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4. Paint Adhesion on Steel Test a. Purpose of Test (1) The paint adhesion test is used to determine the bond of
the coating to steel. This does not apply to non-steel products.
b. Test Procedure (1) This test is based on ASTM D2197-86 “Standard Method of
Test for Adhesion of Organic Coating”. Two sets of eleven parallel lines 1/16" (1.587mm) apart shall be cut with a razor blade to intersect at right angles thus forming a grid of 100 squares. The cuts shall be made just deep enough to go through the coating, but not into the substrate. They shall then be brushed lightly with a soft brush for one minute. Examine under 100-foot candles of illumination.
c. Acceptance Level (1) Ninety or more of the squares shall show finish intact. 5. Paint Hardness on Steel Test a. Purpose of Test (1) The paint hardness test is used to determine the resistance
of the coatings to scratches. b. Test Procedure (1) Pencils, regardless of their brand, are valued in this way: 8-
H is the hardest, and next 11 order of diminishing hardness are 7-H, 6-H, 5-H, 4-H, 3-H, 2-H, H, F, HB, B (soft), 2-B, 3-B, 4-B, 5-B (which are softest).
(2) The pencils shall be sharpened on emery paper to a wide
sharp edge. Pencils of increasing hardness shall be pushed across the paint film in a chisel-like manner until one is found that will cut or scratch the film. The pencil used before that one, that is the hardest pencil that will not rupture the film, is then used to express or designate the hardness.
c. Acceptance Level (1) The paint shall have a hardness of 4-H minimum with no
visible puncture of the finish surface.
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2.06 WORK SURFACES A. Epoxy Resin Work Surface 1. Material: Chemical and abrasion resistant, durable top of one inch thick
cast material of epoxy resins and inert products, cast flat, with a uniform non-glare black matte finish.
2. Backsplash curb: Same material as top, up to 6 inches high, butt jointed
and cemented to top. Provide where indicated on drawings. Include end curb where top abuts end wall.
3. Reagent ledges: Same material as top. Provide 6-inch high x 7-1/2 inch
wide single faced units and 6-inch high x 9-inch wide double faced units as shown on Drawings. Ledge face shall permit installation of service fixtures and top shall be removable for access to service utilities.
2.07 SINKS AND DRAINS A. Epoxy resin sinks: Integrally molded from modified thermosetting black epoxy
resin, specially compounded and oven cured. Cove inside corners and pitch bottom to threaded drain outlet. Size shall be as shown on the Drawings. Drain shall be located as shown on the Drawings and where not shown shall be located in the corner of the sink.
B. Sink Supports 1. Cabinet sinks: Support sinks on 11 gauge, adjustable, 1-inch by 2-inch
by 1-inch channel with reagent resistant finish. Provide 2 channels across width of cabinet, attached to 3/8-inch diameter threaded hanger rods.
2. Caulk joint between top and sink with non-hardening mastic. C. Epoxy resin cup sinks: Integrally molded from modified thermosetting black
epoxy resin, specially compounded and oven cured. Cove inside corners and pitch bottom to threaded drain outlet. Size as shown on the Drawings.
D. Traps to be supplied and installed by Division 15. 2.08 LABORATORY FITTINGS A. Water Service Fittings 1. Water service faucets and valves shall have renewable unit containing all
working parts subject to wear, including replaceable stainless steel seat. Unit shall have serrations for position locking into valve body.
2. Gooseneck vacuum breakers: Brass forgings integral with gooseneck,
with renewable seat and special design valve member for fine flow control.
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3. Goosenecks shall have separate 3/8-inch IPS coupling securely brazed to gooseneck to provide full thread for attachment of anti-splash outlet fittings, serrated tips and filter pumps.
B. Air, Gas and Vacuum Systems Fittings 1. Ground key cocks: Straightway ground key cocks, individually ground
and lapped and tested at 100 psi. air under water. Cocks shall have single arm long easy grip handle with screw-on type index. Ten serrated end is integral with valve body.
2. Needle valves: Small pattern needle valve, straightway type with stainless
steel replaceable floating cone and brass seat (non-renewable). Ten serrated end is integral with valve body.
C. Distilled Water Fittings: All brass fittings tin lined for distilled water service. 1. Provide renewable tin lined unit containing all working parts subject to
wear, including replaceable stainless steel seat. Unit shall have serrations for position locking into valve body.
D. Turrets for gas, air, vacuum, steam or water fixtures: "Round" type design,
provided with brass shanks, locknuts and washers. E. Handles for service cocks, faucets and remote controls: Four-arm type except
ground key cocks. Provide removable screw-on type colored plastic discs with letter stamped on disc in contrasting color as scheduled below:
Service Disc/Letter Colors Letters Gas Blue/White Gas Vacuum Yellow/Black Vac. Compressed Air Orange/White C-Air Cold Water Green/White C.W. Hot Water Red/White H.W. Steam Black/White Stm. Chilled Water Brown/White CH. Distilled Water White/Black D.W. Disc color for special services as determined by OWNER. F. Fixture finish: Chrome finish developed by the following sequence of platings
over properly prepared brass castings or forgings: Minimum Plating Plating Thickness Copper (Initial) 0.000050 IN. Nickel 0.000350 IN. Chromium (Final) 0.000015 IN.
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G. Electrical fixtures and fittings: Flush, pedestal, provided in strict accordance with the current edition of the National Electric Code of the National Fire Protection Association, and with requirements of all local regulatory authorities.
1. Pedestal: Heavy "lustrebrite" corrosion resistant aluminum alloy polished
to a chrome like color. a. Pedestals: Provide with integral bases; low design for use on
either single or double faces. 2. Receptacles: Rated 120 volts A.C. at 20 amps, 3-wire grounding type
with "Automatic Ground" feature. Provide single or duplex receptacles as required, with ivory or black colored molded thermo-set bodies.
3. Switches: Single pole, toggle type. 4. Flush boxes: Galvanized steel. 5. Flush plates: 316 stainless steel flush boxes must be precut and
preinstalled by manufacturer. See the electrical Contract Drawings for required receptacles
H. Accessory Equipment 1. Reagent Racks: Single faced unit at wall tables, double faced unit at
center tables; open front or enclosed as indicated; height and depth of units per manufacturer's standard.
a. Uprights: 1-1/2" and 6" thick, double wall construction of cold
rolled steel. Include access panel on inside of upright for access to fasteners to table top, and provide channel shaped molding of non-absorbent, black vinyl at base of upright.
b. Front panels on enclosed racks: 6-3/4" high cold rolled steel with
return flanges all sides. Attach with screws to standards and to underside of top shelf.
c. Finish on metal uprights and front panels: Powder coat of color
selected from manufacturer's full range of standard colors. d. Tops: Chemically resistant, black high pressure laminate tops on
enclosed racks; same material as work surface for tops on open front racks.
2. Pegboards a. Board: Epoxy resin board finished on face and edges. Where
exposed, finish back with slightly different surface texture and bevel bottom edges.
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b. Pegs: Black polypropylene pegs in 5", 6-1/2" and 8" lengths, with glassware protector base. Base of pegs shall be two prong style for mechanical attachment. Do not bond pegs to board.
1. Service Support Struts: Heavy 1/4" x 1-1/2" steel channel uprights. a. Fasten at top and bottom with U-shaped spreader and bolts,
designed to support tops, box curbs, troughs, hoods, or other heavy loads.
b. Service piping and drain line hanger supports are to be provided
by contractor providing these services. PART 3 EXECUTION 3.01 INSTALLATION A. General 1. All casework shall be installed by the manufacturer’s factory-trained and
certified representative. B. Casework Installation 1. Set casework components plumb, square, and straight with no distortion
and securely anchored to building structure. Shim as required using concealed shims.
2. Bolt continuous cabinets together with joints flush, tight and uniform,
and with alignment of adjacent units within 1/16-inch tolerance. 3. Secure wall cabinets to solid supporting material, not to plaster, lath or
gypsum board. 4. Abut top edge surfaces in one true plane. Provide flush joints not to
exceed 1/8-inch between top units. C. Work Surface installation 1. Where required due to field conditions, scribe to abutting surfaces. 2. Only factory prepared field joints, located per approved shop drawings,
shall be permitted. 3. Secure work surfaces to casework and equipment components with
material and procedures recommended by the manufacturer. D. Sink installation: Sinks which were not factory installed shall be set in chemical
resistant sealing compound and secured and supported per manufacturer's recommendations.
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E. Accessory installation: Mechanical and electrical fixtures supplied by this manufacture shall be turned over to the Division 15 and 16 contractors for installation and connection.
3.02 ADJUSTING A. Repair or remove and replace defective work, as directed by OWNER upon
completion of installation. B. Adjust doors, drawers, hardware, fixtures and other moving or operating parts
to function smoothly. 3.03 CLEANING A. Clean shop finished casework, touch up as required. B. Clean countertops with diluted dishwashing liquid and water leaving tops free of
all grease and streaks. Use no wax or oils. 3.04 PROTECTION OF FINISHED WORK A. Provide all necessary protective measures to prevent exposure of casework and
equipment from exposure to other construction activity. B. Advise CONTRACTOR of procedures and precautions for protection of material,
installed laboratory casework and fixtures from damage by work of other trades.
END OF SECTION
***
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SECTION 13200
FIBERGLASS REINFORCED PLASTIC STORAGE TANKS PART 1 GENERAL 1.01 SUMMARY A. Fiberglass reinforced plastic (FRP) chemical storage tanks and appurtenances
shall be provided as indicated in the schedule specified herein or included on the drawing and shall adhere to the requirements of this specification.
B. Bulk chemical storage tanks shall be single walled FRP as required for chemical
compatibility. C. All items shall be manufactured of material suitable for the service and shall be
certified for such use on the shop drawings. Tanks shall be designed and checked for all loads to be incurred during shipment and service including, but not limited to, wind, temperature and weight relative to specific gravity stresses.
D. Bulk tanks shown on the Drawings with mixers above them shall have the
mixers mounted to a top center flanged nozzle with gasketed flange as needed to prevent chemical fumes from escaping the tank. The tank shall also have baffles installed as shown on the Drawings and specified herein.
1.02 REFERENCES A. American Nation Standard Institute (ANSI)
1. ANSI B16.- Pipe Flanges and Flanged Fittings
B. American Society of Testing Materials (ASTM)
1. ASTM D638 – Standard Test Method of Tensile Properties of Plastics. 2. ASTM D746 – Brittleness Temperature of Plastics and Elastomers by
Impact. 3. ASTM D790 – Standard Test Methods for Flexural Properties of Un-
reinforced and Reinforced Plastics and Electrical Insulation Materials. 4. ASTM D883 – Standard Definitions of Terms Relating to Plastics. 5. ASTM D 1505 – Density of Plastics by the Density-Gradient Technique. 6. ASTM D1525 – Vicat Softening Temperature of Plastic. 7. ASTM D1693 – ESCR Spec. Thickness 0.125’’ F50 – 10% lgepal. 8. ASTM D3299 – Filament Wound Glass Fiber-Reinforced Thermoset Resin
Chemical Resistant Tanks. 9. ASTM D4097 – Contact Molded Glass Fiber Reinforced Thermoset Resin
Chemical Resistant Tanks
C. Where reference is made to one of the above standards, the revision in effect at the time of the bid advertisement shall apply.
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1.03 GENERAL A. Fiberglass tanks shall be filament wound or contact molded conforming to the
following appropriate ASTM specifications: 1. Filament wound tanks shall be designed and fabricated in accordance
with ASTM Specification D-3299 latest edition (no chop hoop allowed), "Filament Wound Glass-Fiber-Reinforced Thermoset Resin Chemical Resistant Tanks."
2. Contact molded tanks shall be designed and fabricated in accordance
with ASTM Specification D-4097 latest edition, "Contact-Molded Glass-Fiber-Reinforced Thermoset Resin chemical Resistant Tanks.
B. The tanks built to these applications shall have the following information
printed on the nameplate: 1. Name of manufacturer/fabricator. 2. Capacity in gallons. 3. Chemical stored. 4. Manufacturer/fabricator serial number. 5. Date of fabrication. 6. Tank model. 7. Purchase order number. 8. Maximum specific gravity. 9. Design pressure and temperature. 10. Corrosion barrier resin. 11. Corrosion barrier veil. 12. Structural layer resin.
13. The nameplate shall be installed and resin coated. C. For tanks storing chemicals, a sign indicating the tank’s chemical contents, for
instance 50 percent sodium hydroxide, and the chemical’s NFPA ratings: Health, Flammability Classification, Reactivity, and Special Hazards shall be visible on the exterior of the tank from the walkway or access door to the area. For 50 percent sodium hydroxide these would be Health – 3, Flammability Classification – 0, Reactivity – 1, and Special Hazards – none. The sign shall use the correct NFPA color scheme, i.e., blue for health, etc., and should be the classic
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“diamond” form. The sign shall be attached to the tank after fabrication. The tank shall contain a standoff bracket for attachment of this sign. Process tanks that do not store chemicals do not require the NFPA sign.
D. Tanks shall be manufactured according to the fiberglass-reinforced Plastic
Institute ASTM RTP-1. E. Tanks shall be as manufactured by Augusta Fiberglass Coatings, Inc., MFG Justin
Tanks, Inc., Diamond Fiberglass, Midwestern Fabricators, Belco Manufacturing, or equal.
1.04 SUBMITTALS A. The fabricator shall submit the following for review and approval prior to
fabrication of the tank(s) in accordance with the front end specifications, Divisions 0 and 1.
1. Detailed and certified design calculations: The laminate sequence used
for all tanks must either be attached to or included on drawings used by the fabricator’s shop personnel.
2. Tank layout drawings showing dimensions, wall thickness, anchor layout,
knuckle radii, nozzle location and orientation, nozzle construction, ladder, platform and safety gage construction and orientation.
3. Instructions for handling, storage and installation tanks on a concrete
slabs or otherwise. 4. Tank manufacturer’s recommended bolt torque for flanges. 5. A certificate listing the type of resin to be used, describing the
manufacturer’s brand name with a statement of suitability for intended service.
6. Design calculations for structural design of walls, design of tie-down lugs
and overall weight of tank. 7. Manufacturer’s certification that tank construction complies with the
applicable ASTM referenced in these specifications. 8. Nozzle, fitting and manway schedule including size, mark, thickness, and
rating. 9. Details of fall clips and lugs for hold down lugs, pipe brackets, and
anchor bolts, as integral parts of the tank. Pipe supports shall be spaced maximum 5 feet on centers.
10. Laminate sequence of construction and all materials of construction
listed.
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11. Statement of chemical compatibility for the bulk storage tanks. 1.05 WARRANTY A. Materials furnished under this Section shall be warranteed in accordance with
Divisions 0 and 1. 1.06 TANK SERVICE CONDITIONS/ENVIRONMENT A. Bulk Chemical Storage Tanks 1. All bulk chemical storage tanks shall be located in the chemical building
in the locations shown on the Drawings. The bulk chemical storage areas should see a minimum temperature of approximately 55 degrees Fahrenheit and a maximum temperature approximately equal to ambient conditions which are assumed to be 105 degrees Fahrenheit. Chemical storage areas will have the temperature adjusted by heaters and exhaust fans.
2. Chemicals stored in the tanks will be at ambient (inside building)
conditions except when delivered. Delivered chemicals may have a slightly higher or lower temperate than ambient (inside building) depending on the chemical’s characteristics such as freezing point, ability to gas off, etc., or temperature change due to delivery method such as pneumatic transfer.
PART 2 PRODUCTS 2.01 MATERIALS – FRP TANKS A. Resin 1. The resin used shall be a commercial-grade, corrosion-resistant
thermoset that has either been evaluated in a laminate by test in accordance with ASTM C-581 or that has been determined by previous documented service to be acceptable for the service conditions. Tanks shall be of fire-resistant construction.
2. The resin shall contain no pigment, dyes, colorants, or filler, except as
follows: a. A thixotropic agent that does not interfere with visual inspection
of laminate quality, or with the required corrosion resistance of the laminate, may be added for viscosity control. The maximum thixotropic agent allowed shall be 5 percent by weight.
(1) Vessels fabricated for sodium hypochlorite or hydrogen
peroxide service shall not contain thixotropic agents as it reacts with thixotropic agents compromising the tank’s corrosion resistance.
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b. Resin pastes used to fill crevices before overlay shall not be
subject to the limitations of 2.01.A.2. c. Ultraviolet absorbers shall be added to the exterior surface for
improved weather resistance. Insulated tanks, where specified, shall have a light grey pigmented exterior gel coat layer.
d. The cure system used for the resin shall be in accordance with the
resin manufacturer’s current recommendations. e. Proper curing of the resin is the fabricator’s responsibility. All
products fabricated to this Specification shall be cured to at least 90 percent of the minimum Barcol hardness specified by the resin manufacturer. This requirement applies to both interior and exterior surfaces. (Note: The use of paraffin in the resin or the use of a polyester veil may lower the Barcol hardness below the resin manufacturer’s specifications.)
(1) Vessels fabricated for sodium hypochlorite service must be
fabricated utilizing a BPO/DMA cure system for the corrosion liner and a modified MEKP catalyst system, with minimal cobalt promoter level for the structural layer. The promotion and catalyzation for the structural layer must be adjusted to minimize the cobalt levels, while obtaining an adequate cure. To ensure proper cure, the vessel must be hot air post cured after all fabrication is complete, according to the section covering post curing.
f. A separately cured gel coat shall not be used. g. No chemical-resistant surface shall be acetone sensitive. Acetone
sensitivity is defined as tackiness of the laminate surface when rubbed with acetone.
B. Reinforcement 1. Unless otherwise noted on the Drawings or data sheet, an inner surface
of 0.015 to 0.030 inch reinforced with one ply “c” veil (chemical glass) or a boron tree E-CR type glass and one ply nexus, or equal.
2. Chopped strand mat shall be commercial grade Type E (an electrical
borosilicate) glass, 1-1/2 oz. or 2 oz. per square foot, with silane finish and a styrene-soluble reactive binder.
3. Continuous roving used in a chopper gun for spray-up shall be
commercial grade Type E glass.
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4. Woven roving shall be Type E glass, nominal 24 oz./square yard, 4 by 5 weave, with silane-type finish. Woven roving shall be in accordance with ASTM Specifications D-2150.
5. Continuous roving used for filament winding shall be Type E glass with a
silane-type finish. 2.02 DESIGN A. General 1. It is the object of this Specification and associated drawing to afford the
fabricator as much design latitude as possible, consistent with the basic requirements. Therefore, it is intended that the fabricator will have ample opportunity to utilize his particular “know-how” in the design and details of tank fabrication in order to produce equipment which will be adequate for the intended purpose and at a minimum cost.
B. Design of Details 1. Details are often indicated without being fully designed. This permits the
equipment fabricator to submit a design for approval. It is intended that the fabricator furnish a design based on the information given which will meet the requirements of the job regarding strength, corrosion resistance, and work ability.
C. Design Basis 1. For custom contact molded storage tanks subject to hydrostatic head, the
design stress shall be 10 percent of the minimum ultimate tensile stress of the selected laminate thickness, thereby providing a factor of safety of 10:1 against shell or head rupture.
2. For filament wound tanks subject to hydrostatic head, the design stress
shall be determined by the following formula: T = PD/2 ETZ where: T= Thickness P = Maximum internal pressure, psi D = Diameter in inches E = Hoop Tensile Modules of the total laminate-psi Z = Allowable Strain-0.0010 in./in. max. 3. Tanks and similar equipment for installation outdoors shall be checked
for wind loading. Four or more hold-down lugs shall be provided for vertical tanks.
4. Other design requirements such as hold down lugs, stiffener rings, lifting
lugs, etc.
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2.03 LAMINATE CONSTRUCTION REQUIREMENTS A. Structural Tank 1. The laminate comprising the structural tank (bottom, cylindrical shell,
and top head) shall consist of 4 separate layers, an inner surface, interior layer, a structural layer, and an exterior surface. The inner surface and the interior layer make up the corrosion barrier. The tank bottom shall be integral with the bottom tank shell. No tank bottom attachment joints are allowed.
a. Inner Surface - The inner surface exposed to the chemical
environment shall be a resin rich 0.015 to 0.030 inches thick, reinforced with 2 ply of synthetic fiber surface mat such as Nexus (Burlington Industries) or equal.
b. Interior Layer - The interior surface layer exposed to the corrosive
environment shall be followed with a layer composed of resin, reinforced only with noncontinuous glass-fiber strands applied in a minimum total of 3 oz/ft2. The combined thickness of the inner surface and interior layer shall not be less than 0.10 inch.
(1) Glass content of the inner liner and the interior combined
shall be 27 percent ± 5 percent by weight. (2) The degree of cure of the laminate shall be such as to
exhibit a Barcol hardness on the inner surface of at least 90 percent of the resin manufacturer's minimum specified hardness for the cured laminate.
c. Structural Layer (1) Filament Wound Structural Layer - Subsequent
reinforcement shall be continuous-strand roving in accordance with 2.01.B.2, that, in combination with 2.01.A.1.a and 2.02.A.1.b. is needed to satisfy the design requirements. Glass content of this filament-wound structural layer shall be 50 percent to 80 percent by weight. Only those constructions evaluated for design properties shall be used.
(2) Contact Molded Structural Layer - Subsequent reinforcement
shall be comprised of 1.5 oz/ft2 chopped strand mat or equivalent weight of chopped roving, or shall be comprised of chopped strand mat or chopped roving and such additional number of alternating piles of 24 oz/yd2 woven roving to a thickness as required to meet the physical properties that are used for the design. Each successive ply or pass of reinforcement shall be well-rolled prior to the application of additional reinforcement. Where woven roving
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is used, chopped strand glass reinforcement shall be used as alternating and final layers. All woven roving and chopped strand shall be overlapped. Laps in subsequent layers shall be staggered at least 2.25 in. from laps in the preceding layers.
d. Exterior Surface (1) The outer surface shall be coated with a resin-rich layer for
spill protection. Where air inhibited resin is exposed to air during cure, a full surface cure shall be obtained by coating the surface with a coat of resin containing 0.2 percent to 0.6 percent paraffin wax surfacing agent. This layer may contain ultraviolet absorbers, pigments, or fire-retardant additives if specified by the customer.
2.04 FABRICATION REQUIREMENTS A. General 1. The fabricator shall not sublet any FRP component assembly without
obtaining the OWNER’S approval in writing. 2. When pigmentation is specified, the pigment shall be dispersed in the
resin used for the finish coat of the laminate. B. Shell and Head Requirements 1. The minimum wall thickness shall be 1/4-inch regardless of operating
conditions. 2. Unless otherwise specified, all vertical tanks shall be of flat-bottomed
construction, continuously supported on a flat concrete pad, or equivalent.
3. The knuckle radius of all flat-bottomed tanks shall be 1-1/2 inch
minimum. 4. There shall be no vertical joints in the FRP tanks. Shell to head joints shall
be in compliance with ASTM D3299 and ASTM D4097, latest edition, Figure 1, Figure 1a and 1b, as applicable.
5. Vertical tank tops shall be reinforced with stiffener rods or other means
to provide structural rigidity to support people or equipment on the tank top, where required. All tanks with top manways shall be supported.
6. Tanks with flange mounted mixers or top center entering mixers which
have not been offset shall be reinforced to support 3 or 4 wall-mounted baffles as required by the mixer supplier.
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C. Laminate Requirement 1. The outer surface of the fabricated product shall be relatively smooth and
no glass fibers shall be exposed. On custom contact molded equipment the final ply shall be mat or spray-up. The addition of reinforcement over this finish surface is optional and, if required, will be specified in the FRP data sheet.
2. An ultraviolet stabilizer shall be incorporated in the final coat of resin.
The amount of stabilizer shall be per the resin manufacturer’s recommendation.
3. All edges of reinforcement material shall be lapped: 1-inch minimum for
mat, and 2-inch minimum for woven roving. Lapped edges of adjacent layers shall be staggered.
4. On laminates containing woven roving, cut edges exposed to the
chemical environment shall be coated with resin and surfacing mat, and all other cut edges may be coated with resin only. The resin used shall be designated in the purchase specification and must contain paraffin to assure adequate surface cure.
5. Mold release agents such as MELINEX polyester film or PVA must be
removed prior to inspection and shipment. 2.05 VISUAL INSPECTION CRITERIA
DEFECT SURFACE INSPECTED CORROSION BARRIER STRUCTURAL LAMINATE
Cracks None None Crazing (fine surface cracks) None Maximum dimension 1”.
Maximum density 5/ft2. A
Blisters (rounded elevations of the laminate surface over bubbles)
None Maximum 1/4” diameter x 1/8” high, maximum 2/ ft2. A
Wrinkles & solid blisters Maximum deviation, 20% of wall thickness, but not exceeding 1/8” A
Maximum deviation, 20% of wall thickness, but not exceeding 3/16”. A
Pits (craters in the laminate surface)
Maximum dimensions, 1/8” dia. x 1/32” deep. Maximum number, 10/ft2. A
Maximum dimension 1/8” dia. x 1/16” deep. Maximum density 10/ ft2. A
Surface porosity (pinholes or pores in the laminate)
Maximum dimensions, 1/16” dia. x 1/32” deep. Maximum number 20/ft2 by 1/16 in. Must be resin-rich. A
Maximum dimension 1/16” dia. x 1/16” deep. Maximum number 20/ft.2 Must be resin-rich. A
Chips (small piece broken from edge or surface)
Maximum dimensions, 1/8” dia. x 1/32” deep. Maximum number 1/ft2. A
Maximum dimension 1/4” dia. by 1/16” deep. Maximum number 5/ ft2. A
Dry Spot (non-wetted reinforcing
None Maximum dimension, 2 in.2. A
Entrapped air (bubbles, Maximum diameter 1/16”, Maximum dia. 1/16”, 10/in.2
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DEFECT SURFACE INSPECTED CORROSION BARRIER STRUCTURAL LAMINATE
voids, or delaminations in laminate)
10/in.2 maximum density. Maximum diameter 1/8”, 2/in.2 maximum density. Maximum depth of 1/32”. A,B
maximum density. Maximum dia. 1/8”, 2/in.2 maximum density. Maximum dia. 3/16”, 2/ft2 maximum density. A,B
Exposed glass None None Burned areas None None Exposure of cut edges None C None C
Scratches None over 0.0005” deep and 4” long
Maximum length 12”. Maximum depth 0.010”, 2/ft2 maximum density. A
Foreign matter None 1/8” dia., maximum density 1/ft2. 3/16” dia., maximum density 1/ft2. A,D
A Maximum 5% of total surface area affected. B Entrapped air or bubbles described are allowed, provided the surface cannot be easily broken with a pointed object, such as a knife blade. C Maximum 5% of total surface area affected. D Maximum 5% of total surface area affected. 2.06 TANK REQUIREMENTS A. Bulk chemical storage tanks and day/feedtanks shall be provided for each
chemical noted in the schedules on the Drawings. The tank size, nominal dimensions, style and chemical data shall be as noted herein and as in the schedules on the Drawings.
B. Each of the tanks will be located inside a temperature controlled building.
Refer to Section 1.05 for additional information. C. The chemicals stored in the tanks are expected to be pure to the concentration
noted except for the maximum level of impurities allowed per American Water Works Association (AWWA) standards as published in AWWA B501.
D. The tanks shall come with the number of nozzles, nozzle sizes and nozzle
locations as shown on the Drawings. See the typical tank details and chemical schematics for nozzle information. Flanges shall be provided for instruments as indicated on the Contract Drawings. Vent lines will exhaust to the building’s exterior, not into the room. All tanks with tap-mounted manways more than 8 feet above the floor shall come with access ladders.
2.07 FITTINGS AND ACCESSORIES A. General 1. Unless otherwise specified, all connections to equipment and tanks shall
be flanged.
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B. Hold Down Lugs 1. Hold down lugs shall be provided on all vertical flat bottom tanks. The
design, number, and attachment of such lugs is the responsibility of the fabricator, based on the wind (if applicable), seismic zone “C,” and other loads specified.
C. Lifting Lugs 1. Lifting lugs shall be provided for all tanks. D. Manways 1. All closed top tanks shall be provided with a minimum 24 inch diameter
top access manway and cover. All single walled tanks shall be provided with a minimum 24-inch diameter flanged side manway with bolted cover. Bolted manways shall be provided with 1/8 inch thick full face gaskets of a material suitable for the chemical in the tank and 316 stainless steel or FRP bolting.
E. Flanged Nozzles 1. All flanged nozzles shall be of a hand lay-up construction with the pipe
stub molded integrally with the pipe flange. Press molded flanges are not acceptable. Compression molded or cemented on flanges are prohibited. Nozzles 4 inches diameter and smaller shall be gusseted conically or reinforced with four 3/8-inch plate gussets. Conical gussets having compatible strength may be substituted for the plate gussets. Conical gussets shall extend from the flange OD to the tank wall. Plate gussets shall be suitably laminated to the flange back side, hub, pipe neck, and tank wall.
2. The machine facing of the back of hand lay-up flanges is not permitted.
All bolt holes shall be spot faced for SAE size washers. 3. Flange drilling on pipe connections shall be in accordance with ANSI B-
16.5 for 150-psi pressure class. 4. Bolt holes in flanged nozzles are to straddle the vertical centerline.
Tolerance in bolt holes location and in diameter of bolt circle shall be as specified.
5. On all flanged joints, use gaskets having a specified Shore A Durometer
hardness. 6. Reinforcement of nozzle and manhole openings in vessel walls shall be in
accordance with the requirements of ASTM D 3299. The reinforcement pad shall consist of alternate piles of mat and woven roving. The edges of all reinforcing overlays shall be tapered to avoid abrupt change in overall thickness of vessel laminates.
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F. Threaded Fittings 1. Threaded fittings shall be used only where indicated herein or shown on
the Drawings. Where specified threaded fittings shall be installed with laminates inside and outside as required for flanged nozzles in the referenced ASTM specifications. Threaded fittings shall be of glass-fiber reinforced resin with molded threads.
G. Flexible Couplings
1. All tank nozzles shall be connected to rigid fixed piping systems by a flexible coupling; expansion joint, or flexible pipe or tubing as specified.
H. Mixing Baffles 1. Tanks with flange-mounted mixers or mixers which enter the tank at the
top center of the tank and are not offset (angled) shall be provided with 3 or 4 wall-mounted mixing baffles. The size and spacing of the baffles shall be as recommended by the mixer supplier.
PART 3 EXECUTION 3.01 GENERAL A. Tanks shall be installed in strict accordance with fabricator's written instructions
and the shop drawings. Because of size and construction, extreme care shall be exercised during handling and settling.
B. The concrete foundation for the tanks shall be level with a tolerance of 1/8-inch
between high and low points. When concrete foundation surface has been accepted by the ENGINEER, place 2 layers of roofing felt over concrete before setting tanks.
C. After tanks are in place, steel lifting ring shall be removed and replaced with
PVC bulkhead type threaded fitting and pipe plug. Do not allow nut and washer to drop on tank floor when removing ring.
3.02 HANDLING A. Tanks shall be handled in accordance with the fabricator's instructions. 3.03 TESTS A. Tanks are to be tested for the degree of surface cure using Barcol hardness and
acetone sensitivity methods as indicated in the referenced ASTM specifications. B. Tanks are to be visually inspected for laminate quality and workmanship as
indicated in the referenced ASTM specifications, and in article 2.05.
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C. After the tank has been installed, a hydrostatic test shall be performed by the purchaser.
3.04 FIELD JOINTS A. Where the field joining of FRP components is required, the fabricator shall
furnish all necessary materials. Fabrication procedures shall conform to the requirements of this Specification.
B. Unless field forces are known to be throughly competent in FRP layup
procedures, a vendor erection supervisor shall be present when field joints are made.
3.05 CLEANING A. Prior to inspection, all dirt and extraneous materials shall be removed from the
equipment interior. The fabricator shall remove all surface markings, coatings, or contaminants prior to inspection.
B. When equipment must be ready for use without further site cleaning, special
cleaning and sealing requirements will be as detailed in the purchase specification.
3.06 SHIPPING A. Whenever feasible, shipments shall be made by truck. B. Tanks which are shipped in horizontal position shall be mounted on padded
cradles. All tank end blocking used to prevent shifting of tanks must be padded and bare only upon the knuckle radius of the tank bottom.
C. Tanks shall be secured to the cradles or skids to prevent rotation or other
movement. In turn, the cradles or skids shall be fastened securely to the truck bed.
D. All tie-down straps shall give provision for thermal expansion and shall be
padded where in contact with the equipment. E. Flange faces shall be protected from damage by covering with suitable plywood
or hardboard, securely fastened. Note: Tanks shall be positively vented at all times.
F. Open top tanks and equipment shall be fitted with internal cross bracing to
prevent damage from distortion during transit and handling. G. Tanks and equipment shall be inspected by the CONTRACTOR before unloading
of the construction site with end damage found to be the carrier’s and/or fabricator’s responsibility.
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3.07 METHOD OF PAYMENT A. All items needed to make a complete job shall be included in the
CONTRACTOR'S lump sum bid.
END OF SECTION
***
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SECTION 13201
UPRIGHT POLYETHYLENE STORAGE DAY TANKS PART 1 GENERAL 1.01 SCOPE
A. This Specification covers upright, cylindrical, tanks molded in one-piece
seamless construction by rotational molding. The tanks are designed for above-ground, vertical installation and are capable of containing chemicals at atmospheric pressure. Included are requirements for materials, properties, design, construction, dimensions, tolerances, workmanship, and appearance. Tank capacities are 550 gallons and smaller unless specifically noted to be constructed of polyethylene.
B. This Specification does not cover the design of vessels intended for use at
pressures above or below atmospheric conditions. It is also not for vessels intended for use with liquids heated above their flash points, temperatures above 140 degrees Fahrenheit for Type I materials, or temperatures above 130 degrees Fahrenheit for Type II materials (see section 4.1 for material classifications).
C. Polyethylene storage day tanks and appurtenances shall be provided as
indicated in the schedules on the Drawings and this Section. D. Tanks shown with mixers shall have flanged nozzle openings for domed top
tanks and hinged, bolted down lids for flat-top tanks. E. This specification covers day tanks as noted in the schedules on the Drawings. 1.02 APPLICABLE DOCUMENTS A. ASTM - (American Society for Testing and Materials) Standards: D618 - Conditioning Plastics and Electrical Insulating Materials for Testing D638 - Tensile Properties of Plastics D790 - Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials D883 - Definitions of Terms Relating to Plastics D1505 - Density of Plastics by the Density-Gradient Technique D1525 - Test Method for Vicat Softening Temperature of Plastics D1693 - Test Method for Environmental Stress-Cracking of Ethylene Plastics D1998 - Standard Specification for Polyethylene Upright Storage Tanks D2765 - Degree of Crosslinking in Crosslinked Ethylene Plastics as Determined by Solvent Extraction D2837 - Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe
Materials D3892 - Practice for Packaging/Packing of Plastics F412 - Definitions of Terms Relating to Plastic Piping Systems
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B. ARM - (Association of Rotational Molders) Standards: Low Temperature Impact Resistance (Falling Dart Test Procedure)
C. ANSI – American National Standards Institute B-16.5 Pipe Flanges and Flanged Fittings
D. OSHA – Occupational Safety and Health Administration Standards: 29 CFR 1910.106 - Occupational Safety and Health Administration,
Flammable and Combustible Liquids
E. UBC CODE: Uniform Building Code 1997 Edition
1.03 CHEMICAL COMPATIBILITY A. Chemical compatibility shall be according to the following chemical resistance
guides: Pruett, Kenneth M., "Chemical Resistance Guide for Elastomers", Compass
Publications. Pruett, Kenneth M., "Compass Corrosion Guide II", Compass Publications. B. These references shall be considered as general guidelines only. In many cases,
combinations of these chemicals are used in such a way that only the customer (by testing molded product samples) can make a determination in regards to acceptability.
1.04 CLASSIFICATION
A. Tanks are classified as Type I – Tanks added from cross-linked polyethylene
resin or Type II - Tanks molded from linear polyethylene resin (not cross-linkable resin).
1.05 SUBMITTALS A. The fabricator shall submit the following for review and approval prior to
fabrication of the tank(s) in accordance with the front end specifications, Divisions 0 and 1.
1. Detailed and certified design calculations: The laminate sequence used
for all tanks must either be attached to or included on drawings used by the fabricator’s shop personnel.
2. Tank layout drawings showing dimensions, wall thickness, anchor layout,
knuckle radii, nozzle location and orientation, nozzle construction, ladder, platform and safety gage construction and orientation.
3. Instructions for handling, storage and installation tanks on a concrete
slabs or otherwise.
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4. Tank manufacturer’s recommended bolt torque for flanges. 5. A certificate listing the type of resin to be used, describing the
manufacturer’s brand name with a statement of suitability for intended service.
6. Design calculations for structural design of walls, design of tie-down lugs
and overall weight of tank. 7. Manufacturer’s certification that tank construction complies with the
applicable ASTM referenced in these specifications. 8. Nozzle, fitting and manway schedule including size, mark, thickness, and
rating. 9. Details of fall clips and lugs for hold down lugs, pipe brackets, and
anchor bolts, as integral parts of the tank. Pipe supports shall be spaced maximum 5 feet on centers.
10. Laminate sequence of construction and all materials of construction
listed. 11. Statement of chemical compatibility for the day tanks. 1.06 WARRANTY A. Materials furnished under this Section shall be warranteed in accordance with
Divisions 0 and 1. 1.07 MARKING, PACKING AND SHIPPING A. The tanks shall be marked to identify the product, date (month and year) of
manufacture, capacity, and serial number. The tank shall be shipped with a 3 of 9, HRI bar code label containing tank description, manufacturing order number, part number, serial number, manufacturer, and date.
B. The proper caution or warning signs as prescribed by OSHA standard 29 CFR
1910.106 shall be customer determined and supplied. C. All packing, packaging, and marking provisions of ASTM Practice D3892 shall
apply to this standard. D. Customer specified labeling is available. E. Tank shrink wrapping and bagging is available upon customer request. F. All fittings shall be installed, removed and shipped separately. G. Since there are variations in methods of shipping, the manufacturer’s instruction
shall be followed in all cases.
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H. Consult the manufacturer’s “Guidelines for Use and Installation” booklet
included with your tank for unloading instructions on specific tanks. This booklet can be found attached to the cap or manway area on the inside of the tank.
I. Upon arrival at the destination, the purchaser and/or his agent shall be
responsible for inspection for damage in transit. If damage has occurred, a claim should be filed with the carrier by the purchaser, and the manufacturer should be notified prior to the tank being put into service.
PART 2 PRODUCTS 2.01 Materials A. The material used shall be virgin polyethylene resin as compounded and
certified by the manufacturer. Type II tanks shall be made from linear polyethylene resin as manufactured by Exxon Chemical, or resin of equal physical and chemical properties.
B. All polyethylene resin material shall contain a minimum of a U.V. 8 stabilizer as
compounded by the resin manufacturer. Pigments may be added at the purchaser's request, but shall not exceed 0.25% (dry blended) of the total weight.
C. For tanks stored indoors the polyethylene resin shall be natural in color unless
otherwise called for and shall have a 1.9 specific gravity and 600 psi which meets ASTM Standards.
D. Mechanical Properties 1. Type I Tank Material
PROPERTY ASTM VALUE
Density (Resin) D1505 0.938-0.946 g/cc
Tensile (Yield Stress 2"/min) D638 2830 PSI
Elongation at Break (2"/min.) D638 700%
ESCR (100% Igepal, Cond. A, F50) D1693 >1000 hours
ESCR (10% Igepal, Cond. A, F50) D1693 >1000 hours
Vicat Softening Degrees F. Temperature
D1525 250
Flexural Modulus D790 100,000 PSI
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2. Type II Tank Material
PROPERTY ASTM VALUE
Density (Resin) D1505 0.940-0.947 g/cc
Tensile (Yield Stress 2"/min) D638 2700 PSI
Elongation at Break (2"/min.) D638 350%
ESCR (100% Igepal, Cond. A, F50) D1693 400-1000 hours
ESCR (10% Igepal, Cond. A, F50) D1693 200-500 hours
Vicat Softening Degrees F. Temperature
D1525 235
Flexural Modulus D790 97,000 - 103,000 PSI
E. Tanks shall be Polyprocessing, Peabody Engineering, Assmann, Snydon
Industries, Chemtainer, or equal. 2.02 DESIGN REQUIREMENTS
A. The minimum required wall thickness of the cylindrical shell at any fluid level
shall be determined by the following equation, but shall not be less than 0.187 in. thick. T = P x O.D./2 SD = 0.433 x S.G. x H x O.D./2 SD
T = wall thickness SD = hydrostatic design stress, PSI P = pressure (.433 x S.G. x H), PSI H = fluid head, ft. S.G. = specific gravity, g/cm^3 O.D. = outside diameter, in. 1. The hydrostatic design stress shall be determined by multiplying the
hydrostatic design basis, determined by ASTM D2837 using rotationally molded samples, with a service factor selected for the application. The hydrostatic design stress is 600 PSI at 73 degrees Fahrenheit for Type I and Type II materials. In accordance with the formula in 6.1, the tank shall have a stratiform (tapered wall thickness) wall.
2. The hydrostatic design stress shall be derated for service above 100
degrees Fahrenheit and for mechanical loading of the tank. 3. The standard design specific gravity shall be 1.9.
B. The minimum required wall thickness for the cylinder straight shell must be
sufficient to support its own weight in an upright position without any external support. Flat areas shall be provided to allow locating large fittings on the cylinder straight shell.
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C. The top head must be integrally molded with the cylinder shell. The minimum thickness of the top head shall be equal to the top of the straight wall.
D. The tank shall be designed to provide a minimum of 4 tie-down lugs integrally
molded into the top head. The tie-down lugs shall be designed to allow tank retention in wind and seismic loading situations without tank damage. Refer to section 12.2 for tank tie-down accessories.
2.03 DIMENSIONS AND TOLERANCES
A. All dimensions will be taken with the tank in the vertical position, unfilled. Tank
dimensions will represent the exterior measurements.
1. The tolerance for the outside diameter, including out of roundness, shall be per ASTM D1998.
2. The tolerance for fitting placements shall be +/- 0.5 in. in elevation and 2
degrees radial at ambient temperature.
2.04 TEST METHODS A. Test specimens shall be taken from fitting location areas or piggy-back test
molds. B. Low Temperature Impact Test
1. Test specimens shall be conditioned at -40 degrees Fahrenheit for a
minimum of 2 hours. 2. The test specimens shall be impacted in accordance with the standard
testing methods as found in ASTM D1998. Test specimens < 1/2" thickness shall be tested at 100 ft.-lb. Test specimens > 1/2" thickness shall be tested at 200 ft.-lb.
C. The tank shall be visually inspected to determine such qualities as are discussed
below.
2.05 WORKMANSHIP A. The finished tank wall shall be free, as commercially practicable, of visual
defects such as foreign inclusions, air bubbles, pinholes, pimples, crazing, cracking and delaminations that will impair the serviceability of the vessel. Fine bubbles are acceptable with Type II tanks to the degree in which they do not interfere with proper fusion of the resin melt.
B. All cut edges where openings are cut into the tanks shall be trimmed smooth.
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2.06 TANK FITTINGS (NOZZLES) A. General 1. Nozzles shall be provided which meet the requirements noted below.
Nozzles 3 inches and smaller may be threaded bulkhead fittings or bolted flange fittings. Nozzles 4 inches and larger shall be bolted flange fittings.
B. Fittings - Threaded Bulkhead
1. Threaded bulkhead fittings may be placed below liquid level when placed
on the tank’s flat spots for tanks less than 48 inches in diameter and on the curved wall or flat spot for larger tanks. Fittings must be placed away from tank knuckle radius' and flange lines. Consult the manufacturer for placement questions. The maximum allowable size for bulkhead fittings placed on a curved sidewall section of tanks 48 in. to 142 in. in diameter is 2 inch size. Tank wall thickness must be considered for bulkhead fitting placement. The maximum wall thickness for each fitting size is shown below.
Fitting Size Maximum Wall
Thickness 1/2 in. 0.750 in. 3/4 in. 0.875 in. 1 in. 0.875 in.
1 1/4 in. 0.875 in. 1 1/2 in. 0.875 in.
2 in. 1 in. 3 in.
1.125 in. (Flat Surface
Only)
2. The bulkhead fittings shall be constructed of PVC, PP, or other specified material. Gaskets shall be a minimum of 1/4" thickness and constructed of 40-50 durometer EPDM, 60-70 durometer Viton, or other specified material.
C. Fittings - Bolted Double 150 lb Flange Fittings
1. Bolted double flange fittings are required for below liquid level
installation for sizes above 2 in. depending on the tank diameter and the placement of the fitting in the tank. Fittings must be placed away from tank knuckle radius and flange lines. Consult the tank supplier for placement questions. Bolted double flange fittings provide the best strength and sealing characteristics of any tank fitting available. Allowable fittings sizes based on tank diameter for curved surfaces are shown below.
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Tank Diameter Maximum Bolted Fitting Size Allowable
48 in. - 86 in. 3 in. 90 in. - 102 in. 6 in. 120 in. - 142 in. 8 in.
The bolted double flange fittings shall allow tank wall thickness up to 2
1/2 in.
2. The bolted double flange fitting shall be constructed with 2 each 150 lb. flanges, 2 each 150 lb. flange gaskets, and the correct number and size of all-thread bolts for the flange specified by the flange manufacturer. The flanges shall be constructed of PVC Type I, Grade I, polypropylene, 316 stainless steel, or other specified material. Gaskets shall be a minimum of 1/4-inch thickness and constructed of 40-50 durometer EPDM Viton or other chemically compatible material. There shall be a minimum of 4 each full thread bolts. The bolts shall be made of a material which is chemically compatible with the tank’s contents and have gasketed flanged metal heads or bolt heads encapsulated in Type II polyethylene material. The encapsulated bolt shall be designed to prevent metal exposure to the liquid in the tank and prevent bolt rotation during installation. The polyethylene encapsulation shall fully cover the bolt head and a minimum of 1/4" of the threads closest to the bolt head. The polyethylene shall be color coded to distinguish bolt material (white - 316 S.S., yellow - Hastelloy C276, red - Monel, green - Titanium). Each encapsulated bolt shall have a gasket to provide a sealing surface against the inner flange.
3. Standard orientation of bolted double flange fittings shall have bolt holes
straddling the principal centerline of the tank in accordance with ANSI/ASME B-16.5 unless otherwise specified.
D. Fittings - Siphon Tube Fittings
1. Siphon tubes may be added to the fittings specified in sections 10.1, 10.2
and 10.3. Siphon tubes will allow these fittings, when used as drainage fittings, to provide better tank drainage.
E. Fittings - Integrally Molded Outlet
1. The integrally molded fitting shall be an integral part of the tank and
provide complete drainage of liquid through the sidewall of a flat bottom container without the use of a special support structure or concrete pad. The outlet provided shall allow solvent weld PVC pipe attachments at the tank pad level. It shall provide a metal reinforcement completely isolated from any chemical attack.
2. The tank attachment shall be constructed from a PVC/CPVC schedule 80
or other chemically compatible material male adapter in 2,3,4 or 6 inch
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and be available for all tanks greater than 50 gallons. This provides a schedule 80 pipe socket attachment (Except for the 6 in. size). The fitting orifice shall not be less than schedule 80 interior pipe size per ANSI B36.10-1979. O-rings shall be constructed of 70 +/- 5 durometer Viton or other specified material.
F. Fittings - Self-Aligning Threaded Bulkhead
1. Self-Aligning fittings are available for installation in vapor phase
applications on curved surfaces depending on the spherical dome radius and the placement of the fitting on the tank dome. Fittings must be placed away from tank radius'. Consult the tank manufacturer for placement questions. The maximum allowable size for self-aligning fittings placed on a spherical section of the tank is shown below.
Tank Diameter Maximum Fitting Size
Allowable 45 in. - 48 in. 2 in. 64 in. - 142 in. 3 in.
Tank thickness and fitting angle may need to be considered for self-
aligning fitting placement. The maximum thickness and installation angle for fitting sizes are shown below.
Fitting Size Maximum Angle Maximum
Thickness 1 in. 27 degrees 1.000 in. 2 in. 25 degrees 0.750 in. 3 in. 20 degrees 1.000 in.
2. The self-aligning fittings shall be constructed of PVC or other specified
material. Gaskets shall be a minimum of 1/4" thickness and constructed of 40-50 durometer EPDM, 60-70 durometer Viton, or other specified material.
G. All tank fitting attachments shall be equipped with flexible couplers or other
movement provisions. The tank will deflect based upon tank loading, chemical temperature, and storage time duration. Tank piping flexible couplers shall be designed to allow 4 percent design movement. Movement shall be considered to occur both outward in tank radius and downward in fitting elevation from the neutral tank fitting placement.
2.07 TANK ATTACHMENTS AND ACCESSORIES
A. Fill Cap (Non-sealed)
1. All tanks shall have a minimum 16-inch manway or a 10 in. vented-
threaded style on various tank sizes with a minimum opening diameter of 7.125 in. per the tank schedules on the Drawings. If no manway is called
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for a 10-inch fill cap shall be provided. Cap attachment shall be provided with all standard 10 in. cap placements with a polyurethane cap tie.
2. All caps shall be constructed of polyethylene material.
B. Down Pipes and Fill Pipes
1. Down pipes and fill pipes shall be provided. All down pipes and fill pipes
shall be supported at 5 ft. maximum intervals with support structures. Standard support structure design shall utilize bulkhead fitting tank attachments. Fill pipes shall be designed to minimize the force of the liquid filling the tank from the supply pump.
2. All down pipes and fill pipes shall be constructed of PVC or other
specified materials.
C. Flange Adapters
1. Flange adapters shall be provided as necessary to adapt threaded or socket fitting outlets to 150 lb. flange connections for connection to piping system components. Flange adapters shall be in PVC, CPVC or other chemically compatible materials. Flange adapter construction shall utilize schedule 80 components in sizes ranging from ¾” to 8” depending on material required.
D. Sight Level Gauge 1. The sight level gauge shall be constructed of flexible PE tubing to allow
for tank contraction and expansion due to loading and temperature changes. The level gauge shall be connected to the tank with 2 appropriate 3/4-inch fittings as described in Article 2.06. Each fitting shall have valves installed for isolation or drainage purposes.
E. Mixing Baffles 1. Tanks with flanged mounted mixers or mixers which enter the tank
vertically at the top center of the tank and are not offset (angled) shall be provided with 3 or 4 wall mounted mixing baffles. The size and spacing of the baffles shall be as required by the mixer supplier.
2.08 TANK SCHEDULE A. See the tank schedule on the Drawings for a complete list of all polyethylene
tanks, their dimensions, etc.
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PART 3 EXECUTION 3.01 GENERAL A. Tanks shall be installed in strict accordance with fabricator's written instructions
and the shop drawings. Because of size and construction, extreme care shall be exercised during handling and settling.
B. The concrete foundation for the tanks shall be level with a tolerance of 1/8-inch
between high and low points. When concrete foundation surface has been accepted by the ENGINEER, place 2 layers of roofing felt over concrete before setting tanks.
C. After tanks are in place, steel lifting ring shall be removed and replaced with
PVC bulkhead type threaded fitting and pipe plug. Do not allow nut and washer to drop on tank floor when removing ring.
3.02 HANDLING A. Tanks shall be handled in accordance with the fabricator's instructions. 3.03 TESTS A. Tanks are to be tested for the degree of surface cure using Barcol hardness and
acetone sensitivity methods as indicated in the referenced ASTM specifications. B. Tanks are to be visually inspected for laminate quality and workmanship as
indicated in the referenced ASTM specifications. 3.04 FIELD JOINTS A. Where the field joining of components is required, the fabricator shall furnish all
necessary materials. Fabrication procedures shall conform to the requirements of this Specification.
B. A vendor erection supervisor shall be present when field joints are made. 3.05 CLEANING A. Prior to inspection, all dirt and extraneous materials shall be removed from the
equipment interior. The fabricator shall remove all surface markings, coatings, or contaminants prior to inspection.
B. When equipment must be ready for use without further site cleaning, special
cleaning and sealing requirements will be as detailed in the purchase specification.
3.06 SHIPPING A. Whenever feasible, shipments shall be made by truck.
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B. Tanks which are shipped in horizontal position shall be mounted on padded
cradles. All tank end blocking used to prevent shifting of tanks must be padded and bare only upon the knuckle radius of the tank bottom.
C. Tanks shall be secured to the cradles or skids to prevent rotation or other
movement. In turn, the cradles or skids shall be fastened securely to the truck bed.
D. All tie-down straps shall give provision for thermal expansion and shall be
padded where in contact with the equipment. E. Flange faces shall be protected from damage by covering with suitable plywood
or hardboard, securely fastened. Note: Tanks shall be positively vented at all times.
3.07 METHOD OF PAYMENT A. All items needed to make a complete job shall be included in the
CONTRACTOR'S lump sum bid.
END OF SECTION
***
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SECTION 13220 FILTER UNDERDRAINS, MEDIA, AND EQUIPMENT PART 1 GENERAL 1.01 SCOPE OF WORK
A. As shown on the Drawings and specified here, furnish and install a new air/water backwash filter system complete, including air scour piping, filter backwash blowers, filter media, underdrains, filter troughs, instrumentation and controls, and associated equipment. Each filter shall have a design capacity of 1920 gpm when filtering at a rate of 5.00 gpm/ft2 of total filter area.
B. The fiberglass reinforced plastic (FRP) filter troughs, as well as the trough
support system, shown on the drawings shall be supplied by the filter system supplier. The troughs and their support system shall be sized by the filter system supplier to handle 1920 gpm when filtering water at 5.00 gpm/ft2, and when backwashing a filter at 7680 gpm or 20 gpm/ft2.
C. The filtration system shall be complete and operable as installed by the
CONTRACTOR. Without exception, the contract price is to include all royalties and costs arising from patents and licenses associated with furnishing the specified filtration equipment. All materials shall be designed to withstand stresses encountered in operation, fabrication, and erection. The CONTRACTOR shall financially reimburse the ENGINEER completely for any and all redesign work resulting from a proposal to substitute equipment of a different configuration or design from that specified, as noted in the Instructions to Bidders and detailed in the General Conditions.
D. The flow rates provided here are actual flow rates but the design flow rates shall
be as noted in Article 2.05.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Sections 00700 (00710) and 01600.
B. Pressure pipe is specified in Division 2.
C. Grout is specified in Division 3.
D. Painting is specified in Division 9.
E. Blowers are specified in Section 11375.
F. Mechanical Work is specified in Division 15. G. Air compressors are specified in Section 11370.
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H. Electrical work is specified in Division 16.
I. Valves are specified in Division 15. J. Instrumentation is specified in Division 17. Filter controls are specified herein
and in Section 17350.
K. Special sequence or schedule requirements (if any) are specified in Section 01010 - Summary of Work.
L. FRP filter troughs are in Section 11201.
1.03 SYSTEMS DESCRIPTION
A. The filtration process shall consist of gravity filters using a dual media bed and an underdrain system that is specifically made for the air water backwash process. The intent of this specification is to provide the OWNER a filtration system capable of maintaining good suspended solids removal performance; long filter runs; a reduction in quantity of backwash water used, as compared to conventional filter backwash systems; and minimal filter media loss during filter backwashing.
B. The drawings show a dual media filter with a media retention plate above a
plastic tile type underdrain. The drawings also show an effluent/backwash flume located in the center of the filter under the underdrains. If the filter system supplier would like to move this flume to another location, he may do so. However, any costs associated with the move such as additional engineering costs due to structural revisions, etc., will be borne by the supplier.
C. The filter backwash method shall consist of the sequential use of air and water
to backwash the filter. The manufacturer will be responsible for supplying the components for his standard sequential backwash.
D. Control shall be provided by 5 consoles as noted herein and on the Drawings.
Filter controls and instrumentation shall be provided by the filter equipment supplier.
1.04 QUALIFICATIONS
A. The equipment specified in this Section shall be furnished by a single manufacturer who has an experience record of similar proven designs and installations of at least 10 years. The system shall be manufactured by F.B. Leopold Company, Roberts Filter, Severn Trent, or equal.
B. Filter media: The filter media shall be furnished by the filter equipment
manufacturer who is experienced, reputable, and qualified in the manufacture of the media to be furnished. The media shall be designed, constructed, and installed in accordance with best practices and methods. The media shall be manufactured by F.B. Leopold Co., Inc., General Filter Co., MicroFLOC, Inc., Roberts Filter Co., or equal.
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PART 2 PRODUCTS 2.01 GENERAL A. The following are covered in this specification: 1. Filter Media 2. Sequential Air/Water Backwash System, including underdrain, air header,
and grout 3. Instrumentation and Controls. 2.02 FILTER MEDIA
A. General
1. These filters are to be dual media filters with a media retention plate.
2. The supplier of materials and equipment under this Section must have approval, prior to bidding date, of the Division of Water of their materials and equipment for the production of potable water by the high filtration rate process.
3. The CONTRACTOR shall pay all royalty or license fees for use of patented
devices or systems, and shall protect the OWNER from patent infringement litigation thereon.
4. Under this section of the Specifications the CONTRACTOR shall furnish
filter media and supporting gravel for each of the 5 filters. Each filter has plan dimensions of 24 feet 0 inches by 16 feet 0 inches, for a filter area of 384 square feet.
B. Filter Media
1. General
a. Filter materials shall be in accordance with ANSI/AWWA Specifica-
tions B100, latest edition. All future reference to section and paragraph numbers shall be those of ANSI/AWWA B100, latest edition.
2. Support Gravel a. Filter gravel physical characteristics shall be in accordance with
AWWA B100 Section 4, paragraph 4.1.2.1, and the subparagraphs. Filter gravel acid solubility shall be in accordance with Section 4, paragraph 4.1.2.4. Gravel size shall be in accordance with Section 4, paragraph 4.1.2.3.
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3. Filter Sand
a. Filter sand physical characteristics shall be in accordance with
Section 4, paragraph 4.1.1.2 and shall have a saturated-surface-dry specific gravity of 2.50 or greater. Filter sand acid solubility shall be in accordance with Section 4, paragraph 4.1.1.2. Filter sand size shall be as hereinafter specified for each type of high rate filter media.
b. A size gradation curve (sieve opening, mm, versus percent passing
by weight) shall be submitted to the ENGINEER along with shop drawings.
4. Filter Anthracite
a. Filter anthracite physical characteristics shall be in accordance with
Section 4, paragraph 4.1.1.1. Anthracite acid solubility shall be in accordance with Section 4, paragraph 4.1.1.1. Anthracite size shall be as hereinafter specified for each type of high rate filter media. A size gradation curve (sieve opening, mm, versus percent passing by weight) shall be submitted to the ENGINEER along with shop drawings.
C. Dual Media Beds
1. General
a. The dual filter media bed shall be furnished to provide a total
depth of 36 inches. The top layer shall be filter anthracite and the bottom layer shall be silica sand.
b. The ratio d90 for anthracite to d10 for sand shall be 2.5 to 3.5.
The ratio of the effective size of anthracite to the effective size of sand shall be 1.65 to 2.35.
2. Media Support / Retention Plate a. A plate shall be provided to retain the filter media. Above the
underdrain the plate shall be securely anchored to the underdrain block. The retainer shall be Leopolds IMS 200 or equal.
3. Silica Sand a. Silica sand shall be 12 inches in depth over top of the support
gravel or torpedo sand. The sand as shipped shall have an effective size (d10) of 0.45 mm to 0.55 mm and a uniformity coefficient (d60/d10) not exceeding 1.40. After the sand has been placed, the filter shall be backwashed thoroughly, and then the top
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of the sand lightly skimmed to remove such fines and debris as can be visually detected.
4. Filter Anthracite a. Filter anthracite shall have a final depth after backwashing and
skimming of 24 inches over top of filter sand. The anthracite as shipped shall have an effective size of 0.95 mm to 1.05 mm and a uniformity coefficient not exceeding 1.50. It is intended that after hydraulic classification in place by backwashing, and removal of the final material by skimming, essentially all of the particles smaller than 0.9 mm be removed. Sufficient excess material shall be furnished to anticipate this requirement.
2.03 AIR BACKWASH BLOWERS A. Two tri-lobe blowers, as specified in Section 11375, shall be provided by the
filter equipment supplier to supply air for their system. The air rate shall be as required for proper backwashing and may vary from that noted in Section 11375.
2.04 FILTER TROUGHS A. Fiberglass reinforced plastic (FRP) filter troughs, as specified in Section 11201,
shall be provided by the filter equipment supplier. 2.05 SEQUENTIAL AIR/WATER BACKWASH A. General 1. Where required, system support angles, bars, plates, anchorage, bolts,
nuts, washers, etc., shall be Type 316 stainless steel. 2. Filter troughs shall be installed so that the edges are level to within 1/8-
inch in 10 feet of height. 3. All welded stainless steel components shall be low carbon stainless steel,
such as Type 304L stainless steel. All non-welded components such as anchor bolts, etc., can be the standard form of stainless steel, such as Type 316 for anchor bolts, etc.
B. Filter Components 1. Underdrain a. The underdrain system for the filters shall be a dual parallel lateral
type with a media retention plate whereby feeder and compensating chambers are provided within the cross section of a single block. The cross section of the underdrain shall be so arranged that the feeder (or primary) chamber is adjacent and
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connected to the compensating (or secondary) chambers through a series of orifices. The orifices shall be located at 4 different elevations and sized to provide uniform distribution of air and water. The primary chamber should provide at least 50 square inches of cross section area per block to reduce flow velocity during backwash.
b. The compensating chambers shall provide the essential uniform
pressure and flow distribution from the top of the blocks. The discharge flow from the top of the blocks into the filter bed shall be provided by a minimum of 20 dispersion orifices per square foot of filter area. The orifices shall be not less than 7/32-inch diameter to prevent clogging and shall be recessed from the surface by approximately 1/8-inch. The top of each orifices shall be encircled by a depression approximately 3/8-inch by 3/4-inch, which shall act to prevent the gravel support media from resting directly on and thereby blocking the dispersion orifice.
c. The underdrain shall have a horizontal flat top discharge surface,
so that the finished filter bottom is essentially flat, with above stated dispersion orifices for uniform energy intensity of air and water coverage which direct flow vertically for effective penetration and cleaning of the media.
d. The underdrain shall have a positive means by which it is anchored
down to prevent flotation during backwashing. 2. Air Header a. Because the proper distribution of air into the underdrain has a
significant effect upon operation, the filter manufacturer shall have the responsibility to design and provide the air distribution header for this underdrain.
3. Performance and Design Requirements a. General Requirements (1) The filter underdrain system shall be designed and installed
to ensure long term stability in its operating characteristics. It shall be resistant to changes in head loss, flow uniformity, and any other effects which should in time cause loss of efficiency or effectiveness in its operation.
(2) The underdrain system is intended to allow for the uniform
collection of filtered water and uniform distribution of backwash water and air over the total area of the filter floor.
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(3) The backwash system shall allow for separate air scouring and water backwashing and for the sequential use of air and water at the specified rate.
(4) The system shall be designed to avoid localized areas of
excessive flow (maldistribution) which may cause mounding, lateral displacement, or other deleterious disturbances in the filter support gravel or media.
(5) When subjected to a flow rate of 20 gpm/sf of filter area,
the headloss through an underdrain lateral 40 feet long shall not exceed 36 inches water column when the water temperature is approximately 60 degrees Fahrenheit. This does not include head losses for special feed arrangements.
(6) To ensure the underdrain will control distribution (limit
maldistribution) and not be overpowered by the media headloss, the minimum headloss through the orifices (primary and secondary) of an individual underdrain block shall not be less than 15 inches water column at a backwash flow rate of 20 gpm/sf of filter area when the water temperature is approximately 60 degrees Fahrenheit.
b. Design Flow Rates (1) The filter underdrain system shall be furnished and installed
to perform satisfactorily and as specified when operated under the following conditions:
(a) Downflow of filtered water up to 6 gpm/sf. (b) Upflow of backwash air at a rate in the range of 2 to
5 scfm/sf. (c) Upflow of backwash water up to 25 gpm/sf. c. Flow Distribution (1) The filter underdrain system, as installed, shall provide
acceptable flow uniformity. Maldistribution (MD) of air and water flows during backwash shall be as follows:
(a) Lateral Water MD (i) The maldistribution in a lateral 40 feet long or
less shall not exceed ±5 percent of the average gpm/sf of filter for a backwash rate of 20 gpm/sf.
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(b) Flume Water MD (i) Note additional maldistribution, due to specific
flume arrangement, entry conditions into both flume and underdrain laterals and flow velocities, must be considered.
(c) System Air MD (i) Visually, the air should show a uniform
pattern. d. Structural Design Requirements (1) General (a) The filter underdrain system, including anchorage,
supports, etc., shall be designed to safely withstand loadings for the specified conditions.
(2) Internal Loading (a) The filter underdrain system, when installed, shall be
designed for a net internal loading during backwash of the greater of either 600 psf or 200 percent of the maximum pressure at maximum backwash rates. No credit shall be taken for the weight of gravel or filter media.
(3) Downward Load (a) The filter underdrain system shall also be designed
to withstand a new downward loading of not less than 1,400 psf.
e. Air Temperature (1) During backwash with air, the underdrain shall be suitable
to withstand a maximum air temperature of 200 degrees Fahrenheit.
4. Materials and Construction a. Underdrain (1) Material (a) The individual blocks used in the system shall be of
impervious high strength, complete corrosion-resistant, high-density polyethylene (HDPE) or
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polyvinylchloride (PVC) material. The blocks shall be resistant to erosion and corrosion and have uniform smooth surfaces. All orifices shall be properly deburred.
(2) Dimensions (a) The block size and weight shall permit ease of
handling and installation. The block nominal dimensions shall be as needed for the proposed filters. The weight of the block shall be approximately 25 pounds.
(3) Block Geometry (a) The blocks shall be essentially rectangular in shape
with dispersion orifices located in the top flat surface. The blocks shall have ridges and pockets for structural rigidity.
(4) Lateral Construction (a) The blocks shall be arranged end-to-end and
mechanically joined to form continuous underdrain laterals approximately equivalent to the length of the filter cell. The joints shall be gasketed, bell and spigot type with internal alignment tabs for proper joint alignment, and be air and water tight. Joints shall be of snap-lock type so that the blocks are joined with integral interlocking snap lugs and lug receptors for ease of assembly and installation of the laterals.
b. Air Header (1) General (a) The air distribution system shall generally be
comprised of a corrosion resistant header specially calibrated to evenly distribute air flow to each underdrain lateral. Sufficient relative velocities shall be maintained to insure proper distribution of air. The filter system supplier shall supply the filter air piping located inside the filter tub and to the flange as shown in the lower filter pipe gallery plan and Section C, under the filter underdrains, approximately 6 inches from the inner well.
(2) Material
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(a) The air header piping shall be type 304L stainless steel Schedule 5S or 10S. The anchors and hardware for anchoring the air header shall be type 316/316L stainless steel.
c. Grout Retainer (1) Grout retaining strips for bridging flumes shall be of high-
impact polystyrene properly keyed to fit the underdrain blocks to allow adjustment of lateral center-to-center distance without difficulty. Retaining strips shall be supplied by the filter manufacturer.
d. Grout (1) The grout used in installing the blocks shall have a
minimum comparative strength of 2500 psi after 30 days of curing. Normally, a grout with 1 part Portland cement and 2 parts clean silica sand properly mixed and wetted with a maximum water-cement ration by weight equal to 0.60 or less will meet the specification.
2.06 INSTRUMENTATION AND CONTROLS A. Instrumentation and controls shall be provided for the system and shall be in
conformance with the Drawings and Specifications and shall be able to control, monitor, and record as follows:
1. Monitoring and Recording Filter effluent turbidity, ntu – Combined filter effluent turbidity Flow, gpm or mgd Filter Run, hours Percentage Open on Effluent Valve Head loss, feet Total Water Filtered per filter run Backwash flow rate, gpm Backwash duration, minutes
Backwash totalizer, gallons Air scour duration 2. Operator Adjustable Controls Set point for high level alarm on filter effluent turbidity. Backwash rate Backwash manual/auto Backwash duration Air scour duration Set point for head loss alarm
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Set point for effluent valve open percentage alarm Filter effluent rate, gpm Filter level, and high level/low level alarm Filter hours before backwash Set point (ntu) for stopping filter to waste Time out period for not meeting required turbidity when wasting after a
backwash 3. Display (in addition to those items listed under monitoring/recording) Filtration/backwash/out of service status Influent valve open closed Backwash valve open/closed Air Wash Blower manual/auto, run/alarm status Air wash valve open/closed Waste valve open/closed Filter to waste valve open/closed 4. See additional instrumentation and control requirements in Section
17350 and on the I/O table in the Contract Drawings. PART 3 EXECUTION 3.01 DELIVERY, STORAGE AND HANDLING
A. Filter Underdrain
1. Delivery, storage, and handling shall be in accordance with Section 01600.
B. Filter Media
1. Delivery, storage, and handling shall be in accordance with Section
01600.
2. Filter media is shipped in either bulk form or bagged, depending upon the equipment available for installing it, the quantity to be furnished, and the CONTRACTOR'S preferred method of handling.
3. If shipped in bulk form and stored at the job site, the media should be
placed on a hard surface which has been covered with polyethylene, preventing contamination of the material. The pile of bulk material should also be covered to prevent contamination. This protective covering should be well secured to prevent excessive losses of material caused by the wind. Also, the protective covering should be periodically checked for any deterioration caused by the weather. (Black polyethylene has been shown to be more resistant to deterioration caused by the sun's rays than clear polyethylene.)
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4. If bagged media is stored at the job site for long periods of time (over three months), sunlight will deteriorate the polyethylene bags to the extent that they become brittle and crack, particularly at the seams. Therefore, bagged media which is stored at the job site should be covered with a sun-shielding material such as black polyethylene or tarpaulin. This protective covering should also be periodically checked for possible deterioration caused by the weather.
5. Boxed media is shipped to the job site in cardboard containers lined with
polyethylene. If these containers are stored on the job site, they must be placed in a waterproof location. Such protection can be provided by placing polyethylene both under and over the boxes. The waterproof, protective covering should be well secured and periodically checked for any deterioration caused by the weather.
C. Air Backwash Distribution Grid 1. Delivery, storage, and handling shall be in accordance with Section
01600. 3.02 INSTALLATION
A. Dual Parallel Lateral Type Underdrain Systems
1. The system shall be installed completely in accordance with the specifi-cations of the manufacturer, and under the direction of an experienced superintendent provided by the manufacturer. The cost of such supervi-sion shall be included in the CONTRACTOR'S bid price for the underdrain system installed.
2. Any conflict with these Drawings and Specifications and the manufac-
turer's recommendations shall be resolved in writing prior to doing any installation work.
B. Sequential Air/Water Backwash 1. Floor Preparation a. Care shall be exercised in preparing the filter floor slab and in
setting the anchors to assure proper alignment and elevation. Steel anchor rods shall be furnished by the filter manufacturer and set in the floor slab on both sides of the distribution flume in accordance with the drawing provided. The floor slab shall be screeded into a flat level plane and be free of protrusions and depressions as recommended by the filter system supplier. After the anchor rods have been installed all anchor rods shall undergo a nondestructive pullout test according to the underdrain manufacturer’s instructions. Any anchor rods which fail the test shall be reinstalled and retested.
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2. Underdrain Lateral Installation a. The underdrain laterals shall be set in relatively level rows on a
bed of grout over the filter floor slab. Plates for closing the ends of each row of blocks shall be furnished by the filter manufacturer and installed by the CONTRACTOR. After joining, aligning and setting the blocks, and the bed grout is setup, as soon as possible, all spaces between the rows of block and walls shall be filled with grout so that the entire bed is totally sealed and held firmly in place. Anchor rods and related block anchors shall be installed according to the manufacturer’s instructions.
3. Cleaning and Protection During Installation, Testing, and Startup a. The CONTRACTOR shall take all precautions recommended by the
underdrain manufacturer or specified herein to ensure that the filter underdrain system and any piping communicating therewith is completely clean and free of any debris, dirt, or other foreign materials which could clog the underdrain system or interfere with flow. Backwash air and water piping shall be thoroughly flushed clean. All loose debris and dirt within the filter cell and flume shall be removed by brooming down and vacuuming. Care shall be taken to keep grout from being deposited anywhere where it could interfere with flow. Any grout so deposited shall be removed. As installation progresses, partially completed portions of the Work shall be protected with heavy visqueen or other suitable material to maintain the cleanliness of the underdrain system. Such protection shall be maintained until the support gravel is installed.
b. Any time the underdrain laterals are to be used as a work surface,
the underdrain block shall be overlaid with 1/2-inch minimum plywood sheeting where necessary, to distribute the load of yard buckets, wheel barrows, ladders, scaffolds, etc., to prevent damage to the underdrain.
4. Checking Underdrain Installation a. After the bottom has been completely set and grouted, it shall be
carefully checked and inspected to see that all holes in the tops of the blocks are open, that all water channels are clear, that all grout has been placed around the blocks, and that the keyways between the ends of the blocks are sealed with good mortar.
b. The filter bottom shall be allowed to stand at least 3 days before
turning full wash water pressure into the underdrain system. c. Sufficient water, however, may be put slowly through the system to
make sure the system is properly sealed and all water passages open.
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d. The filter is now ready for placing of the gravel and sand. If this, however, is not done immediately, then the bottom shall be protected against subsequent construction damage. A plastic sheet over the entire bottom will prevent dirt from entering the holes and will eliminate additional cleaning before placement of the gravel.
C. Placing Media in Water Filters
1. General a. No filter media is to be placed prior to the underdrain system
being completely installed, thoroughly cleaned, tested and ap-proved by the ENGINEER.
b. Workmen placing media in the filter must work from wide boards
to distribute their weight and preclude derangement of media already in place.
c. Prior to start of placing media, layers or gradation depths, as
shown on the Drawings, shall be measured and marked on the filter walls or one wall may be marked and water used as the level indicator.
2. Filter Media Installation a. The filter box and underdrain shall be thoroughly cleaned before
starting media placement. Materials shall be handled to keep them clean during the placement, and any materials becoming dirty shall be removed and replaced. Gravel and filter media installation shall be under technical direction of the filter bed manufacturer.
b. The bottom gravel layer shall be placed carefully by hand to avoid
movement to the underdrain system and to assure free passage for water from the orifices. Each layer shall be completed before the next layer above is started. For materials less than 1/2 inch in diameter, the worker shall not stand or walk directly upon the gravel but shall walk upon boards which will sustain the weight of the workmen without displacing the gravel. Any gravel becoming mixed shall be removed and replaced in layers as herein specified. Backwashing of the gravel shall be utilized at the discretion of the manufacturer to remove dirt, dust or fines accumulations. The correct thickness of each layer for sizes 1/2 inch or larger shall be obtained as follows: Before the gravel is placed, the top of each layer shall be marked on the side of the filter. The top of each layer shall then be leveled against a water surface held at the appropriate mark. None of the particles shall be less than half submerged, and there shall be no places where additional gravel can be placed without the particles extending more than one-half
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their volume above the water surface. For sizes less than 1/2 inch, the gravel shall be leveled to ± 1/4 inch of the water surface.
c. Media shall be placed in a manner similar to the gravel placement
and processed as may be required to achieve the gradation recommended by the manufacturer.
3. Placing of Gravel a. The proper depths for each layer of media should be carefully
marked off on one wall of the filter. The large gravel must be lowered into the filter and placed by hand to prevent breaking. the bottom gravel layer is spread to approximately the correct depth, and then the filter is filled with water up to the mark indicating the top of the layer. The gravel is then carefully leveled to conform with the surface of the water.
b. This procedure is repeated with each of the remaining gravel
layers. Workmen should stand on support platforms when smoothing the gravel so as not to depress the layers with their feet.
c. Backwash the gravel prior to placing the Turbisand to remove any
debris, etc.
4. Installation of Sand a. Fill the filter with water from the backwash line to approximately 6
to 9 inches above the top of the underdrain. The 8 inches of sand is poured into the water. No leveling is necessary, as the backwash will spread and level the surface. After leveling, the top of the sand should be approximately 1 inch above the desired elevation. The filter should be backwashed a minimum of 25 minutes at 20 gpm/S.F. After the final backwash, the filter should be drained and the top level of sand shall be skimmed and discarded. In spite of the care taken in screening and handling sand, some fines and trash invariably occur. The remaining 12 inches of sand shall be installed by the same procedure, i.e., adding 8 inches initially, backwashing, and skimming and discarding the top, leaving an overall sand depth of 12 inches.
b. If it is necessary to add additional sand to bring the bed up to the
desired mark, the filter should be slowly refilled, backwashed and the fines skimmed again.
CAUTION: REFILLING AN EMPTY FILTER TOO RAPIDLY AFTER THE
SAND OR ANTHRACITE IS PLACED CAN CAUSE AIR TO BE TRAPPED IN THE GRAVEL LAYER AND SEVERE DIS-TURBANCE OF THE GRAVEL CAN OCCUR. FILL THE FILTER
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VERY SLOWLY WITH THE BACKWASH LINE TO ALLOW THE TRAPPED AIR TO ESCAPE THROUGH THE MEDIA.
5. Installation of Anthracite
a. The anthracite should be placed with the filter partially filled with
water. Place the anthracite to approximately 1-1/2 inches above the mark, and slowly fill the filter and backwash at a 15 to 20 gpm/S.F. rise rate until the water becomes clear. Approximately 5 to 10 percent of the anthracite will be lost as fines. After drain-ing, the top 1/2 inch of the anthracite should be skimmed with a shovel to remove fines and trash. (Remember to use support plat-forms for workmen.) Additional anthracite should be added as necessary to bring the media up to the desired depth.
b. The filter should be slowly refilled with the backwash line, back-
washed and the fines skimmed again.
c. The installation of the filter media is now complete, and the filter is ready for disinfection as required.
3.03 TESTING A. Underdrain/Air Scour Grid 1. The specific tests to be performed will be developed by the underdrain
manufacturer and be subject to approval by the ENGINEER. Test procedures shall be submitted to the ENGINEER for approval with submittal drawings. Tests will be scheduled with the ENGINEER at least 2 weeks prior to the planned test date.
2. After the filter underdrain system has been installed, and before the filter
media is put into the filter, the filter underdrain system shall be tested for uniform air scour distribution and combined air scour water backwash distribution. Air distribution shall be uniform over the entire range of operation. The test shall be witnessed and certified by the underdrain manufacturer’s field service representative on a form having the company’s letterhead on it.
3. The field service representative shall submit to the ENGINEER a written
report stating that the filter underdrain systems have been checked and are suitable for operation.
4. Inspection by a representative of the underdrain manufacturer who is not
a direct, full-time employee of the manufacturer is not acceptable. 5. All equipment necessary for running the tests, including air flow rate,
etc., shall be supplied by the CONTRACTOR.
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B. Complete Filter System 1. The complete filter system shall be tested for proper operation for both
the filter and backwash cycle. 2. In the filtering cycle the influent and effluent turbidity shall be
continuously monitored via the installed instrumentation on a 15-minute basis for 24 hours. The filter shall continuously provide a maximum of 0.3 NTU in the effluent and normally be 0.15 NTU in the effluent, assuming a filter influent turbidity of 2 NTU or less. Failure to meet this limit shall be cause for rejection of any or all components of the system.
3. Backwash Performance a. The provisions of a backwash system that maintains the filter
media in a clean condition and minimizes mud ball formation and surface cracking are essential to maintaining a high quality effluent. Additionally, the backwash system must be designed to that filter media is not lost during the backwash cycle to the extent continued media replacement will be required.
b. The filtration system provided by the CONTRACTOR shall be
capable of cleaning the filter media so that no more than 3.0 mg of foreign or contaminating solids/gram of filter media shall be observed during an abrasion test run on a core sample of filter media taken immediately following backwashing. The abrasion test procedure shall be as follows:
(1) Backwash the filter using the procedure recommended by
the filter equipment manufacturer. (2) During the last 1 or 2 minutes of the backwash operation,
collect samples of the media in a vertical core throughout the full bed depth at up to 3 points located 1 to 2 feet inside and near the midpoint of a cell wall.
(3) Let water drain from the core sample for 1 to 2 minutes
without additional disturbance. (4) Place the media from all core samples obtained in Step 2
above into a large container and mix the media gently to provide a homogenous mixture.
(5) Place 0.25 to 0.5 liter of the mixture of core samples into a
1-liter plastic or glass bottle (One-quart Mason jars with flat lids are suitable for this purpose.)
(6) Fill the bottle to within 1 inch to the top with clean water.
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(7) Place the cap on the bottle and agitate by shaking the bottle for 2 minutes using about 2 to 3 forward and backward motions per second.
(8) Let the media settle in the bottle for 1 minute and decant
the supernatant liquid into a clean container. (9) Repeat steps 6, 7, and 8 two more times, or until the media
is clean. (10) Measure the volume of decanted liquid and measure its
suspended solids (SS) concentration by the glass fiber filter method as described in Standard Methods for the Examination of Water and Wastewater, 16 Edition.
(11) Dry all the media from step 5 at 103 to 110 degrees
centigrade to a constant weight. (12) Calculate solids retention in the filter as follows: A = (mg/l SS, dry weight, in supernatant liquid) x
(liters volume of supernatant liquid obtained in steps 6-9)
B = grams, dry weight, of media in bottle in step 5 A/B = mg solids/gram media 4. All equipment necessary for running the tests, including air flow rate,
etc., shall be supplied by the CONTRACTOR. 3.04 DISINFECTION A. Upon completion of the work and cleaning up, and prior to final acceptance, the
CONTRACTOR shall disinfect all filters constructed which are to handle treated water.
B. Prior to starting disinfection, all filters must be thoroughly cleaned to remove
dirt, etc. Disinfection will then be accomplished by the adding of a chlorine solution while filling the filter to obtain the initial 50 ppm of chlorine. The CONTRACTOR shall supply all equipment, labor, etc., necessary for flushing and disinfecting the mains. The CONTRACTOR shall submit, in writing, to the ENGINEER, the method he proposes to use for adding the chlorine.
C. The calcium hypochlorite granule or tablet method shall not be used. D. Disinfection shall be accomplished by filling the filters with water having a
chlorine content of at least 50 parts per million and at the end of a 24-hour contact time a residual of at least 25 parts per million shall remain. At the end of the 24-hour contact period, all the sterilized surfaces and areas shall be
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thoroughly flushed from the water system. Chlorinated water shall be disposed of in accordance with 401 KAR 5:031 and 8:020, which state that the allowable in stream concentration of chlorine is 10 ug/l, which is equal to 0.01 mg/l. The CONTRACTOR shall submit, in writing to the ENGINEER, the method he proposes for dechlorinating. Recommended chemicals, as given in AWWA C651, are sulfur dioxide, sodium bisulfite, sodium sulfate, and sodium thiosulfate.
E. For tie-ins to an existing system such has tapping valves where keeping the
main out of service would restrict service to existing customers, disinfection shall, at the ENGINEER’S discretion, consist of thoroughly cleaning the new part with a solution containing not less than 200 mg/l (ppm) chlorine.
F. After initial disinfection and flushing, the OWNER will collect water samples for
bacteriological testing. A new filter shall not be placed in service until negative laboratory results are obtained on the bacteriological analyses. Sample bottles shall be clearly identified as “special” construction tests. If any of the samples are found to be positive or contain confluent growth, the CONTRACTOR shall repeat the disinfection procedure until the required numbers of negative samples are obtained.
3.05 START-UP AND TRAINING
A. Start-up and training shall be in accordance with Section 01600.
B. All items specified under this section must be furnished by a single supplier who will also provide technical direction of installation and plant start-up service and operator training. Such technical direction and operator instruction must be performed by highly skilled personnel who are specialists in the high-rate filtration concept and are direct full-time employees of the filter equipment manufacturer.
C. The underdrain manufacturer shall supply a factory-trained field service
representative to inspect the installation of the filter underdrain/air scour grid. In addition, the field service representative shall instruct the OWNER’S personnel in the proper operation and maintenance of the filter underdrain/air scour grid. As a minimum, the manufacturer’s field service representative must be available for 4 days of service in 2 separate trips. The training shall include a 6-month review of plant operation by correspondence and/or phone and monthly written reports which shall include recommendations for optimizing plant performance.
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3.06 TOOLS AND SPARE PARTS
A. All special tools required for normal operation and maintenance shall be furnished by the equipment manufacturer.
END OF SECTION
***
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SECTION 15010 BASIC MECHANICAL MATERIALS AND METHODS PART 1 GENERAL 1.01 WORK INCLUDED
A. Furnish all labor, materials, equipment and incidentals necessary to provide complete and operational mechanical systems as shown on the Drawings and as specified herein.
B. Installation of equipment that has not been specifically detailed in the Drawings
shall be installed per that equipment manufacturer's recommended installation instructions or industry Standard Methods. All hardware and materials required for said equipment installation shall be included in the bid price.
C. Demolition shall be as shown on the Drawings and shall be in accordance with
the requirements of Division 2. Where HVAC equipment is removed, controls and power (conduit and wiring) shall also be removed and surfaces shall be repaired and painted to match existing surrounding conditions. Actual holes in the roof and walls, from the removal of equipment and accessories, shall be repaired and surfaced to match the existing surrounding construction.
D. Reference the “General Mechanical Notes” that are applicable to all HVAC work
in the Contract Drawings for additional requirements. 1.02 RELATED WORK
A. The following work incidental to the Mechanical System work shall be done under other Sections of the Specifications.
1. Cutting and patching are included in Divisions 3 and 4.
2. Concrete work, including equipment pads, is included in Division 3.
3. Electric work (except as herein specified) is included in Division 16.
4. Field painting is included in Division 9, Section 09900.
5. Firestopping is addressed in Division 7, Section 07840.
1.03 PROTECTION OF MATERIALS, WORKS AND GROUNDS
A. Materials, fixtures, and equipment shall be properly protected and all pipe openings shall be temporarily closed so as to prevent obstruction and damage.
B. Protect and preserve all materials, supplies and equipment of every description
and all work performed. Damages shall be repaired or replaced promptly at no additional cost to the OWNER.
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1.04 CLEANING
A. During the progress of the work, clean up and remove all oil, grease and other debris. At completion, clean all equipment, piping and duct systems, remove all stickers, non-permanent tags, and leave all work in perfect operating condition.
1.05 DRAWINGS
A. All work shown on the Drawings is intended to be approximately correct to scale, but figures dimensions and detailed drawings are to be followed in every case. The Drawings shall be taken in a sense as diagrammatic. Size of pipes and methods of running them are shown, but it is not intended to show every offset and fitting, nor every structural difficulty that may be encountered. To carry out the true intent and purpose of the Drawings, all necessary parts to make complete working systems ready for use shall be furnished without extra charge. All work shall be installed in such a manner to avoid being unsightly.
B. Locations shown on the Drawings are approximate, and it is intended that all
equipment shall be located in accordance with the general and detail Drawings of the construction proper. All measurements shall be taken at the site.
1.06 REFERENCES
A. Kentucky Building Code
B. Kentucky State Plumbing Law, Regulations and Code
C. Standards for Gas Piping on Customer's Premises, Columbia Gas Distribution Companies
D. Kentucky Regulation, 803 KAR 2:200, Confined Space Entry
E. International Mechanical Code
F. Kentucky Boiler and Pressure Vessel and Pressure Piping Law Rules and Regula-
tions
G. ASHRAE, American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc.
H. International Fire Code I. International Energy Conservation Code
1.07 CODES, ORDINANCES AND PERMITS
A. The minimum standard for all work shall be the latest revision of the Kentucky Building Code (KBC), and the National Electrical Code (NEC). Whenever and wherever state laws and/or regulations and/or the ARCHITECT/ENGINEER'S
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design requires a higher standard than the current NEC or KBC, then these laws and/or regulations and/or the design shall be followed.
B. Following is a list of applicable Standards or Codes:
Organization/Code/Standard Abbreviated Title
1. International Mechanical Code IMC 2. Kentucky Building Code KBC 3. National Electrical Code NEC 4. National Electrical Safety Code NESC 5. Underwriters Laboratories, Inc. UL 6. Factory Mutual System FM 7. National Fire Protection Association NFPA 8. National Electrical Manufacturers Association NEMA 9. Occupational Safety and Health
Administration OSHA 10. Instrument Society of America ISA 11. American National Standards Institute, Inc. ANSI 12. Anti-Friction Bearing Manufacturers
Association, Inc. AFBMA 13. American Society of Heating, Refrigera-
ting and Air Conditioning Engineers, Inc. ASHRAE 14. Kentucky Boiler Law 15. Sheet Metal and Air Conditioning
Contractors National Association, Inc. SMACNA 16. International Fire Code IFC 17. International Energy Conservation Code IECC
C. Obtain all required permits, pay all legal fees for the same, and in general, take complete charge and responsibility for all legal requirements pertaining to this Section of the work.
1.08 FEES
A. CONTRACTOR shall be responsible for all fees for connecting natural gas, water, and sewer to construction project unless otherwise noted.
1.09 LABELING
A. All mechanical equipment and items utilizing electrical components shall be UL listed for the application, where a listing exists.
1.10 COOPERATION WITH OTHER TRADES
A. The work shall be so performed that the progress of the entire building construction including all other trades, shall not be delayed nor interfered with. Materials and apparatus shall be installed promptly when and as desired.
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B. Confer with all other trades relative to location of all apparatus and equipment to be installed and select locations so as not to conflict with work of other Sections. Refer to the General Conditions for Dispute Resolution Requirements. All work and materials placed in violation of this clause shall be readjusted to the ARCHITECT/ENGINEER'S satisfaction at no expense to the OWNER.
C. Where work of this Section will be installed in close proximity to work of other
Sections or where there is evidence that the work of this Section will interfere with work of other Sections, assist in working out space conditions to make satisfactory adjustment. If so directed, prepare and submit for approval 3/8-inch scale or larger working drawings and sections, clearly showing how this work is to be installed in relation to the work of other Sections. If the work of this Section is installed before coordinating with other trades or so as to cause interference with work of other trades, make changes necessary to correct conditions without extra charge.
1.11 REVIEW OF MATERIALS
A. Submit to the ARCHITECT/ENGINEER for review within 90 days after award of contract a complete list of materials and equipment to be incorporated in the work, together with the name and addresses of the manufacturer's and their catalog numbers and trade names.
B. The CONTRACTOR is not allowed to substitute manufacturers listed in the Form
of Proposal after the bid is accepted. 1.12 SUBMITTALS
A. Submit to the ARCHITECT/ENGINEER for review, as provided in the General Conditions, the manufacturer's shop drawings and technical literature covering details and installation of all new equipment, fixtures, and accessories being furnished under this Section prior to fabrication, assembly, or shipment.
B. Shop drawings will be required on the following materials as applicable to this
Project:
1. Hangers and Supports - all types and sizes. 2. Insulation - all types for piping, ductwork, etc. 3. Markers and Tags. 4. Piping, Valves, Pumps. 5. Hydronic Specialties. 6. Steam Specialties. 7. Condensate Pumps. *8. Boilers. *9. Refrigerant Specialties. *10. Chemical Feed Equipment and Chemicals. *11. Louvers and Ventilators. *12. Chillers. *13. Cooling Towers. *14. Power Ventilators and Fans.
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*15. Unit Heaters. *16. Air Handlers. *17. Air Conditioners, Furnaces, Heat Pumps. *18. Refrigerant Leak Detection Unit. *19. Heat Pumps. *20. Unit Ventilators and PTAC units. *21. HVAC Control Devices and Systems. 22. Training Outline. 23. Control Systems. 24. Duct Work.
* - A complete wiring diagram that relates specifically to this contract shall
be included with submittal.
C. Shop drawings shall be submitted only after the CONTRACTOR has checked and verified all field measurements, quantities, equipment dimensions, specified performance criteria, installation requirements, electrical requirements, materials, catalog numbers, and similar data with respect thereto and reviewed or coordinated each shop drawing with the requirements of the work and the Contract Documents.
D. At the time of each submission the CONTRACTOR shall give the ARCHITECT/
ENGINEER specific written notice of each variation that the shop drawings may have from the requirements of the Contract Documents.
E. The shop drawings shall have a stamp or specific written indication that
CONTRACTOR has satisfied the requirements stated herein before. Shop drawings submitted without the CONTRACTOR's review and stamp shall be immediately returned to the CONTRACTOR without the ARCHITECT/ENGINEER's review.
1.13 OPERATING AND MAINTENANCE MANUALS
A. Four sets of O&M instructions and manuals shall be submitted in loose-leaf 3-ring cardboard reinforced vinyl binders to the ARCHITECT/ENGINEER in accordance with the General Conditions.
B. Contained in each binder shall also be vendors, vendor phone numbers and
addresses, list of materials, manufacturer’s or vendor’s web site, and materials parts list. Also included for each item shall be a copy of the approved shop drawing.
C. The CONTRACTOR shall fill out the warranty card information (complete) for
each and every piece of HVAC equipment and include a copy in each O&M manual.
D. The O&M manual shall include each and every piece of HVAC equipment and
accessories that a shop drawing was submitted on.
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1.14 POWER SUPPLY
A. Refer to Division 16 (except as noted herein). 1.15 SITE VISIT
A. It shall be the responsibility of the bidder to visit the site before submitting his bid, and thoroughly note the conditions under which the work will be installed. No extra compensation will be later allowed for necessary work not figured that should have been foreseen.
1.16 REMOVAL OF EXISTING EQUIPMENT
A. De-energize, remove and dispose off the site, the existing fans, pipes, pumps, unit heaters, tanks, ductwork, and all existing equipment shown except as noted on Drawings. This demolition work must be planned and scheduled so as not to leave the existing building unconditioned.
1.17 OPERATIONAL TEST A. After the various systems are completed and at which time the ARCHITECT/
ENGINEER shall deem appropriate, the CONTRACTOR shall run an operation test for each system. The CONTRACTOR shall adjust all valves, equipment, controls and accessories so as to obtain maximum operating efficiency. Failure of any component to perform as specified shall constitute cause for rejection and removal.
B. Some specific equipment may be noted to have the startup and checkout
performed by an authorized representative of the manufacturer and a report submitted to the ENGINEER.
1.18 NOISE AND VIBRATION
A. Install vibration isolators, flexible connectors, expansion joints, and other safety measures to prevent noise and vibration from being transmitted to occupied areas. Equipment shall be selected to operate within the noise level recommended for the particular type installation in relation to its location.
B. Following installation, make proper adjustments to eliminate excessive noise
and vibration. 1.19 CUTTING AND PATCHING
A. Cutting and patching shall be held to an absolute minimum, and such work shall be done only under the direction of the ARCHITECT/ENGINEER or OWNER. The CONTRACTOR shall be responsible for and pay for all openings that may be required in the walls, floors, and roofs, and shall be responsible for putting said walls, floors, and roofs back in their original condition.
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1.20 OWNER TRAINING
A. The CONTRACTOR supplying equipment for this division shall provide the OWNER's operations staff with training in the operation and maintenance on the equipment being furnished. The training shall be conducted at the project site by a qualified representative of the manufacturer.
B. The cost of this training shall be included in the bid price.
C. The required training shall consist of both classroom and hands-on situation.
Classroom training shall include instruction on how the equipment works, its relationship to all accessories and other related units, detailed review of shop drawings, detailed presentation of written O&M instructions, troubleshooting and record-keeping recommendations. Hands-on training shall include a review of the manufacturer's O&M instructions, check out of each operator to identify-ing key elements of the equipment, tear down as appropriate, calibration, adjustment, greasing and oiling points, and operating manipulations of all electrical and mechanical controls.
D. The training shall be scheduled through the CONTRACTOR with the OWNER. The
timing of the training shall closely coincide with the startup of the equipment, but no training shall be conducted until the equipment is operational.
E. The minimum number of training hours to be provided by manufacturers
supplying equipment on this project shall be in accordance with the following table as applicable to this Project:
Minimum Training Hours* Item Classroom Hands-on
Boiler/Chiller (each) 2 2 Heat Pumps/Air Conditioners 2 2
Energy Management System 2 2 HVAC Controls 2 2 Sprinkler System 1 2 Fans/Louver Dampers/Unit Heaters 2 2
* or until the OWNER is fully satisfied.
F. At least 30 days prior to the training the manufacturer shall submit through the
CONTRACTOR to the ENGINEER an outline of the training proposed for the ENGINEER's review and concurrence. The OWNER reserves the right to videotape all training sessions.
1.21 RECORD DRAWINGS
A. The CONTRACTOR shall maintain 1 set of the Contract Drawings on the job in good condition for examination at all times. The CONTRACTOR's qualified representative shall enter upon these drawings, from day to day, the actual "as-built" record of construction and/or alteration progress with regards to HVAC,
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plumbing, and fire protection. Entries and notes shall be made in a neat and legible manner and these drawings delivered to the ARCHITECT/ENGINEER after completion of the construction, for use in preparation of Record Drawings.
1.22 WARRANTY
A. The CONTRACTOR shall guarantee all work including equipment, materials, and workmanship. This guarantee shall be against all defects of any of the above and shall start from the date of project substantial completion and continue for a minimum of 1 year. All compressors for heat pump or air conditioning equipment, as a baseline standard, shall have an additional 4-year parts only warranty beyond the CONTRACTOR’S 1-year parts and labor warranty for all equipment. Other items listed throughout Division 15 may have longer warranty requirements - see individual equipment specifications.
B. Repair and maintenance for the guarantee period is the responsibility of the
CONTRACTOR and shall include all repairs and maintenance other than that which is considered as routine. (That is replacement of filters, oiling, greasing, etc.) The ENGINEER shall be the judge of what shall be considered routine maintenance.
C. See General Conditions for additional requirements.
END OF SECTION
***
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SECTION 15060
NON-METALLIC STRUT, PIPE HANGERS AND SUPPORT SYSTEMS PART 1 GENERAL 1.01 SECTION INCLUDES A. The work covered under this section consists of furnishing all necessary labor,
supervision, materials, equipment, and services to completely execute the non-metallic support system for piping and other components as detailed in the drawings, and described in this specification.
B. Continuous slot, fiberglass framing channels and all associated fittings and
hardware. C. Trapeze type supports for pipe, conduit, and other similar systems.
NOTE: Non-metallic hangers and supports have requirements in addition to standard metal materials. For general work details, such as support spacing and placement, etc., not specifically covered by this section, reference section 15140- Pipe Hangers and Supports.
1.02 REFERENCES A. ASTM A167- Standard specification for Stainless and Chromium-Nickel steel
plate, sheet and strip. B. ASTM D4385 – Standard Practice for Classifying Visual Defects in Thermosetting
Reinforced Plastic Pultruded Products. C. ASTM D635 – Standard Test Method for Rate of Burning and/or Extent and Time
of Burning of Plastics in a Horizontal Position. D. ASTM E84 - Test method for Surface Burning Characteristics of Building
Materials. E. ASTM F569 – Standard Specification for Stainless Steel Bolts, Hex Cap Screws,
and Studs. F. AISI – American Iron and Steel Institute G. UL94 - Tests for Flammability of Plastic Materials for Parts in Devices and
Appliances. H. MSS SP-69 - Manufacturers Standardization Society: Pipe Hangers and Supports-
Selection and Application
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1.03 QUALITY ASSURANCE A. The manufacturer shall be regularly engaged in supplying non-metallic support
systems for the types required, and whose products have been in satisfactory use in similar service.
B. The manufacturers name and part number shall be marked on all FRP framing
channels. The product should be color-coded or otherwise indicate the material type.
1.04 SUBMITTALS A. Submit product data and test methods for non-metallic support systems. Data
to include, but not limited to: Material, load ratings and temperature ranges, corrosion resistance, approvals, flame and smoke ratings, and dimensional information.
1.05 DELIVERY, STORAGE, AND HANDLING A. Deliver material carefully to avoid breakage and scoring finishes. Do not install
damaged equipment. B. Store material in original cartons and in clean dry space; protect from
construction traffic. 1.06 DESCRIPTION A. Only non-metallic pipe hangers and supports shall be used in the new chemical
area of the operations building. Only hardware may be metal and they must be 316 stainless steel.
PART 2 PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. Subject to compliance with these specifications, the non-metallic strut, pipe
hangers and supports shall be as manufactured by Cooper B-Line, Inc., Aickinstrut, or equal.
2.02 GENERAL A. Materials - The materials to be used are as follows: 1. Polyester resin fiberglass: Fiber reinforced fire retardant polyester
thermosetting resin. Material shall have a maximum Flame Spread Index rating of 25 in accordance with ASTM E84; flammability shall meet UL 94 VO and shall conform to the self-extinguishing requirements of ASTM D635.
2. Vinyl ester resin fiberglass: Fiber reinforced fire retardant vinyl ester
thermosetting resin. Material shall have a maximum Flame Spread Index
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rating of 25 in accordance with ASTM E84, flammability shall meet UL 94 VO and shall conform to the self-extinguishing requirements of ASTM D635.
3. Glass reinforced polyurethane: Fiber reinforced fire retardant
polyurethane thermoplastic resin, 40% glass reinforced. 4. Stainless steel: AISI type 316 meeting the requirements of ASTM A167. B. Ultraviolet resistance: All materials shall have means of providing UV resistance. 2.03 PIPE HANGERS A. Clevis hangers shall be glass-reinforced polyurethane, B-Line BFP3104, for
support of piping up to 6 inches. Clevis hangers shall be glass reinforced polyester or vinyl ester for support of piping from 8 inch to 12 inch. Provide insulation for hot piping to limit the surface temperature at the hanger to 120 F.
2.04 STRUT CHANNELS AND TRAPEZE SUPPORTS A. All strut channels shall be polyester or vinyl ester resin as appropriate for the
fluid in the area, manufactured by the pultrusion process. The reinforcing material shall consist of unidirectional roving, continuous mat and special spun roving in the channel lips for additional pull out strength. All surfaces shall have a synthetic surface veil to ensure a UV resistant resin rich surface.
B. Strut shall be designed to accept both non-metallic or stainless steel hardware
and accessories. C. Strut shall conform to the requirements of ASTM D4385 for Levels III and IV. D. Strut shall be 1-5/8” wide in varying heights, combinations and contain hole
patterns as required to meet load capacities and designs indicated on the drawings.
E. The manufacturers name and part number shall be marked on the strut to
indicate the product series and material used. 2.05 STRUT FITTINGS AND ACCESSORIES A. Molded strut fittings shall be glass-reinforced polyurethane. B. Non-metallic pipe clamps shall be glass-reinforced PPO with type 316 stainless
steel hardware, B-Line BFV2000 series or equal. Include additional stop-lock kit for vertical applications.
C. Two-hole pipe clamps shall be glass reinforced polyester, B-Line BFP-2400 series
or equal. D. Non-metallic U-Bolts shall be glass reinforced polyurethane, B-Line BFV501 or
equal.
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E. Channel nuts shall be glass-reinforced polyurethane or 316 stainless steel as
appropriate, B-Line BFV-228 [N228-SS6L] for 3/8-inch hardware, BFV-225 [N225-SS6L] for ½ inch hardware.
F. All threaded hardware shall be type 316 stainless steel or glass reinforced
polyurethane as appropriate. Note manufacturers recommended torque for mating hardware (such as non-metallic channel nuts).
2.06 BRACKETS A. Strut brackets shall be polyester or vinyl ester resin, as appropriate for the
conditions, fiberglass with type 316 stainless steel rivets, B-Line BF*-409 or BF*-494 series.
2.07 BEAM CLAMPS A. Beam clamps shall be glass reinforced polyurethane. Setscrew shall be 316
stainless steel meeting the requirements of ASTM F593 Group 2, S4. 2.08 CONTINUOUS CONCRETE INSERTS A. Concrete inserts shall be polyester or vinyl ester fiberglass manufactured by the
pultrusion process. B-Line series BF*-22I or equal. Inserts shall be provided with removable Styrofoam insert.
PART 3 EXECUTION 3.01 FIELD CUTTING AND DRILLING A. Repair all field cuts with resin to seal all exposed fibers, B-Line brush on acrylic
resin RSK-010. Exposed fibers absorb moisture and will accelerate the deterioration of the material.
NOTE: Appropriate protective clothing and respiratory protection should be worn when
field cutting or grinding fiberglass. 3.02 HARDWARE TORQUE A. Follow manufacturers torque requirements for any non-metallic hardware,
noting that the recommended torque is significantly less than the torque for steel hardware.
B. When bolting through the side of strut channels, provide a spacer to prevent
wall compression, B-Line BFPUC650. 3.03 SUPPORT SPACING A. Support spacing for strut trapezes or single rod hangers shall be calculated for
each assembly. The load rating for each assembly is based on the lowest rated component: upper attachment, rod, nuts, hanger, or other components.
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B. Spacing shall not exceed maximum recommended support spacing for piping.
Contact pipe manufacturer for maximum hanger spacing for non-metallic piping. Metal pipe hanger spacing is given in the Manufacturers Standardization Society SP-69, Table 3.
C. Beam loading for strut trapezes shall conform to manufacturers published load
data for the operating temperature. Consideration for deflection shall be given. NOTE: The strength and corrosion resistance of non-metallic materials are temperature
sensitive. Please note the temperature ranges of the areas that the supports are to be installed.
END OF SECTION
***
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SECTION 15100
SMALL PLUMBING VALVES, PLUMBING SPECIALTIES AND SERVICE ACCESSORIES
PART 1 GENERAL 1.01 WORK INCLUDED
A. Furnish all labor, materials, equipment, and incidentals required and install complete and ready for operation all valves and appurtenances as shown on the Drawings and as specified herein.
1.02 RELATED WORK
A. Large Valves and Appurtenances are included in this Division, Sections 15102 and 15104.
B. Mechanical Identification Markers, Tags and Plates are included in this Division,
Section 15190. C. Excavation, Backfill and Grading are included in Division 2.
D. Plumbing Piping and Fittings are included in Division 2.
E. Instrumentation is included in Division 13.
F. Electrical is included in Division 16.
G. Plumbing Piping Insulation is included in this Division, Section 15260.
H. Pipe Hangers and Supports are included in this Division, Section 15140. I. Plastic Valves are included in Section 15230.
1.03 SYSTEM DESCRIPTION
A. All of the equipment and materials specified herein is intended to be standard for use in controlling the flow of wastewater, sludges, water, or air, depending on the applications.
1.04 QUALITY ASSURANCE
A. All of the types of valves and appurtenances shall be products of well estab-lished firms who are fully experienced, reputable and qualified in the manufac-ture of the particular equipment to be furnished. All materials of construction shall be of an acceptable type and shall be designated for the pressure and temperatures at which they are to be operated, for the materials they are to handle and for the use for which they are intended. The materials shall meet established technical standards of quality and strength necessary to assure safe
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installations and conform to applicable standards. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these Specifications as applicable.
1.05 REFERENCES
A. Kentucky Building Code.
B. Kentucky State Plumbing Law, Regulations and Code.
C. Standards for Gas Piping on Customers' Premises, Columbia Gas Distribution Companies.
1.06 SUBMITTALS
A. Copies of all materials required to establish compliance with these Specifica-tions shall be submitted in accordance with the provisions of the General Conditions. Submittals shall include at least the following:
1. Certified drawings showing all important details of construction and
dimensions.
2. Descriptive literature, bulletins, and/or catalogs of the equipment.
3. The total weight of each item.
4. A complete total bill of materials.
5. A list of the manufacturer's recommended spare parts. 1.07 OPERATING INSTRUCTIONS
A. Operating and maintenance instructions shall be furnished to the ENGINEER as required in the General Conditions. The instructions shall be prepared specifi-cally for this installation and shall include all required cuts, drawings, equip-ment lists, descriptions, etc., that are required to instruct operating and maintenance personnel unfamiliar with such equipment.
PART 2 PRODUCTS 2.01 GENERAL
A. All valves and appurtenances shall be of the size shown on the Drawings and as far as possible all equipment of the same type shall be from one manufacturer.
B. All valves and appurtenances shall have the name of the maker, flow directional
arrows, and the working pressure for which they are designed cast in raised letters upon some appropriate part of the body.
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C. Except as otherwise shown on the Drawings or specified herein, all valves with operators located 7 feet or more above the operating floor shall be provided with chain wheel operators complete with chain guides and galvanized steel chain, treated with a rust inhibitor.
D. All buried valves shall open left (counterclockwise). Insofar as possible, all
valves shall open counterclockwise. E. All valves on potable water lines shall meet Senate Law 5.3874 regarding lead-
free in valves, pipes, and fittings. All valves shall be certified for ANSI/NSF 61-8, Annex G.
F. Article 2.02, Table of Valve Application and Service of this Section of the
Specifications will be used to determine what type of valve is to be used for a particular application.
2.02 TABLE OF VALVE APPLICATION AND SERVICE
Application Gate Ball Butterfly Globe Needle Plug Check
Throttling X X X Shut-off X X X X Flow-Reversal X
Service Class
A. Water Service
(2 1/2" & 3") X X X X
(1)Non-Pot. Wat.Serv. (2)Potable Water (3)Dilution Water (4)Sample Water
B. Water Service
(2" & Smaller) X X X X X X X
(1)Non-Pot. Wat. Serv. (2)Potable Water (3)Dilution Water (4)Sample Water
C. Steam (3"&Small.) X X X X
D. Natural Gas and Air X X X X X 2.03 GATE VALVES
A. Gate valves shall be used in shut-off applications and where the valves are scheduled for infrequent use.
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1. Gate Valves for Water
a. Gate valves for water service 3 inches and smaller shall be rated
for safe operation at 125 psi saturated steam and 200 psi non-shock cold water, oil or gas (WOG).
b. The valves shall be of the rising stem, inside screw, screw-in
bonnet, solid wedge disc type.
c. The body, bonnet, disc, packing nut and stem shall be bronze construction. Packing shall be the TFE non-asbestos suitable for a maximum temperature of 200 degrees Fahrenheit.
d. Gate valves with threaded end connections shall be Milwaukee
148, Hammond IB640 or equal.
e. Gate valves with solder end connections shall be Milwaukee 149, Hammond IB635 or equal.
2.04 BALL VALVES
A. Ball valves shall normally be used in quick shut-off and frequent use applica-tions.
1. Ball Valves for Water Service
a. Ball valves for water service 3" and smaller shall be rated for safe
operation at 150 psi saturated steam and 600 psi WOG.
b. Ball valves in sizes 1/4 inch thru 1" and 2-1/2" shall be full port type, other sizes to be conventional port.
c. Ball valves shall be two-piece bronze body construction with non-
blowout stem, brass/chrome plated ball, TFE packing and rein-forced TFE seat rings and seals.
d. Exposed ball valves shall have a corrosion resistant handle opera-
tor with integral stop where exposed, key operators where buried.
e. Threaded end connection ball valves shall be Milwaukee UPBA-100/100S, Hammond 8301 or equal.
f. Solder end connection ball valves shall be Milwaukee UPBA
150/150S, Hammond 8311 or equal. g. Ball valves for small instrument isolation valves in reduced part of
threaded end connection may also be by CFF, United Alloy, or equal.
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2. Ball Valves for Air and Natural Gas
a. Ball valves for natural gas and air service 2" and below shall be rated for safe operation at 125 psi saturated steam and 600 psi WOG.
b. The valves shall be one piece with carbon steel body, type 316
stainless steel ball, reinforced, TFE (non-asbestos) seats and packing, type 316 stainless steel grounding spring or washer, and type 316 stainless steel stem.
c. Ball valves for natural gas and air service shall be Stockham S-127
CSI, Jamesbury, or equal.
d. All valves to be used in air and gas service shall be air tested to normal operating pressure of the particular system.
2.05 BUTTERFLY VALVES
A. Butterfly valves shall normally be used for throttling purposes. They may also be used for positive shutoff with pressures up to 150 psi in some applications.
1. Butterfly Valves for Water and Air Service
a. Butterfly valves for water and air service 3 inches and smaller shall
be rated for 200 psi cold working pressure.
b. The valve body shall be ductile iron, the valve seat and replaceable sleeve EPDM, and the disc aluminum bronze.
c. The valves shall have a locking position lever operator and shall be
of the wafer body type or the lug body type where dead end service is required.
d. Butterfly valves shall be Milwaukee ML133E, Muller or equal.
2.06 GLOBE AND ANGLE VALVES
A. Globe and angle valves shall normally be used for on-off or for throttling purposes where high flow resistances are permissible.
1. Globe and Angle Valves for Water, Natural Gas and Air Service
a. Globe and angle valves for water, natural gas and air service 3
inches and smaller shall be rated for safe operation at 150 psi saturated steam and 300 psi non-shock cold water, oil, or gas.
b. The valves shall be of the union bonnet type with TFE disc and
seat, TFE impregnated non-asbestos packing and bronze body.
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c. Globe valves for water, natural gas, and air service shall be Mil-waukee 590T, Hammond IB413 or equal.
d. Angle valves for water, natural gas, and air service shall be Mil-
waukee 595T, Hammond IB454, Burkert, Type 2000, or equal for threaded end connections.
2.07 NEEDLE VALVES
A. Needle valves shall normally be used for throttling purposes where accurate control of low rates of gas and liquid flow are required.
1. Needle Valves for Water, Natural Gas, and Air Service
a. Needle valves for water, natural gas and air service 1 inch and
smaller shall be rated for safe operation at 200 psi, saturated steam and 400 psi non-chock cold water, oil or gas.
b. The valves shall be of the union bonnet type with bronze body,
bonnet, bonnet ring and packing nut, copper-silicon bronze stem, brass packing gland and non-asbestos TFE impregnated packing.
c. Needle valves for water, natural gas, and air service shall be
threaded end connection Stockham Figure B-64, Whitey, or equal. 2.08 PLUG VALVES
A. Plug valves shall be used for quick shut-off and frequent use applications.
1. Plug Valves for Water, Air, and Natural Gas Service
a. Plug valves for water, air, and natural gas service 3" and smaller shall be of the non-lubricated plug type with 70 percent port opening, rated for safe operation at 285 psi WOG between -20 degrees and 100 degrees Fahrenheit. The valves shall be of the handwheel operator type.
b. The valve body shall be cast steel the plug alloy iron, the O-rings
TFE and the packing non-asbestos impregnated TFE fibers.
c. Plug valves for water, air and natural gas shall be Stockham Figure HA-71, or equal.
2.09 CHECK VALVES
A. Swing check valves shall be used in conjunction with gate valves where change of direction is infrequent and service velocity is low. Lift check valves shall be used in conjunction with globe and angle valves and for high velocity service.
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1. Check Valves for Water, Air or Natural Gas Service
a. Y-Pattern Horizontal Swing Type
(1) Y-pattern, horizontal swing type check valves shall have renewable seat and disc, rated for safe operation at 125 psi saturated steam and 200 psi non-chock cold water, oil or gas.
(2) The valve body and bonnet shall be bronze, the disc and
seat shall be TFE.
(3) The check valves shall be suitable for installation horizon-tally or vertically with upward flow.
(4) The Y-pattern, horizontal swing type check valves shall be
Milwaukee 1509T, Hammond IB912 series with threaded or solder ends or equal.
b. Lift Check Type
(1) The lift check valves shall be of the union cap type rated for
safe operation at 150 psi saturated steam and 300 psi non-shock cold water, oil, or gas.
(2) The valve body and union cap shall be bronze, the disc shall
be TFE.
(3) The valve shall be installed in the horizontal position only.
(4) The lift check valves shall be Stockham Figure B-322 or equal.
2. Check Valves for Compressor Service
a. Check valves for the discharge of reciprocating compressors shall
be in-line type rated for safe operation for pneumatic or light liquid service to 750 psig. The valve shall have a maximum pres-sure drop of 1.01 psig at an inlet pressure of 100 psig.
b. The valve body, spring seat and cages shall be brass. The spring
shall be stainless steel and the seat disc and packing TFE.
c. Check valves for compressor service shall be Rego Series CV or equal.
2.10 BACKWATER VALVES
A. Backwater valves shall be for sanitary drains as shown on the Drawings and shall have a cast iron body, hub inlet and offset spigot outlet, cast iron floor level
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cleanout, automatic type bronze valve seat and flapper which hangs open during periods of non-operation. Backwater valves shall be Zurn Z-1095-6, or equal. Where floor level cleanout is not required Zurn Z-1095, or equal shall be used.
2.11 MISCELLANEOUS COCKS
A. Air Release Cocks
1. Air release cocks shall be for 125 pound pressure, 1/2 inch, bronze plug and body, with handle operator. Air cocks shall be Crane No. 256 Tee Head, Lunkenheimer No. 1571, or equal.
B. Gauge Cocks
1. Gauge cocks for water service shall be 316 stainless steel construction
rated for safe operation at 10,000 psi at 100 degrees Fahrenheit. The valve shall be nitrogen tested for seat leakage, maximum allowable leak rate 0.1 scc./min.
2. Gauge cocks shall be Whitey Co. "BV" series bleed valves or equal.
C. Try (Sample) Cocks
1. Try cocks shall be for 125 pound pressure, 3/4 inch, with bronze body
and stem, tin disc, and brass bibb, and shall have a handwheel operator. Try cocks shall be Crane No. 730, Lunkenheimer, or equal.
2.12 MISCELLANEOUS STOPS
A. Corporation Stops
1. Corporation stops to be used with threaded pipe where connected into cast iron pipe, shall be brass ground joint type with AWWA CC or CS taper thread inlets and iron pipe thread outlets for threaded iron pipe. Stops shall be Mueller H-10045, Ford, or equal.
2. Corporation stops to be used with copper pipe with compression type
connections, where connected into cast iron or asbestos-cement pipe, shall be the same, except with compression type outlet connections. Stops shall be Mueller H-15000, H-15010, H-15020, Ford, or equal.
3. Corporation stops for asbestos-cement and pressure concrete shall be
furnished with iron pipe thread outlets. Stops shall be Mueller H-10010, or equal. On coated and wrapped steel pipe use Mueller H-17800, Ford, or equal curb valve tee.
4. Corporation stops shall be factory tested to (150 psi) (250 psi) to be
compatible with the pipes in which they are installed.
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B. Curb Stops
1. Curb stops to be used with threaded pipe shall be brass inverted key round way with female threaded iron pipe connections for threaded iron pipe. Curb stops shall be Mueller H-10201, Ford, or equal.
2. Curb stops to be used with copper pipe, with threaded type connections,
shall be Mueller H-15200, Ford, or equal.
3. Curb stops to be used with plastic pipe shall be brass, inverted key, round way with compression connections and rigid liner as recommended by curb stop manufacturer. Curb stops to be used with plastic pipe shall be Muller H/5/59 or equal.
4. The CONTRACTOR shall furnish 2 tee wrenches, 4 feet long, for operation
of curb stops.
C. Stop and Drain Valves
1. Stop and drain valves shall be for 175 pound working pressure, 180 degrees Fahrenheit, 3/4 inch thru 2 inches, and shall have a positive sealing system accomplished without metal-to-metal fits. O-ring seals shall be attached to a removable plug for ease of replacement. The O-ring seal shall be prelubricated with a long life lubricant. Valves shall have a plastic thrust washer on top of the plug to provide a means of reducing thrust and rotary friction between metal plug, body, and bronze retaining rings. The valve body and plug shall be cast composition bronze ASTM B62-82; O-rings shall be synthetic rubber. Connections shall be as shown on the Drawings. All valves shall be subject to the following tests:
a. 10 psi air test, valve open and closed position submerged in water.
No leaks permitted.
b. 175 psi hydrostatic, valve open and closed. No leaks permitted. Valves shall be Mueller Company Mark II Oriseal Valves, Crane, or equal.
D. Natural Gas Meter Stops
1. Natural gas meter stops shall be rated for safe operation at 175 psi. The
valves shall be of the iron body, straight way, bronze key, solid head, tamper-proof type capable of being locked in the closed position only. The natural gas meter stops shall be Muller H-11175 or equal.
2.13 PRESSURE REGULATING AND PRESSURE RELIEF VALVES
A. Water Pressure Reducing Valves
1. Pressure reducing valves for water service 1-1/2 inches and smaller shall be a diaphragm type valve, inline serviceable, with a stainless steel seat.
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The body shall be lead free brass construction. The device shall be rated for an inlet pressure of 300 psi with a pressure reduction range of 50 to 145 psi. The pressure drop across a 3/4-inch device shall be a maximum of 10 psi at a flow of 25 gpm. Pressure reducing valves 1-1/2 inches and smaller shall be capable of the pressure reduction noted on the Drawings and shall be Watts LF223 high pressure range, or equal.
2. Pressure reducing valves 2 inches and larger shall be hydraulically
operated, single-diaphragm actuated, full port type, globe body automatic control valves. The valve body, diaphragm disc, and plunger shall be ductile iron. The seat, seat retainer, and cover bushing shall be lead-free bronze. The seat ring shall be Buna-N and the diaphragm shall be nylon reinforced Buna-N. The stem, bolts, nuts, and washers shall be 304 stainless steel. The device shall be rated for an inlet pressure of 250 psi and shall comply with AWWA C530 for pilot operated control valves. Pressure reducing valves 2 inches and larger shall be capable of the pressure reduction noted on the Drawings and shall be GA Industries Series 5000, or equal.
B. Pressure Temperature Relief Valves for Water Service
1. Pressure relief valves for water service shall be of the bronze body, non-
mechanical seat-to-disc alignment type designed for temperature relief at 210 degrees Fahrenheit and pressure range from 75-150 psi. The device shall be ASME rated, A.G.A. certified and C.G.A. listed, Watts series 40 or equal.
2.14 SPECIALTIES AND ACCESSORIES
A. Hydrants
1. Freezeless Wall Hydrants
a. Furnish and install freezeless wall hydrants at the locations shown on the Drawings. The device shall be automatic draining with vacuum breaker, 3/4 inch hose thread nozzle, one piece valve plunger to control both flow and drain functions, hardened stain-less steel operating stem, and polished brass finish on brass castings enclosed in a flush mounted wall box. Two loose tee operating keys are to be furnished with each unit. The device shall include a brass casing pipe.
b. Single temperature freezeless wall hydrant shall be approved
under ASSE Standard 1019 and be Woodford Model B65 or equal.
c. Hot and cold mixing freezeless wall hydrant shall be as specified above, Woodford Model HCB65 or equal.
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2. Interior Wall Hydrants
a. Furnish and install a wall hydrant at the location shown on the drawings. The device shall have a polished chrome finish, vacuum breaker, loose key operating handle, and Teflon impregnated packing with "O" size washer.
b. Interior wall hydrant shall be Woodford 24 or equal.
3. Yard Hydrants
a. Above ground yard hydrants shall be of the anti-freezing,
non-pollutable type, 1" size for 30" cover over water service line. The yard hydrant assembly shall include a ball wheel handle, vacuum breaker, 1" hose connection, and double ball check valve on the drain. The operating valve shall be located at the bottom of the hydrant assembly. When the operating valve is turned off it shall allow the water remaining in the supply line in the hydrant above the valve to drain from the hydrant by means of a by-pass in the valve stem. The hydrant handle, casing, and base shall be cast iron, and the operating valve red brass.
b. The yard hydrant shall be Murdock BFHE10-1" or equal.
c. All hydrants shall be furnished with anti-siphon vacuum breaker.
B. Hose and Nozzles
1. Hose
a. Furnish 3/4 inch and 1 inch hose as indicated below. Hose shall be
multi-purpose, heavy-duty type suitable for air or water applica-tions. The 1 inch hose shall be rated for 250 psi, the 3/4 inch hose rated for 300 psi. The tube shall be medium-high oil resistant, the reinforcement high tensile synthetic cord and the cover EPDM. The hose shall be Gates "Contractor's Gold" or equal.
b. Furnish one 3/4" x 50' hose for each 3/4" hose station and one 1"
x 50' hose for each yard hydrant.
2. Nozzles
a. Furnish 1" x 8" cast plain brass nozzles for each yard hydrant, and 3/4-inch nozzles for each hose station. The 1-inch nozzles shall be Akron Brass, or equal; and the 3/4-inch nozzle for hose stations shall be Leonard N-2, or equal.
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C. Faucets (Hose Bibbs)
1. Hose Stations
a. Hose station shall be preassembled units including a 3/4 inch IPS water inlet, 3/4 inch IPS water outlet with pipe supports, vacuum breaker, and 3/4 inch hose connection, volume control and shutoff valve with heat-resistant handle and bracket for direct wall mounting, and a stainless steel hose rack. The hose station finish shall be rough bronze. CONTRACTOR shall provide couplings necessary for connecting 3/4 inch hose to hose station and nozzle. Hose stations shall be Leonard SW-75-1571 or equal. Blending hose stations shall be Leonard SW-75-EV80 or equal.
2. Hose Rack
a. Hose racks shall be Leonard Valve Co. stainless steel hose racks,
or equal.
3. Hose Connections (Flushing Connections)
a. Hose connections for installation in the chemical and process piping shall be of the sizes as indicated on the Drawings. Con-nections shall be standard female, quick connect coupling. Hose connections for installation in the chemical systems shall be of materials suitably resistant to the respective chemical. Hose connections for installation in process lines other than chemical systems shall be of bronze or brass construction. Hose connec-tions shall be rated 100 psig (minimum).
b. Hose shall be a minimum length of 40 feet, 1-1/4 inch reinforced
high pressure (175 psi), rubber hose with male quick connect couplings.
4. Hose-End Valves
a. Hose-end valves for installation on the plant water lines shall be of
the sizes as indicated on the Drawings, Crane Fig. 117, or equal. Furnish cap and chain. Connections shall be suitable for 1-1/4 inch hose.
D. Strainers, Filters, and Dryers
1. Strainers for Water Service
a. Strainers for water service 1/4" - 2-1/2" shall be rated for safe
operation at 250 psi saturated steam, 400 WOG.
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b. The strainers shall be the "Y" type with a cast iron body and 20 mesh stainless steel screen for sizes 1/4" - 2", 3/64" perforation stainless steel screen for 2-1/2" size. End connections shall be screwed type.
c. Strainers 1/4" - 2-1/2" shall be Watts Series 775 or equal.
d. Strainers in 3" size shall be cast iron body "Y" type with 1/16"
perforation stainless steel screen and flanged end connections. 3" strainers shall be Watts Series 77F or equal rated for safe operation at 250 psi saturated steam, 500 psi WOG.
E. Water-hammer Arrestors
1. Water hammer arrestors shall be rated for safe operation at 150 psi
working pressure. The devices shall be of the permanently sealed, pre-charged, brass piston and EPDM "O" rings.
2. The device shall meet the requirements of A.S.S.E. 1010 and shall be
P.D.I. WH201 approved and certified.
3. Water hammer arrestors shall be sized and located in accordance with manufacturer’s instructions, or as shown on the Drawings.
4. Water hammer arrestors shall be Watts Series 15 or equal.
F. Air Vents
1. Air vents shall be used on water lines as shown on the Drawings for the
removal of unwanted air. Vents shall be rated at 150 psi working water pressure, shall have a safety drain connection, stainless or copper clad steel internal components and a cast iron or brass body and cap. Vents shall be Armstrong or equal.
2. See Division 15 of these Specifications for air vents on unit heaters.
G. Solenoid Valves
1. Solenoid valves shall be packless piston type direct acting, 2-way or 3-way
valves as indicated on the Drawings and shall be ASCO Valve Red Hat as manufactured by Automatic Switch Co., MAC, Burkert Type 290, or equal.
2. Valves on water seal lines to stuffing boxes and for flushing water shall
be of the normally closed type.
3. Valves on the plant water seal lines shall have forged brass bodies, NPT end connections of the size shown on the Drawings, 300 or 400 series stainless steel internal parts, and Buna-N or Ethylene Propylene valve seats. Valves shall have a 150 psig (minimum) safe working pressure and zero minimum operating pressure differential. Valves for the polymer
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feed system shall be similar except for having stainless steel bodies. Pipe connections shall be threaded with nipples for the plant water lines and flanged with threaded stainless steel adapters for the PVC lines.
4. Except as otherwise specified herein, valves shall have NEMA 4 solenoid
enclosures, shall be suitable for operation on a 120V, 60 Hz, single phase power supply, and shall be provided with a continuous duty Class F coil and a manual operator.
5. Valves located in hazardous areas, as noted on the Drawings, shall be
furnished with explosion proof enclosures suitable for Class I, Division I, Group D locations.
H. Dielectric Pipe Fittings/Unions
1. Dielectric pipe fittings/unions shall be installed where it is necessary to
couple 2 dissimilar metals in any piping system. The fitting used shall be appropriate for the pipe material to be joined in accordance with the manufacturer's instructions.
2. Dielectric unions shall be rated for 250 psi working pressure. Dielectric
flanged fittings shall be rated for 175 working pressure.
3. The fittings/unions shall be certified to withstand a minimum of 600 volts on a dry line with no flashover.
4. Dielectric pipe fittings/unions shall be Watts Series 300 or equal.
I. Compressed Air Ejector Accessories
1. Strainers
a. Strainers shall be required where shown on the Drawings. They
shall be the wye type of cast steel construction with screwed ends and flanged blowoff connection. The screen shall be 316 stainless steel with .027 inch perforations. A spare screen with .065 inch perforations shall be provided. The strainer shall be Fisher Type 260B, Leslie Catalog No. 7501, Armstrong or equal.
2. Pipe Expansion Joints and Compensators
a. Expansion joints for connection of compressors to pipelines shall
be flexible steel hose type, designed for 200 psi working pressure. The expansion joint shall be temperature rated at 450 degrees Fahrenheit. The assembly shall have forged steel flanges. The expansion joint shall be the Metraflex Company's stainless steel flexible hose unit, Keflex, or equal.
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J. Backflow Prevention Devices
1. Reduced Pressure Principle Backflow Preventers
a. The reduced pressure principle backflow preventer shall be a complete assembly consisting of 2 independently acting springloaded toggle lever or poppet type check valves together with an automatically operating pressure differential relief valve located between the 2 check valves. The first check valve shall reduce the supply pressure a predetermined amount so that during normal flow and the cessation of normal flow, the pressure between the checks is less than the supply pressure. In the case of leakage of either check valve, the differential relief valve shall discharge to atmosphere to maintain the pressure between the checks at a level less than the supply pressure.
b. The unit shall include tightly closing shutoff valves located at each
end of the device, and shall be fitted with 4 properly located test cocks. Operation shall be completely automatic. All parts must be removable or replaceable without removal of the unit from the line. The total head loss through the complete backflow assembly shall not exceed 11 psi at rated flow.
c. The reduced pressure principle backflow preventer shall be in
accordance with AWWA C506, ASSE 1013 and shall have prior approval of the Kentucky Natural Resources and Environmental Protection Cabinet. The assembly shall be Watts 909S or equal.
d. The reduced pressure principle backflow preventer on the fire
protection line shall be as noted above except without a strainer, and the shutoff valves shall be OS & Y gate valves. The device shall have UL and Factory Mutual System approval for use on fire protection systems in addition to the above mentioned approvals. The assembly shall be Watts 909 or equal.
e. The reduced pressure principle backflow preventer shall be tested
by a certified tester in accordance with the test procedure outlined in the Manual of Cross-Connection Control published by the Foundation for Cross-Connection Control and Hydraulic Research of USC in the presence of the ENGINEER'S representative. A report of the test results shall be furnished the OWNER and the ENGINEER.
f. An acceptable device installation must meet the requirements of
this test.
2. Pressure Vacuum Breaker
a. The pressure vacuum breaker assembly shall be designed to prevent backsiphonage at a maximum working pressure of 150 psi. The assembly shall include an independently operating spring
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loaded check valve and independently operating spring loaded air inlet valve, and two quarter turn, full port, resilient seated bronze ball shut off valves. The assembly shall also include two properly located test cocks.
b. The body, valve seat and bonnet shall be bronze. The hood shall
be stainless steel and the vent and check valve discs shall be silicone rubber.
c. The pressure vacuum breaker assembly shall conform to ASSE
1020, and shall be Watts 800, or equal.
4. Atmospheric Vacuum Breaker
a. The atmospheric vacuum breaker shall be designed to prevent backsiphonage at a maximum working pressure of 125 psi. The device shall include a bronze body and silicone disc.
b. Atmospheric vacuum breaker shall conform to ASSE 1001, and
shall be Watts 288 or equal.
5. Hose Connections Vacuum Breaker
a. Hose connection vacuum breaker shall be brass body with soft rubber disc suitable for interior or exterior use. Where used in areas subject to freezing a manual drainage feature is required.
b. The device shall conform to ASSE 1011, and shall be Watts Series
8, or equal. PART 3 EXECUTION 3.01 INSTALLATION
A. All valves and appurtenances shall be installed in the locations shown, true to alignment and rigidly supported. Any damage to the above items shall be repaired to the satisfaction of the ENGINEER before they are installed.
B. Control valves in all locations shall be so grouped and located that they may be
easily operated, through access panels, doors, or adjacent to equipment.
C. After installation, all valves and appurtenances shall be tested at least one hour at the working pressure corresponding to the class of pipe, unless a different test pressure is specified. If any joint proves to be defective, it shall be repaired to the satisfaction of the ENGINEER.
D. Install all brackets, extension rods, guides, the various types of operators and
appurtenances as shown on the Drawings that in masonry floors or walls, and install concrete inserts for hangers and supports as soon as forms are erected and before concrete is poured. Before setting these items, the CONTRACTOR
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shall check all Drawings and figures which have a direct bearing on their location and he shall be responsible for the proper location of these valves and appurtenances during the construction of the structures.
E. All materials shall be carefully inspected for defects in workmanship and
materials; all debris and foreign material cleaned out of valve openings, etc.; all operating mechanisms operated to check their proper functioning, and all nuts and bolts checked for tightness. Valves and other equipment which do not operate easily, or are otherwise defective, shall be repaired or replaced at no additional cost to the OWNER.
F. Fire hydrants and yard hydrants shall be set at the locations as shown on the
Drawings and bedded on a firm foundation. A drainage pit as detailed on the Drawings shall be filled with screened gravel and satisfactorily compacted.
G. During backfilling, additional screened gravel shall be brought up around and 6
inches over the drain port. Each hydrant shall be set in true vertical alignment and properly braced. Concrete thrust blocks shall be placed between the back of the hydrant inlet and undisturbed soil at the end of the trench. Minimum bearing area shall be as shown on the Drawings. Felt roofing paper shall be placed around hydrant elbow before placing concrete. CARE SHALL BE TAKEN TO INSURE THAT CONCRETE DOES NOT PLUG THE DRAIN PORTS.
H. If directed, the hydrant shall be tied to the pipe with suitable rods or clamps,
galvanized, painted, or otherwise rustproof treated. Concrete used for backing shall be no leaner than 1 part cement, 2-1/2 parts sand, and 5-1/2 parts stone. Hydrant paint shall be touched up as required after installation.
I. Buried flanged or mechanical joints shall be made with cadmium plated bolts.
All exposed bolts and nuts shall be cadmium plated. All exposed bolts and nuts shall be heavily coated with 2 coats of bituminous paint.
J. Yard hydrants shall be installed in accordance with manufacturer's
recommendation and applicable requirements of fire hydrants above.
K. Buried valves and valve boxes shall be set with the stem vertically aligned in the center of the gate box. Valves shall be set on a firm foundation and supported by tamping selected excavated material under the sides of the valve. The valve box shall be supported during backfilling and maintained in vertical alignment with the top flush with finish grade.
3.02 SHOP PAINTING
A. Interior surfaces of all valves, the exterior surfaces of buried valves and miscel-laneous piping appurtenances shall be given a shop finish of an asphalt varnish conforming to Federal Specification TT-V51e for Varnish Asphalt.
B. The exterior surface of various parts of valves, operators, floor stands and
miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease or other foreign matter and thereafter one shop coat of an approved rust-inhibitive
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primer such as Inertol Primer No. 621 shall be applied in accordance with the instructions of the paint manufacturer.
C. Ferrous surfaces obviously not to be painted shall be given a shop coat of
grease or other suitable rust-resistant coating.
D. Field painting is specified under Division 9. 3.03 INSPECTION AND TESTING
A. The various pipelines in which the valves and appurtenances are to be installed are specified to be field tested. During these tests any defective valve or appurtenance shall be adjusted, removed and replaced, or otherwise made acceptable to the ENGINEER.
B. Various regulating valves, strainer, or other appurtenances shall be tested to
demonstrate their conformance with the specified operational capabilities and any deficiencies shall be corrected or the device replaced or otherwise made acceptable to the ENGINEER.
END OF SECTION
***
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SECTION 15102
VALVES (WATER RELATED) PART 1 GENERAL 1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment, and incidentals required and install complete and ready for operation all valves and appurtenances as shown on the Contract Drawings and specified herein.
B. The equipment shall include but not be limited to, the following:
1. Butterfly valves 2. Gate valves 3. Check valves 4. Tapping valves, sleeves and crosses 5. Plug valves 6. Mud valves 7. Ball valves 8. Tapping valves 9. Fire hydrants
1.02 RELATED WORK
A. Excavation, backfill and grading is included in Division 2.
B. Piping is included in the respective sections of Division 2.
C. Painting is in Division 9.
D. Electrical work is in Division 16.
E. Special sequence or schedule requirements (if any) are specified in Section 01010 - Summary of Work.
F. Specialty valves are included in Section 15104.
G. Valves and service accessories on all plumbing systems are included in this
Division, Section 15100.
H. Mechanical identification markers, tag and plates are included in this Division, Section 15190.
I. Plastic valves and accessories are included in Section 15230. J. SCADA/Instrumentation is in Division 17.
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1.03 DESCRIPTIONS OF SYSTEMS
A. All of the equipment and materials specified herein is intended to be standard for use in controlling the flow of water.
B. See the valve schedule for valve sizes, quantities, connections, class, type of
actuator and location. C. All valves shall meet NSF61-Annex G requirements.
1.04 QUALIFICATIONS
A. All of the types of valves and appurtenances shall be products of well established firms who are fully experienced, reputable and qualified in the manufacture of the particular equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these specifications as applicable.
1.05 SUBMITTALS
A. Complete shop drawings of all valves and appurtenances shall be submitted to the ENGINEER in accordance with the requirements of Section 00700/00710.
B. The ENGINEER shall be furnished 2 certified copies of reports covering the
required leakages, hydrostatic and proof-of-design tests on the valves.
C. Gate Valves
1. The manufacturer shall furnish the ENGINEER 2 copies of an affidavit stating that the valve and all materials used in its construction conform to the applicable requirements of the latest edition of ANSI/AWWA C509, and that all tests specified therein have been performed and that all test requirements have been met.
2. The ENGINEER shall be furnished 2 copies of affidavit that the "Valve
Protection Testing" has been done and that all test requirements have been met.
3. The ENGINEER shall be furnished with 2 copies of affidavit that inspection,
testing and rejection are in accordance with the latest edition of AWWA C509.
D. Check Valves
1. The ENGINEER shall be furnished 2 copies of affidavit of compliance stating
that the valves and materials used in their construction conform to the applicable requirements of the latest edition of ANSI/AWWA C508, and that all tests specified therein have been made and that the test requirements have been met.
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1.06 OPERATING INSTRUCTIONS
A. Manufacturer's operating and maintenance instructions shall be furnished to the ENGINEER as set forth in Section 01600.
1.07 REFERENCES A. Where standards for materials or construction of equipment, etc., are noted such
as ANSI, AWWA, ASTM, etc., the standard to be used shall be to the latest published edition as of the bid advertisement date unless a specific year’s standard is noted.
PART 2 PRODUCTS 2.01 MATERIALS AND EQUIPMENT
A. General 1. All valves and appurtenances shall be of the size shown on the Drawings
and as far as possible all equipment of the same type shall be from one manufacturer.
2. All valves and appurtenances shall have the name of the maker,
flow-directional arrows, and the working pressure for which they are designed cast in raised letters on some appropriate part of the body.
3. Except as otherwise shown on the Drawings or specified herein, all valves
with operators located 7 feet or more above the operating floor shall be provided with chain wheel operators complete with chain guides and galvanized steel chain.
4. All buried valves shall open left (counter clockwise). Insofar as possible, all
valves shall open counter clockwise.
5. All valves must be provided with suitable operating devices and adapted for operation in the position in which they are shown on the Drawings.
6. Valves shall have types of operators as shown on the Drawings and/or
listed in the valve schedule.
7. All bolts and studs shall be in accordance with ASTM A-307 Grade B and nuts shall be in accordance with ASTM A-563. Bolts, studs and nuts shall be electrogalvanized according to ASTM B-633.
8. All bolts, studs and nuts in contact with water, in any moist atmosphere or
damp area such as occurs above water, or exposed to weather shall be stainless steel.
9. All bolts delivered to the job shall be free of rust and dirt and shall be
stored in a manner to protect them from rust and dirt. All bolts shall be tightened to the proper torque. They shall be of the size recommended for
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the pipe and fittings they are to be used on and shall be in the recommended quantity. Tightening of bolts shall be alternated, so as to not produce undue stress on the valves and fittings.
B. Butterfly Valves
1. General a. All butterfly valves shown on the Drawings inside structures are
shown as flanged valves. 2. AWWA Rubber Seated Butterfly Valves
a. General
(1) Unless otherwise noted in these Specifications or on the
Drawings, all flanged and mechanical joint butterfly valves shall meet the requirements of the latest edition of ANSI/AWWA Specification C504.
(2) Unless otherwise noted, all flanged valves shall be short body
type.
(3) Unless otherwise shown on the Drawings, the maximum non-shock shutoff pressure will not exceed those specified for the various valve classes. Unless otherwise shown on the Drawings, all potable water valves shall be Class 250 B.
(4) Unless otherwise noted on the Drawings or called for in these
Specifications, flow through the valves will be:
Normal: Not more than 6 fps When Opening: 10 fps When Closing: 16 fps
(5) The manufacturer shall furnish the OWNER dimensions of the
clearance required for the valve disc. (6) The valves shall be Milliken Valve Company, Pratt, GA,
Victaulic or equal.
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b. General Design
Exceptions and Chosen Materials
Component Material
Comment or Description
Valve Body Cast iron or ductile iron
wafer body not acceptable
Valve Ends Flanged, or Groove joint, or Mechanical joint
Valve Shaft stainless steel or nickel-copper alloy
Valve Disc Cast iron, or alloy cast iron, or ductile iron, or stainless steel
Valve Seal Split V packing Standard O-rings
Pull down packing
C. Gate Valves
1. Resilient Seated Gate Valve (AWWA Type)
a. General
(1) Resilient seated gate valves shall conform in all respects to the latest edition of ANSI/AWWA C515 with non-rising or rising stems, in sizes 3, 4, 6, 8, 10, 12, 16, 20, 24, and 30 inch NPS except as otherwise noted below. The minimum design working water pressure for valves 3 through 12 shall be 250 psig and 250 psig for valves 16 through 30 inch.
(2) Valves shall have a clear unobstructed water way, without
pockets or ridges in the seating area of the valve body. When fully open the water way shall be at least as large as the pipe diameter to which it is connected.
(3) The valves shall be Kenney, Clow, Mueller, American, or
equal.
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b. Materials
(1) Physical and Chemical Properties
(a) Physical and chemical characteristics of the valve components shall be in accordance with the “Materials” Section of AWWA C515, except that carbon steel castings for valves are not acceptable. Paint shall be as hereinafter specified under "Valve Protection."
c. Detailed Design
Exceptions and Chosen Materials
Component Material Specification/Comment
Valve Body Cast iron or
ductile iron
Short body, wafer body not acceptable
Valve Ends Flanged, or mechanical joint
Valve Shaft Wrought stainless steel or nickel-copper alloy
Valve Disc Cast iron, or alloy cast iron, or ductile iron, or stainless steel
Valve Seal Valve Ends (Tapping valve)
N/A May be a combination of flanged and mechanical joint, flange and flange.
Stem Seal O-rings
Gaskets O-rings of Buna-N or equal Valve Seats seats applied to the valve body are
not acceptable Exterior Painting ANSI/AWWA C550 Interior Painting ANSI/AWWA C550 of
fusion bonded epoxy or two-part thermosetting epoxy
8 to 10 mil thickness
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D. Check Valves
1. General
a. Check valves shall be of one or more of the following types: outside lever and weight.
2. Swing Check Valves (AWWA)
a. General
(1) This specification covers iron body bronze mounted swing
check valves, 2-24 inch NPS size with outside lever and weight, to operate in both horizontal and vertical position.
(2) When check valves are installed in the vertical position, the
lever arms shall be permanently fixed (keyed) on valve shaft so they point 45° below the horizontal when the valve is closed and 45° above the horizontal when open.
(3) Swing check valves shall meet all appropriate requirements of
the latest edition of AWWA C508 except as otherwise noted below. All further reference to section and paragraph numbers shall be those of the latest edition of AWWA C508.
(4) The valves shall be Clow, GA, or equal.
b. Exceptions and Chosen Materials
Component Material Comment or Description
Valve Body Cast or ductile iron Short body, flanged, mechanical
joint, wafer body not acceptable Valve Shaft Wrought stainless steel or
nickel-copper alloy
Valve Disc Cast iron, alloy cast iron, ductile iron, or stainless steel
Valve Seal Stem Seal
O-rings
Gaskets O-rings of Buna-N or equal Valve Seats Metal to rubber Seats applied to the valve body are
not acceptable, metal to metal are not acceptable
Exterior Painting ANSI/AWWA C550 or ANSI/AWWA C509 paragraph 4.2.2.8
Interior Painting ANSI/AWWA C550 of fusion bonded epoxy or two-part thermosetting epoxy
8 to 10 mil thickness
E. Plug Valves
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1. General
a. Plug valves shall be of the non-lubricating, eccentric type and shall
be designed for a working pressure of 175 psi for valves 12-inch and smaller, 150 psi for valves 14-inch and larger. Valves shall provide bubble or drip tight shut-off at rated pressure.
b. Valves 20 inch and smaller shall have round port design. Valves 24
inch and larger shall be rectangular port design. In lieu of round ports 100 percent rectangular ports may be acceptable.
c. Where plug valves are noted and they will not provide bubble or
driptight closure, such as with electric actuators, ball valves shall be provided.
d. The valves shall be Milliken Valve Company, Pratt, GA Industries,
Victaulic or equal.
Standard Flow Through Design
Item Material
Comment
End Connections ANSI B16.1, Class 125 Flanges, mechanical joint, threaded, grooved, Victaulic
Pressure Class 175 psi through 12” 150 psi 14” and larger
Max working pressure 175 psi
Body Cast iron ASTM A126B with welded-in overlay of 90% nickel alloy content on all surfaces contacting the face of the plug
Plug cast iron ASTM A126 Class B, with Buna N resilient seating surface
Bearings sintered, oil impregnated type 316 stainless steel ASTM A-743 Grade CF-8M or bronze ASTM B-127
Permanently lubricated sleeve type bearings conforming to AWWA C504
Shaft Seals “U” cup type, in accordance with AWWA C504 self-adjusting and re-packable without moving the bonnet from the valve
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Item Material
Comment
Body Lining None or rubber Rubber for highly abrasive applications such as sludge
Actuator – exposed valves
4” and smaller wrench type, 6” and larger worm gear type manual actuators, electric, pneumatic, hydraulic
Actuator – buried valves
All sizes worm gear type manual actuators
Exterior Paint Phenolic Primer Red Oxide
3 Way Design
Item Material
Comment
End Connections ANSI B16.1, Class 125 Flanges, mechanical joint, threaded, Victaulic
Pressure Class 25 psi, 75 psi, 125 psi … Max working pressure 175 psi
Body Cast iron ASTM A126B with welded-in overlay of 90% nickel alloy content on all surfaces contacting the face of the plug
Plug cast iron ASTM A126 Class B, with Buna N resilient seating surface
Bearings sintered, oil impregnated type 316 stainless steel ASTM A-743 Grade CF-8M or bronze ASTM B-127
Permanently lubricated sleeve type bearings conforming to AWWA C504
Shaft Seals “U” cup type, in accordance with AWWA C504 self adjusting and re-packable without moving the bonnet from the valve
Body Lining None or rubber Rubber for highly abrasive applications
Actuator – exposed valves
4” and smaller wrench type, 6” and larger worm gear type
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manual actuators, electric, pneumatic, hydraulic
Actuator – buried valves
All sizes worm gear type manual actuators
Exterior Paint Phenolic Primer Red Oxide F. Mud Valves 1. The mud valve shall be of the heavy duty flanged type designed to provide
a positive seal under both seating and unseating conditions. The valves shall be non-rising stem with 2-inch square nut in a floor box.
2. The frame, yoke and gate shall be of strong and rigid construction and be
of cast iron conforming to ASTM A 126 Class B. 3. The stem and stem nut shall be of bronze or stainless steel. The stem shall
be machined with accurately cut and modified Acme threads. The valve stem shall be of the length shown on the Drawings and shall be supplied with stem guides as shown on the Drawings.
4. The seating surfaces shall be of bronze with a tapered, accurately
machined seating face. Seat faces shall be a seamless molded ring of Buna-N tapered to accurately mate with the seat ring to form a positive seal.
5. The mud valve shall have a flanged end suitable for mounting to a flange
per ASA B-16.1 (125 lbs drilling). 6. Mud valves are to be finish coated using Tnemec Pota Pox 2-part epoxy or
equal NSF approved coating, as specified in Section 09900 – Painting. 7. Mud valves shall be Troy Valve, Kennedy Valve, or equal. G. Ball Valves 1. The ball valve shall be a bidirectional ASME Class 150 full port ductile iron,
carbon steel or stainless steel valve of the uni-body or split-body design. The valve may be a resilient or metal seated, trunnion, or non-trunnion mounted ball provided it can handle Kentucky River water with small amounts of solids having a maximum velocity of 20 feet per second. The valve shall have a blowout proof stem. The valve shall have pressure temperature ratings per ASME B16.34. Valves not of stainless steel shall be coated with an AWWA C550 fusion bonded epoxy, or other ENGINEER-approved coating.
2. The ball valves shall be Velan SB-150 Memoryseal, Securaseal, Jamesbury
Metso Series 6000/9000, Hindle, KTM, Fisher/Emerson, A-T Controls, Bray, Milwaukee, GA, Pratt, or equal.
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2.02 ACCESSORIES A. Valve Actuators 1. General a. Valve actuators shall be of type called for in the valve schedule. They
shall be equipped with adjustable mechanical stop limiting devices to prevent over travel of the valve disc in the open and closed positions. Actuator housings, supports, and connections to the valve shall be designed with a minimum safety factor of 5, based on the ultimate strength, or 3, based on the yield strength of the materials used.
b. Manual valve actuating facilities that is handwheel, lever, crank,
chain or valve stand, shall be as shown on the Drawings or as listed in the valve schedule. Valve stands shall be of 2 types, namely, gear at the valve or at the stand. The latter shall be used on all valves which are continuously submerged, except where valve size, operating pressure and length of extension stem dictate that the gear operator be located at the valve. In such cases a positive means of lubrication, from valve stand above is to be provided and a means of determining whether or not the gear case is full of lubricant is to be provided.
c. All valves furnished for modulating service shall be furnished with
4-20 mA analog signals or a fieldbus connection, as shown on the Drawings and as noted in Division 17. Each valve shall have a potentiometer to operate a valve position meter on its controller and an internal reversing relay. A 4-20mA output feedback signal is required to indicate position status.
d. Valves used in conjunction with the rate control will not have manual
handwheel actuators at the valve. e. Except for stand and chain remotely actuated valves, the actuators
shall have sufficient limit switches to stop the valve at each end of its cycle, to operate any auxiliary instruments in regard to controllers and to operate "on" and "off" lights for each valve.
f. Valve actuators shall be in accordance with Section 3, paragraph
3.8, subparagraphs 3.8.1 thru 3.8.5.9. g. Certification for the proof of design test of the valve actuator shall
be submitted in accordance with Section 00820. h. Actuators shall have local controls and shall have provisions for
remote controls and position indicator.
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2. Electric Motor Actuators a. General (1) See Section 17610 for Electric Valve Actuators. 3. Cylinder Actuators a. General (1) Cylinder actuators shall be of the trunion mounted or swivel
type. (2) They shall be designed to hold the valve in any intermediate
position between fully open and fully closed without creeping or fluttering.
(3) Cylinder actuators shall be in accordance with C-540-93,
Section 4. b. Pneumatic Cylinders (1) Pneumatic cylinder actuators shall be equipped with air flow
control valves, which must be adjustable to prevent damage to cylinders from too rapid opening and closing. Compressed air at 60 to 80 psi will be available to actuate the cylinders.
(2) Air pressure shall be maintained on the cylinder piston at
each end of its stroke. A pneumatic valve positioner shall be provided on all rate-of-flow control valve pneumatic cylinder actuators to accurately position the valves from a 3 to 15 psi air signal (linear).
(3) Pneumatic cylinder actuators shall be in accordance with the
latest edition of AWWA C-540, Section 4, paragraphs 4.5 and 46, except that alternate materials of construction may be the same as those allowed for hydraulic cylinder actuators.
(4) Oil resistant, 2 ply, 250 psi working pressure hose shall be
provided. (5) Pneumatic actuators shall be Keystone MRP or MRO, or Bray
Series 92/93, or equal. 4. Valve Floor Stands and Extension Stems a. Valve floor stands shall be of heavy duty pattern and shall, in case of
valve gear at the valve, be equipped with indicators.
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b. Floor stand stems for indicating type stands shall be of bronze or stainless steel and run in adequately designed and lubricated ball bearings.
c. Extension stems may be of cold rolled steel between the valve gear
and stand only. Adjustable cast iron stem bracket shall be provided at 10 foot intervals on all extension stems in excess of 10 foot lengths. They shall be furnished with the stand.
d. In case of valve gear actuator at stand, extension between valve and
gear operator may be extended, bonnet type, with crank operator. Extended bonnets shall be provided with bracket supports at not less than 15 foot intervals.
e. Valve stand shall be heavy pattern cast iron, at least 32 inches high.
They shall be bronze mounted, handwheel operated on ball bearings. Valve stand handwheels shall be the same diameter as those shown for handwheels directly on valves. Non-rising stem stands shall have valve position indicator. Rising stem stands may be furnished without valve position indicators.
f. Extension stems for non-rising stem valves shall have stem guides
for each 10 foot length of extension stem. g. All extension stems shall be connected by bolted couplings for
connection to a removal from the valves and stands. Nuts and bolts in connections shall be stainless steel. All extension stem connecting pins shall be stainless steel.
5. Buried Actuators a. Buried valve actuators shall be lubricated for life of the valve and be
designed for satisfactory operation in groundwater conditions. (They shall be designed for operation of Class 150 B butterfly valves.) They shall also be nut and key type of 30 inch bury over top of pipe. All valves with nuts over 30 inches below top of valve box shall have extension stems to within 12 inches of top of boxes.
B. Workmanship and Painting 1. Workmanship and painting shall be in accordance with Section 4,
paragraphs 4.1 and 4.2, and subparagraphs 4.2.1 thru 4.2.2, except that non-buried or submerged valves inside plants shall be prepared for and given a prime coat only.
C. Marking and Shipping 1. In addition to valve marking as specified under Section 6, paragraph 6.1
Marking, each valve shall be given a tag number which will correspond to the valve locations shown on the Drawings. Tags shall be of durable
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material and markings and shall be secured to the valve by pliable steel wire.
D. Valve Boxes
1. Valve boxes shall be provided for each buried valve. They shall be cast iron,
of heavy pattern, adjustable type and provided with cast iron cover. The upper section of each box shall have a bottom flange of sufficient bearing area to prevent settling. The bottom of the lower section shall enclose the stuffing box and operating nut of the valve. Boxes shall have barrels of not less than 5 inch in diameter and be of length adapted to pipe cover. Boxes shall be adjustable, with a lap of at least 6 inch when in the most extended position. Covers shall have the word "OPEN" and an arrow indicating the direction of opening cast into covers in raised letters. Provide valve stem extensions for all buried valves.
2.03 TAPPING VALVES AND TAPPING SLEEVES AND CROSSES
A. Tapping Valves
1. Tapping valves for use with tapping sleeve and crosses shall be in accordance with the specifications for resilient seated gate valves, except that one end shall have a flanged connection and the other end either a hub or mechanical joint connection.
2. They shall be for 250 psi in sizes 2-inch through 30-inch.
3. Valves shall open by turning counterclockwise.
4. Inlet flanges of valves shall meet ANSI B16.1, Class 125 or 250 standard,
depending on the rated pressure of the line. 5. Tapping valves shall be Clow, American Darling, Flow Control, M&H, or
equal.
B. Tapping Sleeves and Tapping Crosses
1. Tapping sleeves and tapping crosses shall have heavy cross sections to strengthen the existing water main at the point of installation.
2. Mainline end connections to existing pipeline shall be mechanical joint
with large and small gaskets or hub end for lead and jute joints.
3. Mechanical joint tapping sleeves and crosses shall have a maximum working pressure of 250 psi. Sleeves and crosses with caulked-type joints shall have a maximum water working pressure of 150 psi.
4. Outlet end of tapping sleeves and crosses shall have ANSI B16.1, Class 125
or Class 250 flanges, depending on the rated pressure of the line.
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C. Quality Standard
1. All tapping valves, tapping sleeves and tapping crosses shall be in features and quality equal to those of American Flow Control Series 2500, Mueller Company or Dresser Manufacturing Company.
D. Test and Certification
1. Tests on tapping valves shall be in accordance with these Specifications for
resilient seated gate valve.
E. Protection
1. Tapping Valves
a. Protection of tapping sleeves and valves shall be in accordance with these Specifications for double disc parallel seat gate valves.
2. Tapping Sleeves and Crosses
a. Protection for tapping sleeves and crosses shall be in accordance
with these Specifications for cast iron pipe fittings.
F. Marking and Tagging Valves
1. Tagging of tapping valves shall be in accordance with these Specifications for resilient seated gate valves or in accordance with C-500 for double disc parallel seat gate valves.
2.04 DRY BARREL FIRE HYDRANTS
A. General
1. This standard covers post-type dry barrel fire hydrants with compression type valves, operating against pressure. They shall meet all requirements of ANSI/AWWA Specification C502.
2. They shall have two 2-1/2 inch hose connection nozzles and one 4-1/2 inch steamer connection nozzle, all with caps and drains and have national standard threads (or insert required thread standard here).
3. Main valve opening size shall be 5-1/4 inch which must remain closed when the above ground breakable safety section of the hydrant barrel is broken off.
4. All hydrants shall have 6 inch mechanical joint bell connection designed for 250 psig working pressure for 3-way hydrants and 200 pounds working water pressure for 2– or 1-way hydrants, in accordance with ANSI/AWWA C110/A21.10-93. Joint accessories are to be furnished with the hydrant.
5. Finish paint color of the hydrant barrel above ground line shall be selected by the OWNER.
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6. All hydrants shall have an automatic drain feature providing positive barrel drainage after hydrant use.
7. The lowest outlet level of the hydrant shall be located sufficiently above the indicated ground level to permit a 360° swing of a 15-inch hydrant wrench. One standard hydrant wrench is to be provided. All hydrants shall open by turning counterclockwise.
8. Where the OWNER has standardized on one particular make and model fire hydrant and desires that the hydrants furnished under this project be such standard, that make and model hydrant, namely Mueller Super Centurion A423 or M&H 129, will govern.
9. All further reference to section and paragraph numbers shall be those of ANSI/AWWA C502.
B. Affidavit of Compliance
1. The manufacturer shall furnish the OWNER, through the ENGINEER, 3 copies of an affidavit in accordance with Section 1, paragraph 1.7.
C. Materials
1. All materials used in the production of dry-barrel fire hydrants shall conform to the referenced standards for each material as set forth in Section 2 - Materials, paragraphs 2.2.1 thru 2.2.5.
D. General Design and Detailed Design
1. General Design
a. General design of hydrants shall be in accordance with Section 3, paragraph 3.1 and subparagraphs 3.1.1 thru 3.1.6.
2. Detailed Design
a. Valves
(1) Valves shall be in accordance with Section 3, paragraph 3.4.1 and subparagraphs 3.4.1.1 thru 3.4.1.4.
b. Size
(1) Hydrant size shall be in accordance with Section 3, paragraph 3.2.4, except that main valve opening diameter may not be less than 5-1/4 inches.
c. Bury-length and Trench Depth
(1) Unless otherwise noted, depth of hydrant will be 3'-6". In the event that a hydrant is installed at a location requiring greater than the "standard bury" depth, the CONTRACTOR will be required to provide the riser sections required at no additional cost to the OWNER.
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d. Barrel Sections
(1) Hydrant barrel sections shall be in accordance with Section 3, paragraph 3.2.2 and subparagraphs 3.2.2.1 and 3.2.2.2 except that the flange or other joint at 2 inches above the ground line shall be a breakable joint.
e. Outlet Nozzles
(1) Hydrant outlet nozzles shall be in accordance with Section 3, paragraph 3.2.3 and subparagraph 3.2.3.1 and 3.2.3.2 except that leading shall not be used in fastening nozzles to the hydrant barrel.
f. Operating Stem and Mechanism
(1) The hydrant operating mechanism shall be in accordance with Section 3, paragraph 3.2.5 and subparagraphs 3.2.5.1 thru 3.2.5.5.
g. Drain Outlet
(1) An automatic drain outlet shall be provided. The outlet shall be located in the base or barrel or between the base and barrel. Tapping of the outlet is not required. Other features of the drain outlet shall be in accordance with Section 3, paragraphs 3.4.2 thru 3.4.2.4.
h. O-ring Seals
(1) A seal that uses O-rings shall be used. O-rings and their ring groves shall be in accordance with Section 3, paragraph 3.6.1 and subparagraph 3.6.1.1.
i. Gaskets
(1) Gaskets shall be in accordance with Section 3, paragraph 3.6.4.
j. Bolts and Nuts
(1) With the exception of flange bolts at breakable hydrant barrel section, all bolts and nuts shall be of corrosion resistant material, in accordance with Section 3, paragraph 3.7. Breakable section bolts may be of steel.
k. Hydrant Inlet
(1) The base of the hydrant shall have a side inlet provided with a hub end for mechanical joint connection provided with strapping lugs for strapping hydrant to water main to prevent separation of the hydrant and hydrant branch from the main line, or the hub end may be plain mechanical joint, provided
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locked type pipe joints are used between the hydrant and water main. Refer to Section 02610 of these Specifications for optional methods of restraint for fire hydrants.
E. Workmanship and Painting
1. Workmanship shall be in accordance with Section 4, paragraph 4.1 and subparagraph 4.1.1 through 4.1.3.
2. Painting shall be in accordance with Section 4, paragraph 4.2 and sub-paragraphs 4.2.1 through 4.2.4.
3. Hydrants shall carry a 10-year limited warranty on material and workmanship.
F. Inspection, Testing and Rejection
1. Testing shall be in accordance with Section 5, paragraph 5.1 and (subparagraphs 5.1.1 through 5.1.3). The ENGINEER shall be furnished 2 copies of all tests.
2. Inspection and rejection shall be in accordance with Section 5, paragraph 5.3, with 2 copies of affidavit being supplied the ENGINEER.
G. Marking and Shipping
1. Marking and shipping shall be in accordance with Section 6, paragraphs 6.1 and 6.2, except that hydrants having a depth of bury greater than the standard 3'-6", shall be given a tag number which corresponds to the hydrants plant location number. Tags, if required, shall be of durable materials and markings.
PART 3 EXECUTION 3.01 INSTALLATION (In Structures, Vaults and Basins)
A. Interior
1. All valves and appurtenances shall be installed at the locations shown on the Drawings. All necessary materials, parts, operators and gaskets shall be furnished and installed under this Contract.
2. All valves shall be installed with their operators located in such a plane that
it will not interfere with pedestrian traffic. All valves with the operator more than 7'-0" off the floor shall be modified for chain operation at no cost to the OWNER.
3. Particular attention shall be paid to the location and orientation of all valve
operators to provide an accessible installation. Should any valve be located with the operator inaccessible and simple re-orientation of the valve would make it accessible, the valve shall be moved at no cost the OWNER.
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4. All pipe and valves shall be supported by pipe hangers, concrete piers or other special supports as required to prevent undue stress being placed on the pipe, any fitting, valve or item of equipment. Equipment shall not be used to support pipe and fittings. The pipe shall be free of all openings in walls and slabs when the final position of the piping is attained and before sealing the annular space about the pipe.
5. The CONTRACTOR shall thoroughly clean the valves fittings before starting
erection. All scale, rust and dirt shall be removed by power brushing and/or solvent cleaning.
B. Exterior
1. Valves in ground shall be installed with operating stems vertical, unless
otherwise shown on the Drawings or called for in these Specifications. Tops of operating nuts shall be not more than 30 inches below ground surface. Where valve operating nuts are more than 30 inches below tops of valve boxes, stems shall be provided to bring the operating nut to within 12 to 24 inches of box tops.
2. Valve boxes shall be accurately centered over valve operating nuts and the
backfill shall be mechanically tamped about them, to prevent subsequent movement. Tops of boxes shall be flush with ground surface, paving, walk, or road surface.
3. The cost of the concrete collar, required about valve boxes, shall be
included in the unit price for the valve and/or box.
4. All valves, valve stands, extension stems, sluice gates, shear gates, mud valves, check valves, and floor boxes, on or in structures, shall be installed as shown on the Drawings. Valve stands shall be set plumb and level and shall be anchored as shown on the Drawings. Stands shall be properly centered over valve stems or operating mechanism. Any valve or stand found to be binding unduly shall be made to operate freely.
C. For AWWA butterfly valves, installation shall be in accordance with Appendix A of
ANSI/AWWA C504.
D. For gate valves, installation shall be in accordance with Appendix A of ANSI/AWWA C515.
3.02 SHOP PAINTING A. Interior surfaces of all valves, the exterior surfaces of buried valves and
miscellaneous piping appurtenances shall be given a shop finish of an asphalt varnish conforming to Federal Specification TT-V51e for Varnish Asphalt.
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B. The exterior surface of various parts of valves, operators, floorstands and miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease, or other foreign matter and thereafter 1 shop coat of an approved rust-inhibitive primer such as specified in Section 09900 shall be applied in accordance with the instructions of the paint manufacturer.
3.03 INSPECTION AND TESTING
A. The various pipelines in which the valves and appurtenances are to be installed are specified to be field tested. During these tests any defective valve or appurtenance shall be adjusted, removed and replaced, or otherwise made acceptable to the ENGINEER.
B. Various regulating valves, strainer, or other appurtenances shall be tested to
demonstrate their conformance with the specified operational capabilities any deficiencies shall be corrected or the device replaced or otherwise made acceptable to the ENGINEER.
C. Testing shall be done in accordance with Section 02610 "TESTING" with no visible
leaks allowed on valves. 3.04 FIELD PAINTING
A. Field painting is specified in Section 09900.
B. The CONTRACTOR and the equipment manufacturer shall coordinate shop paint and field paint to assure compatibility, in accordance with Section 09900.
3.05 START-UP AND TRAINING A. None required. 3.06 TOOLS AND SPARE PARTS
A. All special tools required for normal operation and maintenance shall be furnished by the valve manufacturer.
3.07 METHOD OF PAYMENT
A. Payment for the complete system shall be included in the lump sum or unit price bid for the project and shall include the furnishing of materials, equipment and parts and installation of all components to provide a completely functional system.
END OF SECTION
***
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SECTION 15104
SPECIALTY VALVES (WATER) PART 1 GENERAL 1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment, and incidentals required and install complete and ready for operation all valves and appurtenances as shown on the Contract Drawings and as specified herein.
B. The equipment shall include but not be limited to, the following:
1. Air and vacuum valves. 2. Air release valves. 3. Surge relief valves. 4. Pressure reducing. 5. Pump control valves. 6. Flow control valves.
1.02 RELATED WORK
A. Excavation, backfill and grading is included in Division 2.
B. Piping is included in Division 2
C. Valves and service accessories for plumbing systems are included in Division 15.
D. Painting is in Division 9.
E. Electrical work is in Division 16.
F. Special sequence or schedule requirements are specified in Section 01010 - Summary of Work.
G. Valves for water isolation are specified in Section 15102.
H. Valves and service accessories on all plumbing and chemical systems are
included in this Division, Section 15101.
I. Mechanical identification markers, tag and plates are included in this Division, Section 15190.
1.03 DESCRIPTIONS OF SYSTEMS
A. All of the equipment and materials specified herein are intended to be standard for use in controlling the flow of water.
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B. See the Drawings for valve sizes, quantities, connections, class, type of actuator and location.
1.04 QUALIFICATIONS
A. All types of valves and appurtenances shall be products of well-established firms who are fully experienced, reputable, and qualified in the manufacture of the particular equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these Specifications as applicable.
B. Acceptable Manufacturers
1. Air and Vacuum Valves - Valve and Primer Corp., APCO, Golden Anderson,
ARI, or equal. 2. Air Release Valves - Valve and Primer Corp., APCO, Golden Anderson, ARI,
or equal. 3. Surge Relief Valves - Golden Anderson, Ross, or equal. 4. Pressure Reducing – Golden Anderson, Cla-Val, or equal. 5. Pump Control Valves – Golden Anderson (GA), or equal. 6. Flow Control Valves – Golden Anderson (GA), or equal.
1.05 SUBMITTALS
A. Complete shop drawings of all valves and appurtenances shall be submitted to the ENGINEER in accordance with the requirements of Sections 00820 and 00700/00710.
B. The manufacturer shall furnish to the ENGINEER 2 copies of written certification
that the valves have been tested hydrostatically and tested for proper performance, and that the materials of construction conform to the appropriate ASTM specifications. Refer to the Special Conditions for the number of copies of descriptive literature, catalog data sheets, and Drawings to be submitted to the ENGINEER, for review and comment.
1.06 OPERATING INSTRUCTIONS
A. Manufacturer's operating and maintenance instructions shall be furnished to the ENGINEER as set forth in Section 01600.
1.07 EQUIPMENT OR SYSTEM WARRANTY
A. Refer to Section 01600 for warranty requirements.
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PART 2 PRODUCTS 2.01 MATERIALS AND EQUIPMENT
A. General
1. All valves and appurtenances shall be of the size shown on the Drawings and as far as possible all equipment of the type shall be from one manufacturer.
2. All valves and appurtenances shall have the name of the maker,
flow-directional arrows, and the working pressure for which they are designed cast in raised letters on some appropriate part of the body.
3. All buried valves shall open left (counterclockwise). Insofar as possible, all
valves shall open counterclockwise.
4. All valves must be provided with suitable operating devices and adapted for operation in the position in which they are shown on the Drawings.
2.02 AIR AND VACUUM VALVES (FOR PIPELINES AND PUMPS)
A. General
1. Air and vacuum valves shall be designed to allow large quantities of air to escape out of the orifice when filling a pipeline and to close watertight when water enters the valve. To break a vacuum, the air and vacuum valve shall also permit large quantities of air to enter through the orifice, when a pump is stopped or the pipeline is being drained. The discharge orifice area shall be equal to or greater than the inlet of the valve. The valve shall consist of a body, cover, baffle, float, seat and where called for, a water diffuser. The baffle will be designed to protect the float from direct contact of the rushing air and water to prevent the float from closing prematurely in the valve. The seat shall be fastened into the valve cover without distortion and shall be easily removable. The float shall be of stainless steel designed to withstand 1,000 psi. The float shall be center guided for positive seating.
2. Air and vacuum valves for installation on pump discharge lines, where the
water working pressure is 150 psi or less, in sizes 3 inch and under, shall be provided with water diffuser and throttling devices and have screw connections. In sizes 4 inch and over they shall be provided with surge check units and have flanged connections.
3. Air and vacuum valves for installation on pump discharge lines, where the
water working pressure is over 150 psi, in sizes 3 inch and under, shall be provided with diffuser and throttling devices and have screw connections. In sizes 4 inch and over they shall be provided with surge check units and have flagged inlet and outlet connections.
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4. Air and vacuum valves on water transmission mains, at change of downward gradient and drastic change in gradient (not peaks), in sizes 2-inch and under, shall have water diffusers and screw connections. In sizes 3 inch and over they shall be provided with surge check units and have flanged inlet connection and protection hoods on outlet.
5. Air and vacuum valves on water transmission mains at peak changes in
grade (highest point between adjacent low points) with the auxiliary (small) air release valve meeting requirement of these Specifications for Air Release Valves.
B. Materials of Construction
1. Body, Cover and Baffle
a. Valve bodies, covers and baffles shall be of cast iron, ASTM A48,
Class 30.
2. Float
a. Valve floats shall be of stainless steel, ASTM A240.
3. Seat
a. Valve seats shall be of Buna-N, nitrile rubber.
4. Bushings, Screws and Float Guides
a. Bushings, screws and float guides shall be stainless steel or bronze, with selection being best to avoid galvanic action.
5. Water Diffuser
a. Water diffuser shall be bronze.
C. Throttling Device
1. Throttling devices shall be of cast iron or malleable iron with screw
connections, Valve and Primer Corp., APCO, or equal.
D. Surge Check Unit
1. The surge check unit shall be iron body, bronze mounted, Valve and Primer Corp., APCO Model 1600, Surge Check Valve, or equal. Surge check units shall have flanged ends.
E. Flanged Ends
1. Unless otherwise noted on the Drawings all flanged connections (inlet
and outlet) shall be ANSI B1.6.1, 125 pound standard.
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F. Drainage Provision
1. All valve bodies shall be provided with drain plugs.
G. Painting
1. Valves shall receive a heavy coat of red lead TTP86, Type IV, or equal.
H. Testing
1. All air and vacuum valves shall be hydrostatically and shop tested for
proper performance prior to shipment.
I. Marking
1. Cast markings shall appear on the valve body showing valve size, manufacturer's name or trade mark, water working pressure and model number.
2.03 AIR RELEASE VALVES (FOR PIPELINES AND PUMPS)
A. General
1. Air release valves shall be designed with a small orifice to serve as a venting port wherever air is entrained in water under pressure. They shall be capable of automatic intermittent release of accumulated air in the valve and closing tight when water enters the valve.
2. Air release valves for installation (along with air and vacuum valves) on
vertical turbine and deep well pumping units, where pump operation is continuous or nearly so, and water working pressure does not exceed 150 psi, shall be simple lever type and have screw connections. If operating water pressure exceeds 150 psi, the valves shall have com-pound levers and screw connections.
3. Air release valves on water transmission mains, regardless of whether
they are used in conjunction with air and vacuum valves (as custom combination air release valves) or whether they are used alone on long stretches of transmission main without a summit, shall be compound lever type with screw connections.
B. Material of Construction
1. Materials of construction for Air Release Valves shall be the same as
specified for Air and Vacuum Valves.
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C. Other Features and Requirements
1. Drainage and/or blowoff provisions, painting, testing and marking shall be the same as specified for Air and Vacuum Valves.
2.04 SURGE RELIEF VALVE A. Construction 1. Surge relief valve shall consist of a main valve assembly and a pilot
control system, completely assembled and tested as a unit and ready for field installation.
B. Main Valve 1. Main valve body shall be angle style of high strength cast iron
conforming to ASTM A126, Class B, with integral flanges, faced and drilled per ANSI B16.1, Class 125, as listed in the valve schedule or shown on plans. The valve shall be full-ported, with a flow area through the valve no less than the area of its nominal pipe size when the valve is fully open.
2. The main valve shall operate on the differential piston principle such that
the area on the underside of the piston is no less than the pipe area and the area on the upper surface is greater than that of the underside. There shall be no diaphragms or springs in the main valve.
3. The valve piston shall be guided on its outside diameter by long
stationary vee-ports located downstream of the seat to minimize the consequences of throttling. All throttling shall be by the vee-ports and not by the seat itself. All internal guiding and sealing surfaces shall be stainless steel.
a. A replaceable seat ring of Buna-N or other suitable material shall
be mechanical attached to the piston by means of a stainless steel follower ring and stainless steel fasteners.
b. The piston shall be sealed by Buna-N or other resilient material
suitable for the opening pressures and fluid type. c. A position indicator rod shall be provided, mechanically attached
to the piston, and passing through the valve cover. The indicator rod shall be sealed by a compression-type, Teflon packing.
4. The valve shall be fully capable of operating in any position without the
need of springs and shall not incorporate stems, stem guides, or spokes in the water way.
5. The main valve shall be serviceable in the line through a single flanged
cover which provides easy access to all internal components.
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C. Provide a system of hydraulic controls to enable the valve to perform the function(s) listed below.
1. Provide a direct-acting, diaphragm-operated, spring-loaded stainless steel
relief pilot. The pilot spring shall be factory set at the desired relief pressure, but easily field adjustable from near zero to 15 percent above the factory setting. The relief pilot shall be factory set at 175 psig.
2. Provide an adjustable closing speed control, y-strainer with stainless steel
screen, pilot isolating valves, and all stainless steel pilot piping. Pilot system shall be suitable for the working pressure.
D. Function 1. The pressure relief valve shall remain tightly closed whenever system
(inlet) pressure is below the setting of the relief pilot. 2. The pressure relief valve shall quickly open when the system pressure
exceeds the setting of the relief pilot. a. The pressure relief valve shall remain open as long as the system
pressure equals or exceeds the setting of the relief pilot. b. The pressure relief valve shall close slowly when the system
pressure falls below the setting of the relief pilot. The speed of valve closure shall be adjustable.
E. Shop Finishing 1. Exterior ferrous surfaces shall be painted with primer as specified in
Section 09900. 2. Interior, submerged ferrous surfaces shall be painted with paint system
as specified in Section 09900. F. Manufacturer 1. GA Industries, Inc., Cranberry Township, Pennsylvania, Figure No. 6600-
angle body; Ross; Val-Matic; or equal. 2.05 PRESSURE REDUCING VALVES
A. General
1. The reducing valve shall function to maintain a uniform valve downstream pressure preadjusted on the control pilot handwheel or adjusting screw. The control pilot shall be capable of field adjustments from near zero psi to 10 percent above the factory preset pressure, which shall be 90 psi.
2. The valve shall be completely piped ready for installation.
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B. Description
1. The main valve shall operate on the differential piston principle such that
the area of the underside of the piston is no less than the pipe area, and the area on the upper surface of the piston is of a greater area than the underside of the piston.
2. The valve piston shall be guided on its outside diameter by long stroke
stationary Vee ports which shall be downstream of the seating surface to minimize the consequences of throttling. Throttling shall be done by the valve Vee ports and not the valve seating surfaces.
3. The valve shall be capable of operating in any position and shall
incorporate only one flanged cover at the valve top from which all internal parts shall be accessible. There shall be no stems, stem guides, or spokes within the waterway. There shall be no springs to assist the valve operation.
C. Materials of Construction
1. The valve body shall be of cast iron ASTM A-126 with flanges conforming
to the latest ANSI Standards. The valve shall be extra heavy construction throughout. The valve interior trim shall be bronze B-62 as well as the main valve operation.
2. The valve seats shall be easily renewable while no diaphragm shall be
permitted within the main valve body.
3. All controls and piping shall be of non-corrosive construction.
4. A visual valve position indicator shall be provided for observing the valve piston position at any time.
D. Figure Number
1. The valve shall be as manufactured by GA Industries of Mars, Pennsylva-
nia, size as indicated on the plans, and shall be their Fig. 4500-d (globe), or equal.
E. Painting
1. After testing, the valve and parts shall be cleaned and all surfaces, except
machined surfaces, shall receive 2 coats of manufacturer's standard shop coat paint. Machined surfaces shall receive a coating of water repellent, rust inhibitive compound.
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F. Marking
1. Cast marking on valve bodies or covers shall show manufacturer's name or trademark, valve size and figure number.
2.06 FLOW CONTROL VALVES A. Construction 1. The valve body shall be of the in-line wye pattern of cast iron conforming
to ASTM A-126, Class B or ductile iron conforming to ASTM A-536, Grade 65-45-12, depending on line pressure or system conditions, with integral flanges faced and drilled to ANSI B16.1, Class 125 or Class 250 depending on line pressure or system conditions. The valve shall be inherently self-cleaning with a net flow area of no less than the area of its nominal pipe size. The body shall have a replaceable 316 stainless steel seat and a seat inspection port.
2. The valve disc shall be ductile iron with a renewable resilient seat ring of
ultra-high molecular weighty polyethylene (UHMWPE) or other suitable resilient material, retained by a stainless steel follower ring with stainless steel screws. The valve stem shall be stainless steel and guided by a long bronze bearing in the valve cover and sealed where it passes through the cover by means of a replaceable pressure actuated seal.
3. The valve disc shall be designed to close quickly upon flow reversal,
independent of the actuator, to prevent backflow. A spring shall be provided to assist valve closure.
4. The electric motor actuator shall be multi-turn, non-modulating 230/460
VAC, 60 Hertz, 3-phase NEMA 4 meeting AWWA C540 with integral limit switches, torque switches, visual position indicator and manual handwheel. Controls shall include reversing starter, control transformer, local-off-remote selector, indicating lights and open/close push buttons. The actuator shall provide a minimum valve operating time of 300 seconds with an integral stepping mode to extend the operating time over any portion of the valve stroke. The start/end and the on/off pulse time shall be field adjustable.
B. Function 1. The pump control valve with electric motor actuator shall function to
minimize surges associated with the normal starting and stopping of the pumps. The valve shall slowly open after the pump has come up to speed and pressure at pump start. A normal pump shut down shall be initiated by the valve slowly closing against the running pump, turning off the pump only after the valve has completely closed. The valve shall quickly close independently of the actuator upon flow reversal resulting from power outage, pump or pump motor failure or other sudden stoppages of pumping. The valve shall be designed to handle pressures of up to
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320 psig when the valve is closed and pressures of up to 230 psig with the valve is full open.
C. Manufacturer 1. The valve shall be the Series 1600-M “CHECKtronic” Pump Control Valve
as manufactured by GA Industries, Inc., Cranberry Township, Pennsylvania, USA, or equal, with a Limitorque MX Actuator as manufactured by Flowserve or equal.
2.07 PUMP AND FLOW CONTROL VALVES A. Construction 1. The valve body shall be of the in-line wye pattern of cast iron conforming
to ASTM A-126, Class B or ductile iron conforming to ASTM A-536, Grade 65-45-12, depending on line pressure or system conditions, with integral flanges faced and drilled to ANSI B16.1, Class 125 or Class 250 depending on line pressure or system conditions. The valve shall be inherently self-cleaning with a net flow area of no less than the area of its nominal pipe size. The body shall have a replaceable 316 stainless steel seat and a seat inspection port.
2. The valve disc shall be ductile iron with a renewable resilient seat ring of
ultra-high molecular weighty polyethylene (UHMWPE) or other suitable resilient material, retained by a stainless steel follower ring with stainless steel screws. The valve stem shall be stainless steel and guided by a long bronze bearing in the valve cover and sealed where it passes through the cover by means of a replaceable pressure actuated seal.
3. The valve disc shall be designed to close quickly upon flow reversal,
independent of the actuator, to prevent backflow. A spring shall be provided to assist valve closure.
4. The electric motor actuator shall be multi-turn, non-modulating 230/460
VAC, 60 Hertz, 3-phase NEMA 4 meeting AWWA C540 with integral limit switches, torque switches, visual position indicator and manual handwheel. Controls shall include reversing starter, control transformer, local-off-remote selector, indicating lights and open/close push buttons. The actuator shall provide a minimum valve operating time of 300 seconds with an integral stepping mode to extend the operating time over any portion of the valve stroke. The start/end and the on/off pulse time shall be field adjustable.
B. Function 1. The pump control valve with electric motor actuator shall function to
minimize surges associated with the normal starting and stopping of the pumps. The valve shall slowly open after the pump has come up to speed and pressure at pump start. Once the valve is fully open, it shall throttle
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as necessary in response to a remote 4-20mA position signal. A normal pump shut down shall be initiated by the valve slowly closing against the running pump, turning off the pump only after the valve has completely closed. The valve shall quickly close independently of the actuator upon flow reversal resulting from power outage, pump or pump motor failure or other sudden stoppages of pumping. The valve shall be designed to handle pressures of up to 320 psig when the valve is closed and pressures of up to 230 psig with the valve is full open.
C. Manufacturer 1. The valve shall be the Series 1600-M “CHECKtronic” Pump Control Valve
as manufactured by GA Industries, Inc., Cranberry Township, Pennsylvania, USA, or equal, with a Limitorque MX Actuator as manufactured by Flowserve or equal.
PART 3 EXECUTION 3.01 INSTALLATION (IN STRUCTURES, VAULTS AND BASINS)
A. Interior
1. All valves and appurtenances shall be installed at the locations shown on the Drawings. All necessary materials, parts, operators and gaskets shall be furnished and installed under this Contract.
2. All valves shall be installed with their operators located in such a plane
that it will not interfere with pedestrian traffic.
3. Particular attention shall be paid to the location and orientation of all valve operators to provide an accessible installation. Should any valve be located with the operator inaccessible and simple re-orientation of the valve would make it accessible, the valve shall be moved at no cost to the OWNER.
4. All pipe and valves shall be supported by pipe hangers, concrete piers or
other special supports as required to prevent undue stress being placed on the pipe, any fitting, valve or item of equipment. Equipment shall not be used to support pipe and fittings. The pipe shall be free of all open-ings in walls and slabs when the final position of the piping is attained and before sealing the annular space about the pipe.
5. The CONTRACTOR shall thoroughly clean the valves and fittings before
starting erection. All scale, rust and dirt shall be removed by power brushing and/or solvent cleaning.
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B. Exterior
1. Valves in ground shall be installed with operating stems vertical, unless otherwise shown on the Drawings or called for in these Specifications. Tops of operating nuts shall be no more than 30 inches below ground surface. Where valve operating nuts are more than 30 inches below tops of valve boxes, stems shall be provided to bring the operating nut to within 12 to 24 inches of box tops.
2. Valve boxes shall be accurately centered over valve operating nuts and
the backfill shall be mechanically tamped about them, to prevent subse-quent movement. Tops of boxes shall be flush with ground surface, paving, walk, or road surface.
3. All valves, valve stands, extension stems, and floor boxes, on or in
structures, shall be installed as shown on the Drawings. Valve stands shall be set plumb and level and shall be anchored as shown on Draw-ings. Stands shall be properly centered over valve stems or operating mechanism. Any valve or stand found to be binding unduly shall be made to operate freely.
3.02 SHOP PAINTING
A. Interior surfaces of all valves, the exterior surfaces of buried valves and miscel-laneous piping appurtenances shall be given a shop finish of an asphalt varnish conforming to Federal Specification TT-V51e for Varnish Asphalt.
B. The exterior surface of various parts of valves, operators, floorstands and
miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease, or other foreign matter and thereafter on shop coat of an approved rust-inhibitive primer such as specified in Section 09900 shall be applied in accordance with the instructions of the paint manufacturer.
C. Ferrous surfaces obviously not to be painted shall be given a shop coat of
grease or other suitable rust-resistant coating.
D. Field painting is included under Division 9. 3.03 INSPECTION AND TESTING A. The various pipelines in which the valves and appurtenances are to be installed
are specified to be field tested. During these tests any defective valve or appurtenance shall be adjusted, removed and replaced, or otherwise made acceptable to the ENGINEER.
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B. Various regulating valves, strainer, or other appurtenances shall be tested to demonstrate their conformance with the specified operational capabilities and any deficiencies shall be corrected or the device replaced or otherwise made acceptable to the ENGINEER.
3.04 FIELD PAINTING
A. Field Painting is specified in Section 09900.
B. The CONTRACTOR and the equipment manufacturer shall coordinate shop paint and field paint to assure compatibility, in accordance with Section 09900.
3.05 START-UP AND TRAINING
A. Valve actuator supplier shall provide on site, factory-certified personnel for start-up and operation and maintenance training for a period of one day.
END OF SECTION
***
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SECTION 15140 HANGERS AND SUPPORTS PART 1 GENERAL 1.01 SCOPE OF WORK A. Furnish all labor, materials, equipment, and incidentals and install pipe (and
tubing), hangers, supports, beam clamps, hanger rods, turnbuckles, rings, friction clamps, concrete inserts, and anchor bolts including, in general, all hanging and supporting devices for supporting piping, tubing, and appurtenances. Supports shall be as shown on the Drawings, as specified herein, in other sections, or as acceptable to the ENGINEER.
B. Unless otherwise noted, whenever the word "support" is used herein it shall
mean any overhead hangers, wall bracket, supports from the floor, friction clamps and attendant beam clamps, concrete inserts, rods, support pipes, and other necessary equipment for supporting and/or anchoring any pipes, tubing, or appurtenances. Where the word pipe is used it shall refer to valves, pipe, appurtenances, and tubing.
C. Special supports shall be constructed in accordance with details shown on the
Drawings or as acceptable to the ENGINEER.
D. The CONTRACTOR shall be sure that all supports are consistent with the most recent state and local code requirements in this regard.
1.02 RELATED WORK
A. Concrete is included in Division 3.
B. Painting is included in Division 9, Section 09900.
C. Valves, appurtenances pipe and fittings are included in Divisions 2 and 15. D. Non-metallic supports are specified in Section 15060.
1.03 DESCRIPTION OF SYSTEM
A. All piping, tubing, valves, fittings, and appurtenances shall be properly and adequately supported and anchored so as to maintain the supported loads in proper position under all operating conditions without unnecessary movement or strain on any piece of equipment. There shall be no visible sagging between supports. Supports shall be approved standard design and in compliance within MSS-SP-58 and all government codes, where applicable. All support of the same type shall be identical, varying only with size, and the product of one manufacturer or fabricator. Supports shall be provided where indicated on the Drawings, where required, and where acceptable to the ENGINEER to form a complete workable system. If other types of pipe support other than those
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shown on the Drawings or specified are required, they shall be as acceptable to the ENGINEER. Perforated or solid strap iron and strap copper will not be permitted.
B. The minimum working factor of safety for supports shall be a minimum of 5
based on the ultimate tensile strength of the material, assuming waterfilled pipe is being supported at the maximum spacing as specified.
C. All pipe and appurtenances connected to equipment shall be supported in such
a manner as to prevent any strain being imposed on the equipment. When manufacturers have indicated requirements that piping loads shall not be transmitted to their equipment, the CONTRACTOR shall submit written certifi-cation stating compliance.
1.04 QUALIFICATIONS AND RESPONSIBILITY
A. The CONTRACTOR shall have the sole responsibility for proper permanent support and/or anchorage of the piping systems.
B. Any reference to specific manufacturer or model number is for the purpose of
establishing a quality or parameter for specification writing and is not to be considered proprietary.
1.05 SUBMITTALS
A. A system schematic and loading calculations shall be submitted that shows the location types and maximum loads for each pipe support for all piping 3 inches in diameter or larger.
B. Wherever exceptions to the Specifications are taken or substitute equipment is
used, they shall be clearly defined by the CONTRACTOR in the Shop Drawing submitted.
PART 2 PRODUCTS 2.01 MATERIAL AND EQUIPMENT
A. These Specifications call attention to certain features, but do not purport to cover all details of construction of the units.
B. All the manufactured or fabricated items shall be fabricated in the manufac-
turer's or vendor's shop.
C. Support and hangers should be as manufactured by Anvil, B-Line, Carpenter and Patterson, or equal.
D. All parts of the supports shall be amply proportioned for all stresses that may
occur during fabrication, erection, and operation.
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E. Anchor bolts, nuts, sleeves, plates, washers, and other hardware are to be supplied and installed by the CONTRACTOR and shall be of ample size and number for their intended use and installed as recommended by the appropriate manufacturer.
F. For plastic and other similar piping as noted, supports shall be free of burrs
with a suitable pliable support liner. They should also provide the maximum support contact with the pipe for a minimum length of 3 inches along the length of the pipe.
2.02 PIPE HANGERS AND SUPPORTS FOR METAL PIPE
A. Suspended single pipes shall be supported by hangers suspended by steel rods from concrete inserts as indicated below:
1. Hanger rods shall be machine threaded and the strength of the rod shall
be based on root diameter. Hanger rods shall be of carbon steel (except rods under and above water shall be stainless steel) and shall have the minimum diameters as indicated on the Drawings.
2. Where applicable, concrete inserts for hanger rod sizes up to and
including 3/4 inch diameter shall be continuous type slotted metal inserts designed to be used in ceilings, walls or floors before the concrete is poured, as manufactured by the Unistrut Corp., Wayne, Michigan, or equal. Series P3200 inserts shall be used where supports are parallel to the main slab reinforcement and Series P3300 where the supports are perpendicular to the main slab reinforcement. Spot inserts shall be equal to Catalog No. P3245 or M24, as applicable.
3. Unless otherwise shown on the Drawings, concrete inserts for pipe
hanger rods for pipes up to 8 inches shall be Anvil "CB-Universal Concrete Insert" Figure 282 or Richmond "Malleable Adjustable Insert," or equal. For pipes larger than 8 inches, inserts shall be Richmond "Rocket Insert," or equal. Extra reinforcing steel must be placed around inserts so that the load from the pipe will be distributed over a greater area.
4. Turnbuckles shall be forged steel, Anvil Figure 230, or equal. 5. Pipe clevises shall be Anvil Figure 65, 260, 590 or equal. Pipe clamps
shall be Anvil Figure 216 or equal.
B. Wall or column supported pipes shall be supported by welded steel brackets equal to Anvil Figure 194, 195, and 199, or equal as required. Additional wall bearing plates shall be provided where required.
C. Where the pipe is located above the bracket, the pipe shall be supported by an
anchor chair and U-bolt assembly supported by the bracket for pipes 4 inches and larger and by a U-bolt for pipes smaller than 4 inches. Anchor chairs shall be equal to Carpenter & Patterson Figure No. 127, or equal. U-bolts shall be equal to Anvil Figure 120 and 137, or equal.
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D. Where the pipe is located below the bracket, the pipes shall be supported by
hangers suspended by steel rods from the bracket. Hangers and steel rods shall be as specified above.
E. Wall or column-supported pipes 2 inches and smaller may be supported by
hangers equal to Carpenter & Patterson Figures 179 or 237, or equal, as required.
F. Floor-supported pipes 3 inches and larger in diameter shall be supported by
either cast-in-place concrete supports or adjustable pipe saddle supports unless specifically indicated on the Drawings. In general, concrete supports shall be used when lateral displacement of the pipes is probable (unless lateral support is provided), and pipe stanchion-type supports shall be used where lateral displacement of the pipes is not probable.
G. Each concrete support shall conform to the details shown on the Drawings or as
accepted by the ENGINEER. Concrete shall be poured after the pipe is in place with temporary supports. Top edges and vertical corners of each concrete support shall have 1-inch bevels. Each pipe shall be secured on each concrete support by a wrought iron or steel anchor strap anchored to the concrete with cast-in-place bolts or with expansion bolts. Where directed by the ENGINEER, vertical reinforcement bars shall be grouted into drilled holes in the concrete floor to prevent overturning or lateral displacement of the concrete support. Unless otherwise directed by the ENGINEER, maximum support height shall be 5-feet.
H. Concrete piers used to support base elbows and tees shall be similar to that
specified above. Piers may be square or rectangular.
I. Each adjustable pipe saddle support shall be screwed or welded to the corresponding size 150-lb. companion flanges or slip-on welding flanges, respectively. Supporting pipe shall be of Schedule 40 steel pipe construction. Each flange shall be secured to the concrete floor by a minimum of 2 expansion bolts per flange. Adjustable saddle supports shall be equal to Anvil Figure No. 264, or equal. Where used under base fittings, a suitable flange shall be sub-stituted for the saddle.
J. Floor-supported pipes less than 3 inches shall be supported by fabricated steel
supports.
K. Vertical piping shall be supported as follows:
1. Where pipes change from horizontal to vertical, the pipes shall be supported on the horizontal runs within 2 feet of the change in direction by pipe supports as previously specified herein.
2. For vertical runs exceeding 15 feet, pipes shall be supported by approved
pipe collars, clamps, brackets, or wall rests at all points required to insure a rigid installation.
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3. Where vertical piping passes through a steel floor sleeve, the pipe shall
be supported by a friction type pipe clamp which is supported by the pipe sleeve. Pipe clamps shall be equal to Anvil Figure 261, or equal.
L. Unless otherwise noted on the Drawings or in the Specifications, concrete
anchors shall be Hilti Fastening Systems "KWIK-BOLT," ITT Phillips Drill Division "Wedge Anchor," Ramset "Trubolt Wedge Anchor," or equal. Where required by the Drawings or Specifications, chemical grout-type anchors shall be Hilti "HVA Adhesive Anchor," Ramset "Chemset Chemical Anchors," or equal. Installation shall be in strict accordance with the manufacturer's recommendations which shall be available on the job site.
M. All rods, hangers, inserts, brackets, and components shall be furnished with
galvanized finish or stainless steel, except that stainless steel is required for use in concrete, under and above water, and all outside locations.
N. Pipe supports for stainless steel pipe shall be of stainless steel, galvanized steel,
electro-galvanized steel, factory applied epoxy coated steel or factory applied plastic coated steel. Plain carbon steel, cast iron, ductile iron and malleable iron shall not come in contact with the stainless steel pipe. Mixing of stainless steel pipe support materials which are readily different in appearance shall not occur.
2.03 PIPE HANGER AND SUPPORTS FOR NON-METAL PIPE
A. Single plastic pipes shall be supported by pipe supports as previously specified herein or as noted below for multiple pipes.
B. Multiple, suspended, horizontal plastic pipe runs, where possible, shall be
supported by ladder-type cable trays such as MP Husky, the Globetray by Cooper B-Line, or equal. Ladder shall be of mild steel construction. Rung spacing shall be approximately 18 inches. Ladder-type cable trays shall be furnished complete with all hanger rods, rod couplings, concrete inserts, hanger clips, etc., required for a complete support system. Individual plastic pipes shall be secured to the rungs of the cable tray by strap clamps or fasteners. Spacing between clamps shall not exceed 9 feet. The cable trays shall provide continuous support along the length of the pipe.
C. Individual clamps, hangers, and supports in contact with plastic pipe shall
provide firm support but not so firm as to prevent longitudinal movement due to thermal expansion and contraction.
D. Pipe supports shall be provided to support the vertical runs of all plastic pipes.
The pipes shall be supported by means of a supporting framework suitably anchored into the floor or curbing. The vertical piping shall be suitably secured to horizontal support members connected at each end to vertical support members and spaced to provide a rigid installation.
E. The complete supporting system shall be as specified in Section 15060 and/or
as manufactured by the Unistrut Corporation, Globe-Strut as manufactured by
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the Cooper B-Line, or equal. Non-metallic pipes in the chemical area of the operations building shall be as specified in Section 15060 with support locations as specified herein.
F. Vertical and horizontal supporting members shall be U-shaped channels similar
to Unistrut Series P1000, or equal. Vertical piping shall be secured to the horizontal members by pipe clamps or pipe straps equal to Unistrut Series Series P2558, or equal. All components shall be of mild steel.
G. The assemblies shall be furnished complete with all nuts, bolts, and fittings
required for a complete assembly.
H. The design of each individual framing system shall be the responsibility of the CONTRACTOR. Shop drawings shall show all details of the installation, including dimensions and types of supports.
2.04 SPECIAL SUPPORTS
A. Any required pipe supports for which the supports specified in this Section are not applicable shall be fabricated or constructed from standard structural steel shapes, concrete and anchor hardware similar to items previously specified herein, and shall be subject to the review of the ARCHITECT/ENGINEER.
B. All parts of the supports shall be amply proportioned for all stresses that may
occur during fabrication, erection, and operation.
C. Anchor bolts, nuts, sleeves, plates, washers, and other hardware are to be supplied and installed by the CONTRACTOR and shall be of ample size and number for their intended use and installed as recommended by the appropriate manufacturer.
D. For plastic and other similar piping as noted, supports shall be free of burrs and
shall include a suitable pliable support liner. They should also provide the maximum support contact with the pipe for a minimum length of 3 inches along the length of the pipe.
PART 3 EXECUTION 3.01 INSTALLATION
A. All required piping, tubing fittings, valves, and appurtenances shall be rigidly supported from the structures by approved supports, hangers, inserts, or clamps, with adequate provisions for expansion and contraction. Support shall be provided at, or near, changes in direction, hubs, joints, valves, appurte-nances, branches, and elsewhere within 3 feet of couplings in accordance with the manufacturer's recommendations, as shown on the Drawings, and as specified with the following support spacings. In no case shall pipe supports be spaced any further apart than the spacing noted in the 2006 International Mechanical Code, Section 305.
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Horizontal Runs
Maximum Support Spacing Type of Pipe (Unless Otherwise Noted)
Soil, waste drain, vent, 5 ft and other gravity pipe of any size below or in con- crete (except concrete pipe)
Metal tubing of any size, and 6 ft any metal pipe 1-1/2 inch in diameter or smaller
Cast or ductile iron process 12 feet with at least one support for
each section of 4 inch in diameter or larger.
Plastic pipe 3.5 feet
All other metal pipe 10 ft.
All other types of pipe As above
FRP pipe less than 3” 7 ft FRP pipe 3” and greater 10 ft
B. Additional supports and anchors where required, other than the type of pipe
supports shown on the Drawings, shall be the CONTRACTOR'S responsibility and as acceptable to the ENGINEER.
C. All vertical pipes shall be supported at each floor or at intervals of minimum 10
feet, except at 3.5 feet interval for plastic pipe, and at all points necessary to ensure rigid construction by pipe collars or clamps that shall rest on floor sleeves, brackets, or wall rests.
D. Piping shall not be supported from other piping ductwork, or from metal stairs,
ladders, or walkways unless specifically directed by the ENGINEER. Piping shall be a minimum distance of 1-1/2 inches (flanges or bells, 1-inch) from finished floors, walls, or ceilings unless otherwise shown on the Drawings, or specified. Where piping is installed on structural steel supports, blocking of pipe rolls shall be provided to arrest lateral pipe movement.
E. Concrete inserts shall have faces flush with the exposed concrete face. Where
dimensions correspond, inserts may be used as the support for the reinforced steel during the concrete pour. A waxed cardboard filler shall be placed in the insert to prevent concrete from flowing into the slot.
F. Supports in contact with plastic and other piping, where noted, shall provide
firm support but not so firm as to prevent longitudinal pipe movement due to
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thermal contraction and expansion. In addition, point loading shall be avoided for the above piping. Plastic pipe shall be securely anchored to continuous supports with U-bolts spaced at a maximum of 4 feet along the pipe.
G. Each section of pipeline shall be laid out and all connections (cemented, welded,
screwed, flanged, couplings, etc.), made while the pipe is held in temporary supports. After completion of connections, the pipe may be clamped in position. When piping is correctly installed on its permanent supports, a temporary clamp or pipe may be loosened or removed without displacement of the pipeline.
H. All pipe shall be anchored at locations and by methods acceptable to the
ENGINEER. Special attention is drawn to the need to anchor plastic piping and metal tubing at every 90° and 45° elbow. All continuous pipe supports shall be anchored to the structure at a maximum of every 5 feet. Plastic piping shall be supported so that there are no point loads inflicted on the pipe.
3.02 COATING
A. After installation, all metal surfaces of pipe supports, anchors, rods, support pipes, brackets, nuts, bolts, washers, and other metal used shall be painted as specified in Division 9.
3.03 INSPECTION AND TESTING
A. Hangers, supports, and anchors installed on the piping system shall operate satisfactorily as specified during the testing of the respective pipe systems. The hangers, supports, and anchors shall maintain the pipelines in position without evidence of bending, sagging, warping, vibration, or stress.
END OF SECTION
***
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SECTION 15190 MECHANICAL IDENTIFICATION PART 1 GENERAL 1.01 SCOPE OF WORK
A. Provide all labor, materials, and services required to install the identification products as specified herein.
1.02 RELATED WORK
A. Mechanical insulation is included in this Division, Section 15260.
B. Plumbing pipe is included in this Division.
C. Ductwork is included in this Division, Section 15890. 1.03 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ENGINEER in accordance with the General Conditions.
B. Submit list of working symbols, letter size, and color coding for mechanical
identification. Submit valve chart and schedule, including valve tag number, location, function, and valve manufacturer's name and model number.
PART 2 PRODUCTS 2.01 MARKERS
A. Colors unless specified otherwise shall conform with ANSI/ASME A13.1.
B. Plastic nameplates shall be laminated 3-layer plastic with engraved black letters on light contrasting background color.
C. Plastic tags shall be laminated three-layer plastic with engraved black letter on
light contrasting background color. Tag size minimum 1-1/2 inch diameter/square.
D. Metal tags shall be brass or aluminum with stamped letters. Tag size shall be
minimum 1-1/2 inch diameter with smooth edges.
E. Stencils shall have the following size letters:
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Arrow *Outside Diameter of Length x Width Size of Letters Pipe (Inches) (Inches) Less than 1-1/2 1-1/2 x 1/2 1/2 1-1/2 - 2 4 x 1 3/4 2-1/2 - 6 8 x 2 1-1/4 8 - 10 12 x 3 2-1/2 Over 10 20 x 5 3-1/2 Ductwork & Equipment 12 x 3 2-1/2 *Including insulation if applicable.
F. Stencil paint shall be in accordance with paint specification contained herein.
G. Plastic pipe markers shall be factory fabricated, flexible, semi-rigid plastic, preformed to fit around pipe or pipe covering; minimum information indicating flow direction arrow and fluid being conveyed.
H. Plastic tape pipe markers shall be flexible vinyl film tape with pressure sensitive
adhesive backing and printed markings.
I. Underground plastic pipe markers shall be bright colored continuously printed plastic ribbon tape of not less than 6-inch wide by 4-mil thick, manufactured for direct burial service.
2.02 PAINTING
A. All piping that is exposed or located in accessible pipe chases shall be painted.
B. The paint system to be used shall be recommended by the manufacturer for the particular surface to be painted and certified by the manufacturer for long term compatibility of all coatings with all substrates, both new and existing. Shop drawing submittal shall contain sufficient information to confirm the compatibility of the paint system for the surface to be painted and manufacturer’s recommendations for application.
C. Where prime coats are required they shall be of the same manufacture as the
finish coat.
D. Painting systems shall be as manufactured by Rustoleum Corp., Porter International, Sherwin-Williams, or equal.
E. Colors shall be in accordance with ANSI A13.1 unless otherwise specified in
Section 09900.
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PART 3 EXECUTION 3.01 PREPARATION
A. Degrease and clean surfaces to receive adhesive for identification materials. Prepare surfaces to be painted in accordance with manufacturers instructions.
3.02 INSTALLATION
A. Install plastic nameplates with corrosive-resistant mechanical fasteners, or adhesive.
B. Install plastic or metal tags with corrosive resistant chain.
C. Apply stencil painting in accordance with paint manufacturer’s instructions.
D. Plastic pipe markers shall be installed in accordance with manufacturer's
instructions.
E. Underground plastic pipe markers shall be installed 6 to 8 inches below finished grade, directly above buried pipe.
F. Identify all fans, louvers, unit heaters, packed AC and heat pump units, air
handling units, controls, pumps, test transfer equipment, tanks, and water treatment devices with plastic nameplates and stencil painting. Small devices, such as in-line pumps, may be identified with plastic/metal tags.
G. All control panel and major control components outside panels with plastic
nameplates. H. Identify all valves in main and branch piping with tags.
I. Identify piping, concealed or exposed, with plastic pipe markers, plastic tape
pipe markers, stenciled painting or tags may be used on small diameter piping. Identify service, flow direction, and pressure. Install in clear view and align with axis of piping. Locate identification not to exceed 20 feet on straight runs including risers and drops, adjacent to each valve and "T," at each side of penetration of structure or enclosure, at each obstruction, fitting and change of direction.
J. Identify ductwork with plastic nameplates or stenciled painting. Identify as to air
handling unit number, and area served. Locate identification at air handling unit, at each side or penetration of structure or enclosure, and at each obstruction.
K. Surfaces to be painted shall be cleaned, primed, and painted in strict
conformance with paint manufacturer’s instructions.
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3.03 VALVE CHART AND SCHEDULE
A. Provide valve chart and schedule in aluminum frame with clear plastic shield. Install at location as directed.
END OF SECTION
***
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SECTION 15230
PLASTIC PROCESS VALVES AND ACCESSORIES
PART 1 GENERAL 1.01 SUMMARY This sections covers the use of plastic valves and accessories in water,
wastewater, chemical, process, air, etc., pipelines and systems. A. Section Includes
Furnish all labor, materials, equipment, and incidentals required and install complete and ready for operation all valves and appurtenances as shown on the Drawings and as specified herein.
The equipment shall include but not be limited to the following: 1. Gate valves 2. Ball valves 3. Butterfly valves 4. Globe valves 5. Needle valves 6. Diaphragm valves 7. Check valves 8. Pressure relief valves 9. Constant flow valves 10. Sight glass gauge valves 11. Y - Strainers B. Products Furnished But Not Installed Under This Section
Any plastic valves and accessories which are being supplied as part of a manufactured package or system shall meet the requirements of this section but be installed as part of their equipment package and its requirements.
C. Products Installed But Not Furnished Under This Section
Any metallic valves which are to be installed in plastic pipelines shall be, installed and tested, etc., according to this section’s requirements.
D. Related Sections
1. Plumbing Valves and Appurtenances are in Section 15100.
2. Mechanical Identification Markers, Tags and Plates are in Section 15190. 3. Pipe Hangers and Supports are in Sections 15140 and 15060.
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4. Process Pipe Insulation is in Section 15261. 5. Process Piping and Fittings for are in Division 2.
6. Excavation, Backfill and Grading are in Division 2.
7. Instrumentation is in Division 13.
8. Electrical is in Division 16. 1.02 REFERENCES A. Kentucky Building Code B. Kentucky State Plumbing Law, Regulations and Code. C. Standards for Gas Piping on Customers' Premises, Columbia Gas Distribution
Companies. D. ASTM – American Society for Testing and Materials E. AWWA –American Water Works of Association F. ASME – American Society of Mechanical Engineers G. ASSE – American Society of Safety Engineers 1.03 DEFINITIONS A. ABS – Acrylonitrile Butadiene Styrene B. EPDM – Ethylene Propylene Diene Terpolymer C. CPVC – Chlorinated Polyvinylchloride D. FEP – Fluorinated ethylene propylene E. FKM – Fluorocarbon, Viton F. +GF+ - George Fisher G. IPS – Iron Pipe Sizes H. PFA – Perfluoroalkoxyalkane I. PP - Polypropylene J. PTFE or PFE – Polytetrafluoroethylene or Teflon K. PVC – Polyvinylchloride L. PVDF – Polyvinylidene fluoride or Kynar or Solef 1.04 SYSTEM DESCRIPTION
All of the equipment and materials specified herein is intended to be standard for use in controlling the flow of wastewater, sludge, water, chemicals, or slurries depending on the applications.
A. Design or Performance Requirements
1. All of the valves except throttling valves are intended to provide bubble tight shutoff when closed or meet or exceed the leakage requirements specified herein or in the referenced standard. All throttling or flow control valves shall be accompanied by an isolation valve to provide bubble tight shut-off.
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2. All valves and gates shall be designed and manufactured according to the
referenced standard unless an exception is noted herein. Where major components of valves have multiple materials of construction to choose from, the acceptable materials are noted in this specification. Any material noted, is acceptable for that component. If a material is noted as acceptable in the referenced standard but not listed in the table of materials for that component, that material shall not be used.
1.05 SUBMITTALS A. Product Data
Copies of all materials required to establish compliance with these Specifications shall be submitted in accordance with the provisions of the General Conditions. Submittals shall include at least the following:
1. Certified drawings showing all important details of construction and
dimensions.
2. Descriptive literature, bulletins, and/or catalogs of the equipment.
3. The total weight of each item.
4. A complete total bill of materials.
5. A list of the manufacturer's recommended spare parts. B. Contract Closeout Submittals
1. Operating and maintenance instructions shall be furnished to the ENGINEER as required in the General Conditions. The instructions shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc., that are required to instruct operating and maintenance personnel unfamiliar with such equipment
1.06 QUALITY ASSURANCE
A. Qualifications
All of the types of valves and appurtenances shall be products of well estab-lished firms who are fully experienced, reputable and qualified in the manufac-ture of the particular equipment to be furnished. All materials of construction shall be of an acceptable type and shall be designated for the pressure and temperatures at which they are to be operated, for the materials they are to handle and for the use for which they are intended. The materials shall meet established technical standards of quality and strength necessary to assure safe installations and conform to applicable standards. The equipment shall be
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designed, constructed and installed in accordance with the best practices and methods and shall comply with these Specifications as applicable.
B. Certifications
All valves to be used in potable water applications or their materials of construction shall have been certified by the National Sanitation Foundation (NSF) as meeting standard 61, as acceptable for being in contact with potable water and therefore, carry NSF 61 approval.
C. Field Samples Field samples are not necessary unless called for in Section 00710. 1.07 DELIVERY, STORAGE AND HANDLING A. Packing and Shipping
1. All valves shall be fully assembled, complete with all accessories and appurtenances when shipped. The units shall be carefully prepared and packaged so that no damage is caused in handling or transit. Any component needing to be shipped unattached to the main body shall be properly protected and clearly marked for easy identification and field assembly. Valves shall be drained of any fluid and be in the closed position. Valves shall have the connections securely blocked by a weather resistant material like plywood or plastic board to protect the flanges, etc., from damage and to prevent foreign material from entering the valve. Small valves may be fully packaged at the manufacturer’s/supplier’s discretion. All unpainted steel or machined iron surfaces shall be coated with a corrosion inhibitor.
B. Acceptance at the Site
1. All valves shall be inspected at the time of receipt for damage caused during shipment. Included in the inspection should be verification that the valves or gates comply with the specifications with regard to size, opening direction, type of end connections, actuator type, number of turns full open to close or vise versa. Valves should be operated through one complete open and closing cycle in the position it will be installed to verify its operation.
C. Storage and Protection
1. Valves should be stored indoors. In the event that outdoor storage is required, the units shall be protected from the weather, especially the possibility of water getting into the valve and freezing. All power actuators and controls shall have the electrical components energized or otherwise protected to prevent corrosion due to condensation caused by temperature variation. Also, see the manufacturer’s storage instructions.
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1.08 PROJECT/SITE CONDITIONS
A. Environmental Requirements
1. All valves will be located inside climate controlled structures unless otherwise noted. The units operating in the chemical area of the new Operations building will operate within the room’s temperature range of 55 degrees Fahrenheit to 105 degrees Fahrenheit. Once the chemical in its line leaves this space the temperatures may be hotter or colder than this depending on location. Inside other buildings or building areas the temperature will be range between 55 degrees Fahrenheit and 85 degrees Fahrenheit while outside temperature conditions will be ambient, typically 0 degrees Fahrenheit to 105 degrees Fahrenheit.
B. Field Measurements
1. It is the CONTRACTOR’S responsibility to field verify the site conditions,
dimensions, elevations, etc. The CONTRACTOR’S responsibility to obtain field dimensions is addressed further in Section 00700/00710 General Conditions.
2. Any location where new equipment is being placed in an existing
structure, or where the CONTRACTOR is being given the option to install things at locations at his discretion, it is the CONTRACTOR’S responsibility to field verify dimensions, etc.
1.09 MAINTENANCE A. Maintenance Service
1. Manufacturer's installation, operation and maintenance instructions shall be furnished to the ENGINEER as set forth in Section 01600.
B. Extra Materials
1. Lubricants, spare parts and special tools needed for the equipment shall be furnished to the ENGINEER as set forth in Section 01600.
PART 2 PRODUCTS 2.01 GENERAL
A. All valves and appurtenances shall be of the size shown on the Drawings and as far as possible all equipment of the same type shall be from one manufacturer.
B. All valves and appurtenances shall have the unit size, name of the maker, flow
directional arrows, body material of construction and the working pressure for which they are designed cast in raised letters, stamped, or affixed to the body by a label.
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C. Except as otherwise shown on the Drawings or specified herein, all valves with operators located 7 feet or more above the operating floor shall be provided with chain wheel operators complete with chain guides and stainless steel chain.
D. All buried valves shall open left (counterclockwise). Insofar as possible, all
valves shall open counterclockwise. E. All thermoplastic valves shall be constructed from PVC conforming to ASTM
D1784 Type I Cell Classification 12454; or CPVC conforming to ASTM D1784 Cell Classification 23447 or 23567-A; or polypropylene conforming to ASTM D4101 Cell classification C PP0210B67272; or PVDF conforming to ASTM D3222 Cell Classification Type II unless otherwise noted below. Not all valve types are available in all these materials. See below or on the Contract Drawings for materials of construction.
F. Article 2.02, Table of Valve Application and Service of this Section of the
Specifications will be used to determine what type of valve is to be used for a particular application.
2.02 TABLE OF VALVE APPLICATIONS AND SERVICE In the table below water is considered non-potable water, i.e., plant service water for dilution, flush, hose down, etc., or sample water unless otherwise noted. Application Gate Ball Butterfly Globe Needle Plug Check Diaphragm Throttling
X X X X X X
Shut-off
X X X X X
Flow-Reversal X Service 2 ½” TO 12” Water
X X X X X X X X
½” TO 2” Water
X X X X X X X X
Coagulants, SC-10F Alum, Ferrous sulfate, etc.
X X X X X
Flocculant Aid—Polymer
X X X X X
Polyphosphate
X X X X X
1Hydrogen peroxide
X X X X X X X
Fluosilicic acid X X X X X X X
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Application Gate Ball Butterfly Globe Needle Plug Check Diaphragm 1Sodium hypochlorite
X X X X X X
Carbon slurry
X X X X
Sodium hydroxide
X X X X X X X
1 Only vented ball valves should be used. Plain ball valves are not acceptable. 2.03 GATE VALVES – PVC AND CPVC
A. Gate valves shall be used in shut-off applications and where the valves are scheduled for infrequent use.
1. Gate Valves for Non-Potable Water, Chemicals and Slurries
a. All O-rings shall be Buna-N, EPDM or genuine Viton as applicable
for the fluid involved. All valves shall have non-rising stem and polypropylene handwheel, 2 inch square nut or “T” style operator. All gate valve wedges shall have strain equalizing threads. PVC valves shall have polypropylene wedge and CPVC valves shall have CPVC wedges. All valve components shall be replaceable. All valves 2 inches and smaller shall be rated for safe operation at 200 psi, all valves 2 ½” and 3” valves shall be pressure rated to 150 psi and all 4” valves shall be pressure rated at 235 psi non-shock for water at 73 degrees Fahrenheit. Gate valves shall have threaded, flanged, or socket weld end connections.
b. Gate valves shall be as manufactured by Spears Manufacturing
Company, Hayward Industrial, George Fisher, Asahi America or equal.
2.04 BALL VALVES – PVC, CPVC, PP AND PVDF
A. Ball valves shall normally be used in quick shut-off and frequent use applica-tions.
1. Ball Valves for Non-Potable Water, Chemicals and Slurries
a. All O-rings shall be EPDM or FKM with PTFE seats or genuine Viton
as applicable for the fluid involved. All valves shall have Safe-T-Shear stem and double stop polypropylene handle, 2 inch square nut or “T” style operator. All valve union nuts shall have Buttress threads. All valve components shall be replaceable. All valves 2 inches and smaller shall be rated for safe operation at 230 psi, except PP valves which shall be rated for 150 psi for all sizes, all valves 2 ½” through 6” valves shall be pressure rated to 150 psi non-shock for water at 70 degrees Fahrenheit. Ball valves shall be
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rated for full vacuum service to 26 inches of mercury. Ball valves shall have true union or flanged end connections.
b. Ball valves shall be Spears Manufacturing Company, Hayward
Industrial, Asahi America, Chemtrol TU series, GF Plastic Systems type 342, Plastic Engineering Products, Inc., or equal.
2. 3-Way Ball Valves
a. All O-rings shall be EPDM or Viton (FKM) with PTFE seats or genuine Viton as applicable for the fluid involved. All valves shall have Safe-T-Shear stem with double O-rings stem seals and polypropylene handle with lockout mechanism, 2 inch square nut or “T” style operator. All valve union nuts shall have Buttress threads. All seals carriers shall be Safe-T-Blocked. All valve components shall be replaceable. All PVC and CPVC valves 2 inches and smaller shall be rated for safe operation at 230 psi, except PP valves which shall be rated for 150 psi for all sizes, all valves 2 ½” through 6” valves and all flanged valves shall be pressure rated to 150 psi non-shock for water at 70oF. Ball valves shall have union end on all 3 ends (and be flanged). Ball valves shall be vertical type with (single “L” port) (double “L” port)(triple “L” port)(“T” port). Ball valves shall be horizontal type with (“L” port) (“T” port).
b. Ball valves shall be true union 2000 as manufactured by Spears
Manufacturing Company, Hayward Industrial, Asahi America, Chemtrol TU series, GF Plastic Systems type 342, Plastic Engineering Products, Inc., or equal.
3. PVC and CPVC Ball valves for Use with Sodium Hypochlorite and Hydrogen
Peroxide
a. All O-rings shall be EPDM or FKM with PTFE seats or genuine Viton as applicable for the concentration involved. All valves shall have Safe-T-Shear stem and double stop polypropylene handle, 2 inch square nut or “T” style operator. All valve union nuts shall have Buttress threads. All valve components shall be replaceable. All valves 2 inches and smaller shall be rated for safe operation at 230 psi, all valves 2 ½” through 6” valves shall be pressure rated to 150 psi non-shock for water at 70 degrees Fahrenheit. Ball valves shall be rated for full vacuum service to 26 inches of mercury. Ball valves shall be true union (or be flanged). Valves shall come with vented balls to relieve built up gas.
b. Ball valves shall be Spears Manufacturing Company, Asahi America,
or equal.
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2.05 BUTTERFLY VALVES – PVC, CPVC, PP AND PVDF
A. Butterfly valves shall normally be used for throttling purposes. They may also be used for positive shutoff with pressures up to 150 pounds in some applications.
1. Butterfly Valves for Non-Potable Water, Chemicals and Slurries
a. All O-rings shall be Buna-N, EPDM or Viton (FKM) with PTFE seats or
genuine Viton as applicable for the fluid involved. Valve seats shall be non-liner type interlocked to the valve body. Bolt hole patterns shall conform to ANSI/ASME B-16.5 CL 125/150. Discs shall be offset design with type 316 stainless steel stem. Lever operated valves shall be equipped with high impact polypropylene handle with lockout capability, 2 inch square nut or “T” style gear operator. Gear operated valves shall have position indicator and high impact polypropylene handwheel. Valve bodies shall accept field installable lug inserts or shall be factory installed true lug type. Lugs shall be stainless steel. All valves 12 inches and smaller shall be rated for safe operation at 150 psi, 14” PP valves shall be rated for 150 psi for all sizes, all valves 2 ½” through 6” valves shall be pressure rated to 100 psi, 16” PP valves shall be rated for 85 psi, 18” through 24” PP valves shall be rated to 70 psi and all 30” through 60” PP valves shall be rated to 55 psi non-shock for water at 70 degrees Fahrenheit.
b. Butterfly valves shall be Spears Manufacturing Company, Hayward
Industrial, Asahi America, Chemtrol, GF Plastic Systems, Plastic Engineering Products, Inc., or equal.
2.06 GLOBE VALVES – PVC AND PP
A. Globe valves shall normally be used for on-off or for throttling purposes where high flow resistances are permissible.
1. Globe Valves for Non-Potable Water and Chemicals
a. All globe valves shall be of thermoplastic construction and have no
metal part that comes in contact with the fluid media. Sizes ½” through 2” shall be of union bonnet design, 2 ½” through 4” shall be of outside stem and yoke design. PVC valves shall be rated to 150 psi at 70 degrees Fahrenheit through 2” and 110 psi at 70 degrees Fahrenheit for 2 ½” through 4”. PP valves shall be rated to 110 psi for ½” through 4”.
b. Valves shall be as manufactured by Asahi America or equal.
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2.07 NEEDLE VALVES – PVC, CPVC & PP
A. Needle valves shall be used for throttling purposes where accurate control of low liquid flow rates are required.
1. Needle Valves for Non-Potable Water and Chemicals
a. All valves shall be either globe or angle body pattern with ¼”, 3/8”
or ½” female NPT end connections. All valves shall have removable bonnet cap with replaceable PTFE seal. No elastomer seals shall be used. All valves shall have built-in panel mounting nut and high impact PP handles. All PVC and CPVC valves shall be pressure rated to 230 psi and all PP valves shall be pressure rated to 150 psi for water at 70 degrees Fahrenheit.
b. Needle valves shall be as manufactured by Spears Manufacturing
Company or equal. 2.08 DIAPHRAGM VALVES – PVC, CPVC, PP AND PVDF
A. Diaphragm valves shall be used for quick shut-off and frequent use applications.
1. Diaphragm Valves for Non-Potable Water, Chemicals and Slurries
a. All diaphragm valves shall be of the weir type with EPDM, Viton or PTFE with (EPDM) (Viton) bonded backing or Hypalon. All valves shall have built in indicator with high impact polypropylene handwheel. All valve union nuts shall have Buttress threads. All seals carriers shall be Safe-T-Blocked. All PVC and CPVC valves 2 inches and smaller shall be rated for safe operation at 230 psi, all 2 ½” through 4” and all flanged valves shall be pressure rated to 100 psi and all 8” valves shall be pressure rated to 75 psi non-shock for water at 70 degrees Fahrenheit. (Valves shall have stainless steel reinforced threaded end connections.) All PP valves shall be rated for 150 psi non-shock for water at 70 degrees Fahrenheit.
b. Diaphragm valves shall be Spears Manufacturing Company,
Hayward Industrial, Asahi America, Chemtrol, GF Plastic Systems, Plastic Engineering Products, Inc., or equal.
2.09 CHECK VALVES – PVC, CPVC, PP & PVDF
A. Swing check valves shall be used in conjunction with gate valves where change of direction is infrequent and service velocity is low. Lift check valves shall be used in conjunction with globe and angle valves and for high velocity service.
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B. Check Valves for Non-Potable Water, Chemicals and Slurries 1. Swing Check a. All thermoplastic swing check valves shall be of flanged
connection constructed such that no metal comes into contact with the fluid media except when and outside lever and weight or stainless steel spring option is called for. Valves shall incorporate a single disc design suitable for horizontal or vertical installation. All O-rings shall be EPDM or Viton. All valve components shall be replaceable. All valves shall have top entry access with O-ring sealed drain plug for in-line servicing. All valves shall have an external arrow position indicator or external counter balance. All valves 4” and smaller shall be pressure rated to 150 psi, all 6” valves shall be rated to 100 psi and all 8” valves rated to 70 psi non-shock for water at 70 degrees Fahrenheit.
b. Swing check valves shall be Spears Manufacturing Company, Hayward Industrial, Asahi America, Chemtrol series, GF Plastic Systems, Plastic Engineering Products, Inc., or equal
2. Ball Check Valves
a. All O-rings shall be EPDM or Viton (FKM) with PTFE seats or
genuine Viton as applicable for the fluid involved. Valves shall have flanged, true union, spigot end, socket end, or threaded end connections. All valve union nuts shall have Buttress threads. All valve components shall be replaceable. All valves 2 inches and smaller shall be rated for safe operation at 230 psi, except PP valves which shall be rated for 150 psi for all sizes, all valves 2-½ inches through 4 inches shall be pressure rated to 150 psi non-shock for water at 70 degrees Fahrenheit.
b. Ball check valves shall be Spears Manufacturing Company, Hayward
Industrial, Asahi America, Chemtrol BC series, GF Plastic Systems type 360, Plastic Engineering Products, Inc., or equal.
2.10 PRESSURE RELIEF VALVES
A. All thermoplastic pressure relief valves shall be constructed from PVC conforming to ASTM D1784 Type I Cell Classification 12454; or PP conforming to ASTM D4101 cell classification PP0210B67272 and have no metal parts in contact with the fluid. PVC valves 2 inches and smaller shall be rated to 110 psi, and 2-½ inch through 4 inch rated to 75 psi, PP rated to 75 psi for all sizes at 70
degrees Fahrenheit. Valves shall be as manufactured by Asahi America or equal. 2.11 CONSTANT FLOW VALVES A. Constant flow valves shall be used where a constant flow rate is desired,
regardless of changing line pressure or head in a tank.
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B. All thermoplastic constant flow valves shall be constructed from PVC conforming
to ASTM D1784 Type I Cell Classification 12454-A; or CPVC conforming to ASTM D1784 Cell Classification 23567-A. All valves shall be flanged with all wetted parts being non-metallic. Sizes ½” and ¾” shall be in-line design and 1” through 4” shall be Y pattern. Spring construction shall be stainless steel type 304 with an ETFE coating. All constant flow valves shall have a calibrated flow dial and position indicator. Valve accuracy shall be +/- 6 percent of full scale. Valves 3” and smaller shall have a maximum upstream pressure of 150 psi at 120 degrees Fahrenheit and 4-inch unit shall have a maximum upstream pressure of 70 psi at 120 degrees Fahrenheit. Valves shall be as manufactured by Asahi America or equal.
2.12 SIGHT GLASS GAUGE VALVES A. Sight glass gauge valves shall be used on bulk storage or day tanks where called
for or in place of ball valves with ENGINEER’S approval. B. All thermoplastic sight glass gauge valves shall be constructed from PVC
conforming to ASTM D1784 Type I Cell Classification 12454; or PP conforming to ASTM D4101 cell classification PP0210B67272. Valves shall be compact design and shall eliminate the need for multiple valves and fittings. Valves shall incorporate a double O-ring union end design to allow easy maintenance of the glass and a drain plug to permit sampling of the fluid. All valves shall be rated for 70 psi at 70 degrees Fahrenheit and be as manufactured by Asahi America or equal.
2.13 ACCESSORIES
A. Y Strainers
1. All thermoplastic valves shall be constructed from PVC conforming to ASTM D1784 Type I Cell Classification 12454; or CPVC conforming to ASTM D1784 Cell Classification 23447. All Y-strainers shall have replaceable PVC, CPVC, type 316 stainless steel screens (20, 40 or 60 mesh) with EPDM or Viton O-ring sealed (drain plug)(magnetic drain plug) Strainers shall be true union, flanged, or socket end connections. Strainers 2 omcjes and smaller shall be rated to 150 psi and 3-inch and 4-inch units shall be rated to 85 psi non-shock for water at 70 degrees Fahrenheit.
2. Y-Strainers shall be as manufactured by Spears Manufacturing Company,
Hayward Industrial, Asahi America, Chemtrol, GF Plastic Systems, Plastic Engineering Products, Inc., or equal.
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2.14 SPECIALTIES AND ACCESSORIES
A. Solenoid Valves
1. Valves shall be PTFE bellows-type designed for pressure, drain and vacuum applications.
2. Valves shall be spring return normally closed and direct acting with a
simple push-pull plunger design. 3. Valve bodies shall be all plastic construction of PVC, CPVC, glass-filled
polypropylene, or PVDF as appropriate for the chemical. 4. Seals shall be Viton (FKM) or FPM. 5. Coils shall be designed for continuous duty, be corrosion-resistant and be
powered by 12/24 VDC 120/240 VAC. 6. The valves shall be as manufactured by Plast-O-Matic, Hayward, or equal.
B. Dielectric Pipe Fittings/Unions
1. Dielectric pipe fittings/unions shall be installed where it is necessary to
couple 2 dissimilar metals in any piping system. The fitting used shall be appropriate for the pipe material to be joined in accordance with the manufacturer's instructions.
2. Dielectric unions shall be rated for 250 psi working pressure. Dielectric
flanged fittings shall be rated for 175 working pressure.
3. The fittings/unions shall be certified to withstand a minimum of 600 volts on a dry line with no flashover.
4. Dielectric pipe fittings/unions shall be Watts Series 300 or equal.
3. Pressure Vacuum Breaker
a. The pressure vacuum breaker assembly shall be designed to
prevent backsiphonage at a maximum working pressure of 150 psi. The assembly shall include an independently operating spring loaded check valve and independently operating spring loaded air inlet valve, and 2 quarter turn, full port, resilient seated bronze ball shut off valves. The assembly shall also include 2 properly located test cocks.
b. The body, valve seat and bonnet shall be bronze. The hood shall
be stainless steel and the vent and check valve discs shall be silicone rubber.
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c. The pressure vacuum breaker assembly shall conform to ASSE 1020, and shall be Watts 800, or equal.
4. Atmospheric Vacuum Breaker
a. The atmospheric vacuum breaker shall be designed to prevent
backsiphonage at a maximum working pressure of 125 psi. The device shall include a bronze body and silicone disc.
b. Atmospheric vacuum breaker shall conform to ASSE 1001, and
shall be Watts 288 or equal.
5. Hose Connections Vacuum Breaker
a. Hose connection vacuum breaker shall be brass body with soft rubber disc suitable for interior or exterior use. Where used in areas subject to freezing a manual drainage feature is required.
b. The device shall conform to ASSE 1011, and shall be Watts Series
8, or equal. PART 3 EXECUTION 3.01 INSTALLATION
A. All valves and appurtenances shall be installed in the locations shown, true to alignment and rigidly supported. Any damage to the above items shall be repaired to the satisfaction of the ENGINEER before they are installed.
B. Control valves in all locations shall be so grouped and located that they may be
easily operated, through access panels, doors, or adjacent to equipment.
C. After installation, all valves and appurtenances shall be tested at least one hour at the working pressure corresponding to the class of pipe, unless a different test pressure is specified. If any joint proves to be defective, it shall be repaired to the satisfaction of the ENGINEER.
D. Install all brackets, extension rods, guides, the various types of operators and
appurtenances as shown on the Drawings that in masonry floors or walls, and install concrete inserts for hangers and supports as soon as forms are erected and before concrete is poured. Before setting these items, the CONTRACTOR shall check all Drawings and figures which have a direct bearing on their location and he shall be responsible for the proper location of these valves and appurtenances during the construction of the structures.
E. All materials shall be carefully inspected for defects in workmanship and
materials; all debris and foreign material cleaned out of valve openings, etc.; all operating mechanisms operated to check their proper functioning, and all nuts and bolts checked for tightness. Valves and other equipment which do not
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operate easily, or are otherwise defective, shall be repaired or replaced at no additional cost to the OWNER.
F. Fire hydrants and yard hydrants shall be set at the locations as shown on the
Drawings and bedded on a firm foundation. A drainage pit as detailed on the Drawings shall be filled with screened gravel and satisfactorily compacted.
G. During backfilling, additional screened gravel shall be brought up around and 6
inches over the drain port. Each hydrant shall be set in true vertical alignment and properly braced. Concrete thrust blocks shall be placed between the back of the hydrant inlet and undisturbed soil at the end of the trench. Minimum bearing area shall be as shown on the Drawings. Felt roofing paper shall be placed around hydrant elbow before placing concrete. CARE SHALL BE TAKEN TO INSURE THAT CONCRETE DOES NOT PLUG THE DRAIN PORTS.
H. If directed, the hydrant shall be tied to the pipe with suitable rods or clamps,
galvanized, painted, or otherwise rustproof treated. Concrete used for backing shall be no leaner than 1 part cement, 2-1/2 parts sand, and 5-1/2 parts stone. Hydrant paint shall be touched up as required after installation.
I. Buried flanged or mechanical joints shall be made with cadmium plated bolts.
All exposed bolts and nuts shall be cadmium plated. All exposed bolts and nuts shall be heavily coated with 2 coats of bituminous paint.
J. Yard hydrants shall be installed in accordance with manufacturer's recom-
mendation and applicable requirements of fire hydrants above.
K. Buried valves and valve boxes shall be set with the stem vertically aligned in the center of the gate box. Valves shall be set on a firm foundation and supported by tamping selected excavated material under the sides of the valve. The valve box shall be supported during backfilling and maintained in vertical alignment with the top flush with finish grade.
3.02 SHOP PAINTING
A. Interior surfaces of all valves, the exterior surfaces of buried valves and miscel-laneous piping appurtenances shall be given a shop finish of an asphalt varnish conforming to Federal Specification TT-V51e for Varnish Asphalt.
B. The exterior surface of various parts of valves, operators, floor stands and
miscellaneous piping shall be thoroughly cleaned of all scale, dirt, grease or other foreign matter and thereafter one shop coat of an approved rust-inhibitive primer such as Inertol Primer No. 621 shall be applied in accordance with the instructions of the paint manufacturer.
C. Ferrous surfaces obviously not to be painted shall be given a shop coat of
grease or other suitable rust-resistant coating.
D. Field painting is specified under Division 9.
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3.03 INSPECTION AND TESTING
A. The various pipelines in which the valves and appurtenances are to be installed are specified to be field tested. During these tests any defective valve or appurtenance shall be adjusted, removed and replaced, or otherwise made acceptable to the ENGINEER.
B. Various regulating valves, strainer, or other appurtenances shall be tested to
demonstrate their conformance with the specified operational capabilities and any deficiencies shall be corrected or the device replaced or otherwise made acceptable to the ENGINEER.
END OF SECTION
***
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SECTION 15260
MECHANICAL INSULATION PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment, and services to install insulation on all mechanical piping and equipment as shown on the Contract Drawings and/or specified herein.
B. Provide insulation on ducts, plenums, mixing boxes, filter boxes, and casings on heating, ventilating and air conditioning systems as shown on Contract Drawings and/or specified herein.
C. All conditioned air supply and outside air ducts shall be insulated. Return ducts in unconditioned spaces shall also be insulated. Duct liner and duct board shall not be used unless specifically called for on the Drawings.
D. Multiple insulation types are described in this Section. See Tables I through IV at the end of the Section to determine which types are required for each application as applicable to this Project.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in the General Conditions.
B. Mechanical Identification is included in this Division, Section 15190.
C. Fire Stopping is included in Division 7, Section 07840.
1.03 QUALIFICATIONS
A. Materials
1. Where required, insulation shall have a flame spread rating of 25 and smoke developed rating of 50 in accordance with ASTM E84, UL 723, and NFPA 255.
2. All pipe, ductwork, and equipment insulation shall be installed by mechanics specializing in this type of work. The finished product shall present a neat and workmanlike appearance. Insulation shall not be applied until all tests, except operating tests, have been completed; all foreign material such as rust, scale, or dirt has been removed; and the surfaces are clean and dry. Insulation shall be clean and dry when installed and during the application of any finish.
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3. The insulation, insulation materials, and related items shall be delivered to the job in the manufacturer's unopened containers. The containers shall have labels stating the manufacturer's name, contents, quantity, and other pertinent data.
4. Insulation damaged on existing piping, ductwork, and/or equipment due to installation of new work shall be removed. After cleaning the outside surface of the piping, ductwork, and/or insulation shall be applied as hereinafter specified for the new piping, new ductwork, and/or new equipment.
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Contract Drawings and these Specifications shall be submitted to the ENGINEER in accordance with the General Conditions.
PART 2 PRODUCTS
2.01 INSULATION
A. Type A (Indoor Cold/Hot Piping from -20 degrees Fahrenheit to 850 degrees Fahrenheit); ASTM C 547; 6 lb heavy density sectional glass fiber pipe insula-tion; "K" value of 0.35 at 300 degrees Fahrenheit mean temperature.
1. Type A1; Pipe Insulation with No Jacket
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Composite of insulation shall be tested and listed by Underwriters Laboratories and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
d. Insulation shall be Certainteed "Snap On" heavy density pipe insulation, or equal products manufactured by Knauf, Manville, Owens/Corning, or equal.
2. Type A2; Pipe Insulation with Factory Applied All Service Jacket (ASJ)
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
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c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be Certainteed "Snap On" heavy density pipe insulation, or like products manufactured by Knauf, Manville, Owens/Corning, or equal.
3. Type A3; Pipe Insulation with Factory Applied All Service Jacket with Self-sealing Lap
a. a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate and self-sealing feature.
d. d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. e. Insulation shall be Certainteed "Snap On" heavy density pipe insulation, or equal products manufactured by Knauf, Manville, Owens/Corning, or equal.
B. Type B (Indoor Hot/Cold Piping to -20 degrees Fahrenheit to 400 degrees Fahrenheit); ASTM C 547; 4 Lb. Density Sectional Glass Fiber Pipe Insulation; "K" Value of 0.23 at 75 degrees Fahrenheit Mean Temperature
1. Type B1; Pipe Insulation with No Jacket
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Composite of insulation shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
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d. Insulation shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning, or equal.
2. Type B2; Pipe Insulation with Factory All Service Jacket
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning, or equal.
3. Type B3; Pipe Insulation with Factory All Service Jacket with Self-sealing Lap
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate and self-sealing feature.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning, or equal.
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C. Type C (Outdoor Cold/Hot Piping from -20 degrees Fahrenheit to 850 degrees Fahrenheit); ASTM C 547; 6 Lb. Heavy Density Sectional Glass Fiber Pipe Insulation; "K" Value of 0.35 at 300 degrees Fahrenheit Mean Temperature
1. Type C1; Pipe Insulation with Factory Applied All Service Jacket
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning or equal.
2. Type C2; Pipe Insulation with Factory Applied All Service Jacket with Self-sealing Lap
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate and self-sealing feature.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning, or equal.
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D. Type D (Outdoor Cold/Hot Piping from -20 degrees Fahrenheit to 400 degrees Fahrenheit); ASTM C 547; 4 Lb. Density Sectional Glass Fiber Pipe Insulation; "K" Value of 0.23 at 75 degrees Fahrenheit Mean Temperature
1. Type D1; Pipe Insulation with Factory Applied All Service Jacket
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be manufactured by Knauf, Manville, Certainteed, Owens/Corning, or equal.
2. Type D2; Pipe Insulation with Factory Applied All Service Jacket with Self-sealing Lap
a. Insulation shall be snap-on pipe insulation composed of fine glass fibers bonded together with phenolic resin molded in one-piece, 3, 4, or 6 foot sections.
b. Insulation shall be made with a single seam which spreads open to receive pipe and snaps closed after placement.
c. Insulation shall be furnished with factory applied vapor barrier composed of reinforced white craft and aluminum foil laminate and self-sealing feature.
d. Composite of insulation and jacket shall be tested and listed by Underwriters Laboratory and shall meet fire hazard classifications for flame spread, fuel contributed, and smoke developed as required by State Building Code.
e. Insulation shall be manufactured by Knauf, Manville, Certainteed, Owens/Corning, or equal.
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E. Type E (Indoor Hot/Cold Equipment from -20 degrees Fahrenheit to 450 degrees Fahrenheit); ASTM C 612; 6 lbs./cu. ft. fiberglass insulation; "K" value of 0.22 at 75 degrees Fahrenheit mean temperature. Insulation shall be Certainteed "IB Fiber Glass Insulation Board," or equal product manufactured by Knauf, Manville, Owens/Corning, or equal.
1. Type E1; Fiberglass board with no facing.
2. Type E2; Fiberglass board with all service jacket facing.
3. Type E3; Fiberglass board with foil scrim kraft facing.
F. Type F (Buried Piping) Insulation shall be factory fabricated assembly with inner all-purpose service jacket with self-sealing lap and asphalt impregnated open mesh glass fabric, with 1 mil thick aluminum foil sandwiched between 3 layers of bituminous compound; outer surface faced with polyester film. Insulation shall be manufactured by Knauf, Certainteed, Manville, Owens/Corning, or equal.
G. Type G (Indoor Hot/Cold Equipment from -20 degrees Fahrenheit to 450 degrees Fahrenheit); ASTM C 612; 6 lbs./cu. ft. fiber glass insulation; "K" value of 0.45 at 250 degrees Fahrenheit mean temperature.
1. Insulation shall be faced with reinforced white kraft and aluminum foil laminate.
2. Insulation shall be Certainteed "SNAP-WRAP FIBER GLASS INSULATION," or equal product manufactured by Knauf, Manville, Owens/Corning, or equal.
H. Type H (Heating and/or Cooling Air Ductwork Metal Concealed or Exposed); ASTM C 1290, ASTM C553; type 75 fiberglass duct wrap 3/4 lb. cu. ft.; “R” value of 8.6 and "K" value of 0.29 at 75 degrees Fahrenheit mean temperature; 2-1/2 inches thick. Insulation shall be Certainteed "Soft Touch Duct Wrap" or equal material manufactured by Knauf, Manville, Owens/Corning, or equal.
1. Type H1; fiberglass duct wrap with no facing.
2. Type H2; fiberglass duct wrap with vinyl film vapor retarder facing.
3. Type H3; fiberglass duct wrap with foil scrim kraft (FSK) vapor retarder facing.
I. Type I (Heating and/or Cooling Air Ductwork Metal Exposed); ASTM C 612; 6 lbs./cu. ft. fiberglass board; "K" factor of 0.22 at 75 degrees Fahrenheit mean temperature; 1 inch thick. Insulation shall be Certainteed "IB Fiber Glass Insulation Board" or like material manufactured by Knauf, Manville, Owens/Corning or equal.
1. Type I1; fiberglass board with no facing.
2. Type I2; fiberglass board with all service jacket facing.
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3. Type I3; fiberglass with foil scrim kraft facing.
J. Type J (Acoustical Duct Lining); ASTM 1071; fiberglass duct liner.
1. Air handling ducts within the building (both supply and return) shall be thermally and acoustically insulated on the duct interior with 1 inch thick fiberglass duct liner.
2. The insulation characteristics shall be fire-retarding and meet the requirements of the National Fire Protection Association Standard 90A.
3. Duct liner shall be adhered to the sheet metal with 100 percent coverage on adhesive, and exposed leading edges and all transverse joints coated with adhesive.
4. Liner shall be additionally secured with mechanical fasteners which compress the duct liner sufficiently to hold it firmly in place.
5. Joints and laps in the insulation shall be tightly sealed.
6. All duct insulation shall be installed in strict adherence to manufacturer's recommended installation instructions.
7. The duct liner shall be Owens/Corning Fiberglass Aeroflex 150 duct Liner or equal material manufactured by Certainteed, Manville, Knauf, or equal.
8. Duct liner is only allowed where specifically called for on the Drawings.
K. Type K (Ductboard) ASTM C 411; UL 181; ASTM # 96; ASTM C553; ASTM C 518. Heavy duty type fiberglass board with "R" factor of 4.3 at 75 degrees Fahrenheit mean temperature and thermal conductivity not to exceed 0.23 with foil scrim kraft facing. Ductboard shall be Type 800 UL Class 1 duct as manufactured by Owens/Corning Fiberglass, or like material manufactured by Knauf, Certainteed, Manville, or equal. Ductboard shall be 1 inch thick. Duct board is only allowed where specifically called for on the Drawings.
L. Type L (Refrigerant Piping, Hot/Cold Piping, Domestic Water Piping), Condensate Piping ASTM C 534 flexible elastomeric tubular insulation. Insulation shall be Armstrong "Armaflex II Pipe Insulation" or equal material manufactured by Manville, Knauf, Owens/Corning, or equal.
M. Type M (Hot Water Storage Tank) semi-rigid fiberglass board. Form faced with factory-applied vapor retardant or glass mat facing. ASTM C 411, ASTM C 177. "K" value of 0.27 at 75 degrees Fahrenheit mean temperature. Board shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning, or equal.
N. Type N (Exhaust Ductwork for kitchen hoods, ovens, griddles, deep fat fryers, steam kettles, vegetable steamers, high pressure cookers, and mobile serving units); 2-inch thick boards.
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1. Type N1; Mineral fiber conforming to ASTM C 612, Type II, Class 5. Insulation shall be Owens/Corning "Fiberglass TIW" mineral insulating wool or equal material manufactured by Knauf, Certainteed, Manville, or equal.
2. Type N2; Calcium silicate conforming to ASTM C 533, Type II. Board shall be Owens/Corning "Pink Calcium Silicate Insulation" or equal product manufactured by Knauf, Manville, Certainteed, or equal.
O. Type O (Boiler Stacks and Breeching and Diesel Exhaust Piping Insulation); ASTM C 592, ASTM C 612, or ASTM C 533. Insulation and minimum thickness shall comply with Table IV. Fill joints in the block insulation with mineral wool or equivalent insulation cement. For equipment operating at surface temperatures above 600 degrees Fahrenheit, apply block in double layer construction with staggered joints. Block insulation shall be manufactured by Knauf, Certainteed, Manville, Owens/Corning, or equal.
P. Equipment: Insulate all equipment and accessories as specified in Table III. In outside locations, provide insulation 1 inch thicker than specified. Increase the specified insulation thickness for equipment only where necessary to equal the thickness of angles or other structural members to make a smooth, exterior surface. Factory applied insulation shall meet the flame spread and smoke-developed rating of 25/50.
Q. Manufacturers: Insulation shall be manufactured by Certainteed, Knauf, Manville, Owens/Corning, Armstrong, or equal.
2.02 PIPING INSULATION FINISHES
A. All-purpose Jacket: Factory applied all-purpose jacket with or without integral vapor barrier shall be as required by service. Provide jackets in exposed locations with a white surface suitable for field painting. Allow a maximum water vapor permeance of 0.05 perm, a puncture resistance of not less than 50 Beach units, and minimum tensile strength of 35 pounds-force per inch of width.
B. Vapor Barrier Material: Material shall be resistant to flame, moisture penetration, and mold growth. Provide vapor barrier material on pipe insulation as required in Tables.
C. Metal Jackets
1. Jacket shall provide a moisture barrier lining for metal jackets outside.
2. Aluminum Jackets: ASTM B 209, Alloy 3003 or 3004 Temper H14, 0.020 inch thick smooth.
3. Stainless Steel Jackets: ASTM A 167, Type 304 or 306, 0.010 or 0.016 inch thick smooth.
4. Piping, Fittings, Flanges in Outside Locations: Finish elbows and curved piping with factory fabricated metal covers. Finish tees, flanges and
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valves with metal covers. Covers shall be same thickness and material as jackets on adjacent piping.
D. Elastomer Insulation Finish (Outdoors): Finish shall be Armstrong "Armaflex" with Armstrong WB Armaflex Finish" or equal material manufactured by Halstead, Knauf, Certainteed, Owens/Corning, Manville, or equal.
2.03 DUCT INSULATION FINISHES
A. All-purpose Jacket: Provide a factory applied all-purpose jacket with or without integral vapor barrier as required by the service. In exposed locations, provide jackets with a white surface suitable for field painting. All-purpose jacket shall have a maximum water vapor permeance of 0.05 perm per ASTM E 96; a puncture resistance of not less than 50 Beach units; and a tensile strength of not less than 35 pounds-force per inch of width in accordance with ASTM D 828.
B. Vapor-barrier Material: ASTM C 1136, for duct. Material shall be resistant to flame, moisture penetration, and shall not support mold growth. Provide vapor barrier on HVAC duct insulation, except insulation for heating only.
C. Metal Jackets
1. Provide metal jackets with moisture barrier lining for externally insulated ductwork located outside.
2. Aluminum Jackets: ASTM B 209, Alloy 3003 or 3004, Temper H14, 0.020-inch thick, smooth.
3. Stainless Steel Jackets: ASTM A 167, Type 304, 0.010-inch thick, smooth.
2.04 ADHESIVES, SEALANTS, AND COATING COMPOUNDS
A. Insulation and vapor barrier adhesive for securing insulation to metal surfaces and for vapor barrier lap in building interior shall be nonflammable in the liquid state and will pass the edge-turning test.
B. Lagging adhesive for bonding fibrous glass cloth to unfaced fibrous glass insulation; for bonding cotton brattice cloth to faced and unfaced fibrous glass insulation board; for sealing edges of and bounding fibrous glass tape to joints of fibrous glass board; or for bonding lagging cloth to thermal insulation, or Class 2, for attaching fibrous glass insulation to metal surfaces.
C. Mineral Fiber Insulation Cement, ASTM C 195, thermal conductivity 0.85 maximum at 200 degrees Fahrenheit mean when tested in accordance with ASTM C 177.
D. Vapor Barrier Coating: For indoor applications only with surface temperature above 60 degrees Fahrenheit, provide a white coating recommended by the manufacturer of the insulation.
E. Weatherproof Coating: For outside applications provide a weatherproof coating recommended by the manufacturer of the insulation and jackets.
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F. Elastomeric Insulation Adhesive: Seal joints and seams with Armstrong "520 Adhesive" or equal product manufactured by Manville, Owens/Corning, or equal.
2.05 ACCESSORY MATERIALS
A. Staples: ASTM A 167, Type 304 or 316 stainless steel outside clinch type.
B. Insulation Bands: 3/4-inch wide; 0.021-inch galvanized steel or 0.018-inch stainless steel or 0.20-inch aluminum.
C. Bands for Metal Jackets: 3/8-inch minimum width; 0.01-inch stainless steel or 0.020-inch aluminum.
D. Anchor Pins: Provide anchor pins and speed washers recommended by insulation manufacturer.
E. Glass Cloth and Tape: Glass cloth shall be 20 by 20 maximum size mesh. Tape shall be 4-inch wide rolls. Tape shall be 4.5 ounces per square yard. In lieu of glass cloth and tape, open weave glass membrane may be provided.
F. Wire: soft annealed stainless steel, 0.047-inch nominal diameter.
G. PVC Pipe Fitting Cover: ASTM C 553, Type 1, Class B-2 factory one-piece PVC jacket cover.
PART 3 EXECUTION
3.01 PREPARATION
A. Do not insulate materials until system tests have been completed and surfaces to be insulated have been cleaned of dirt, rust, and scale and dried. Insulate return ducts, outside air intakes and supply ducts to the room outlets, flexible runouts, plenums, casings, mixing boxes, filter boxes, coils, fans, and the portion of air terminals not in the conditioned spaces. Ensure full range of motion of equipment actuators. Modify insulation to avoid obstruction with valve handles, safety reliefs, other such items. Allow adequate space for pipe expansion. Install insulation with jackets drawn tight and cement down on longitudinal and end laps. Do not use scrap pieces where a full length section will fit. Insulation shall be continuous through sleeves, wall and ceiling open-ings, except at fire dampers in duct systems. Extend surface finishes to protect surfaces, ends, and raw edges of insulation. Apply coatings and adhesives at the manufacturer's recommended coverage per gallon. Individually insulate piping and ductwork. Provide a moisture and vapor seal where insulation terminates against metal hangers, anchors and other projections through the insulation on surfaces for which a vapor seal is specified. Keep insulation dry during application of finish. Bevel and seal the edges of exposed insulation. Unless otherwise indicated, do not insulate the following:
1. Factory preinsulated flexible ductwork.
2. Vertical portion of interior roof drain pipelines, chrome plated pipes, and fire protection pipes.
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3. Vibration isolating connections.
4. Adjacent insulation.
5. ASME stamps.
6. Fan nameplates.
7. Access plates in fan housings.
3.02 PIPING INSULATION
A. Pipe Insulation (except elastomeric and calcium silicate insulation): Place sections of insulation around the pipe and joints tightly butted into place. The jacket laps shall be drawn tight and smooth. Secure jacket with fire resistant adhesive factory applied self-sealing lap, or stainless steel outward clinching staples spaced not over 4 inches on centers and 1/2-inch minimum from edge of lap. Cover circumferential joints with butt strips, not less than 3 inches wide, of material identical to the jacket material. Overlap longitudinal laps of jacket material not less than 1-1/2 inches. Adhesive used to secure the butt strip shall be the same as used to secure the jacket laps. Apply staples to both edges of the butt strips. In addition, when a vapor barrier jacket is required, as indicated in Table I, or on the ends of sections of insulation that butt against flanges, unions, valves, fittings, and joints, use a vapor barrier coating or manufacturer's weatherproof coating for outside service. Apply this vapor barrier coating at all longitudinal and circumferential laps. Patch damaged jacket material by wrapping a strip of jacket material around the pipe and cementing, stapling, and coating as specified for butt strips. Extend the patch not less than 1 1/2 inches past the break in both directions. At penetrations by pressure gages and thermometers, fill the voids with the vapor barrier coating for outside service. Seal with a brush coat of the same coating. Do not use staples to secure jacket laps on pipes carrying fluid medium at temperatures below 35 degrees Fahrenheit. Where penetrating roofs, insulate piping to a point flush with the top of the flashing and seal with the vapor barrier coating. Butt tightly the exterior insulation to the top of the flashing and interior insulation. Extend the exterior metal jacket 2 inches down beyond the end of the insulation. Seal the flashing and counterflashing underneath with the vapor barrier coating.
B. Elastomeric Insulation: Bond cuts, butt joints, ends, and longitudinal joints with adhesive. Miter 90-degree turns and elbows, tees, and valve insulation. Where pipes penetrate fire walls, provide mineral-fiber insulation inserts and sheet-metal sleeves. Insulate flanges, unions, valves, and fittings in accordance with manufacturer's published instructions. Apply 2 coats of finish as recommended by the insulation manufacturers to elastomeric insulation in outside locations.
C. Calcium Silicate Pipe Insulation: Secure insulation with stainless steel metal bands on 12-inch maximum centers. For high temperature piping above 600 degrees Fahrenheit, unless single layer insulation is recommended by the manufacturer, apply insulation in 2 layers with the joints tightly butted and staggered a minimum of 3 inches. Secure the inner layer of insulation with 14-gauge soft annealed stainless steel wire on 12-inch maximum centers. The outer
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layer shall be secured with stainless steel metal bands on 12-inch maximum centers. Apply a skim coat of hydraulic setting cement directly to the insulation. When dry, apply a flooding coat of adhesive over the hydraulic setting cement. Press a layer of glass cloth or tape into adhesive and seal laps and edges with adhesive. Coat cloth with adhesive at a ratio of one part water to five parts adhesive in color other than white for the purpose of visual inspection to ensure sizing of entire surface. At CONTRACTOR's option secure 0.016 metal jacket to surface of insulation in accordance with paragraph titled "Metal Jackets for Outside Ductwork."
D. Hangers and Anchors: Pipe insulation shall be continuous through pipe hangers. Where pipe is supported by the insulation, provide galvanized steel shields protection saddles. Band and secure insulation protection shields without damaging pipe insulation. Where shields are used on pipes 2 inches and larger, provide insulation inserts at points of hangers and supports. Insulation inserts shall be of calcium silicate, cellular glass (minimum 8 pcf), molded glass fiber (minimum 8 pcf), or other approved material of the same thickness as adjacent insulation. Inserts shall have sufficient compressive strength to adequately support the pipe without compressing the inserts to a thickness less than the adjacent insulation. Insulation inserts shall cover the bottom half of the pipe circumference 180 degrees and be not less in length than the protection shield. Vapor-barrier facing of the insert shall be of the same material as the facing on the adjacent insulation. Seal inserts into the insulation with vapor barrier coating, manufacturer's recommended weatherproof coating, as applicable. Where protection saddles are used, fill all voids with the same insulation material as used on the adjacent pipe. Where anchors are secured to chilled piping that is to be insulated, insulate the anchors the same as the piping for a distance of not less than four times the insulation thickness to prevent condensation. Vapor seal insulation around anchors.
E. Sleeves and Wall Chases: Where penetrating interior walls, extend a metal jacket 2 inches out on either side of the wall and secure on each end with a band. Where penetrating floors, extend a metal jacket from a point below the back-up material to a point 10 inches above the floor with one band at the floor and one not more than one inch from end of metal jacket. Where penetrating exterior walls, extend the metal jackets through the sleeve to a point inches beyond the interior surface of the wall.
F. Flanges, Unions, Valves and Fittings for Hot Piping: Flanges, Unions, Valves, and Fittings Insulation (except elastomeric insulation) for Hot Piping: Factory fabricated removable and reusable insulation covers may be used. For inside domestic hot water, heating hot water, A/C condensate drains, high temperature hot water, steam and condensate return systems, exposed hot water piping and drains in handicap areas, place factory premolded, precut or field-fabricated segmented insulation of the same thickness and conductivity as the adjoining pipe insulation around the flange, union, valve, and fitting abutting the adjoining pipe insulation. If nesting size insulation is used, overlap 2 inches or one pipe diameter, whichever is larger. Use insulating cement to fill voids. Elbows insulated using segments shall have not less than three segments per elbow. Place and joint the segments with manufacturer's recommended
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water-vapor resistant, fire retardant, and adhesive appropriate for the temperature limit of the service. Upon completion of installation of insulation, apply 2 coats lagging adhesive with glass tape embedded between coats. Overlap tape seams 1 inch. Extend adhesive onto adjoining insulation not less than 2 inches. The total dry film thickness shall be not less than 1/16-inch. Where unions are indicated not to be insulated, taper the insulation to the union at a 45 degree angle. Coat the insulation and all purpose jacket with 2 coats of lagging adhesive and with glass tape embedded between coats. The total dry film thickness shall be not less than 1/16-inch. At the option of the CONTRACTOR, factory premolded one-piece PVC fitting covers may be provided in lieu of 2 coats of adhesive with tape embedded between coats. Factory premolded field-fabricated segment or blanket insert insulation shall be provided under the fitting covers. Install factory premolded one-piece PVC fitting covers over the insulation and secure by stapling, taping with PVC vapor barrier tape, or with metal or plastic tacks made for securing PVC fitting covers. Do not provide PVC fitting covers where exposed to the weather. Provide PVC fitting covers only in ambient temperatures below 150 degrees Fahrenheit.
G. Flanges, Unions, Valves, Anchors, Fittings for Cold Piping: Factory-fabricated removable and reusable insulation coves may be provided. For piping insulation inside the building that service dual temperature, domestic cold water above ceilings, chilled water supply and return, refrigerant suction, drinking fountain drain piping to sewer tie-in, horizontal roof drain leaders, and exposed laboratory drains, coat pipe insulation ends with vapor barrier coating not more than 6 inches from each flange, union, valve, anchor or fitting. Place insulation of the same thickness and conductivity as the adjoining pipe insulation, either premolded or segmented, around the item butting the adjoining pipe insulation. If nesting size insulation is provided, overlap the insulation 2 inches or one pipe diameter. Use loose fill mineral wool or insulating cement to fill the voids. Elbows insulated using segments shall not have less than three segments per elbow. Secure insulation by wire or tape until finish coating is applied. Apply 2 coats of vapor barrier coating with glass tape embedded between coats. Overlap tape seams one inch. Extend the coating out onto the adjoining pipe insulation 2 inches. Where unions are shown not to be insulated, the insulation shall be tapered to the union at a 45-degree angle. Seal the insulation and jacket with 2 coats of vapor barrier coating with glass tape embedded between coats. Insulate anchors attached directly to the pipe for a sufficient distance to prevent condensation but not less than 6 inches from the insulation surface. Insulate flexible connections at pumps and other equipment with fiberglass insulation, unless otherwise indicated. At the option of the CONTRACTOR, premolded, one-piece polyvinyl chloride (PVC) fitting covers will be provided in lieu of the embedded glass tape. Factory premolded insulation or field-fabricated insulation segments shall be provided under the fitting covers. Blanket inserts may be provided. Secure the coves with adhesive and vapor barrier tape with a vapor resistance of maximum 0.05 perm in accordance with ASTM E 96, or with tacks made for securing PVC covers. Then coat all tape seams and tacks with vapor barrier coating. Do not use premolded PVC fitting covers where exposed to weather. Provide PVC covers only when medium temperature is not less than 35 degrees Fahrenheit and ambient temperature is below 150 degrees Fahrenheit.
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H. Piping Exposed to Weather
1. Metal Jackets: Install over the insulation. Metal jackets shall have side and end lap at least 2 inches wide with the cut edge of the side lap turned inside 1 inch to provide a smooth edge. Overlap the jacket not less than 2 inches at longitudinal and circumferential joints and secure with metal bands of not more than 9 inch centers or with screws at not more than 5 inch centers. Overlap longitudinal joints down to shed water. Seal circumferential joints with a coating recommended by the insulation manufacturer for weatherproofing.
2. Flanges, Unions, Valves, Fittings, and Accessories: Insulate and finish as specified for the applicable service. Apply 2 coats of an emulsion type weatherproof mastic for hot service and vapor barrier mastic for cold service recommended by the insulation manufacturer. Embed glass tape in the first coat. Overlap tape not less than 1 inch and the adjoining metal jacket not less than 2 inches. Factory preformed metal jackets may be provided in lieu of the above for hot service.
3.03 HVAC DUCTS, PLENUMS, AND CASINGS INSULATION
A. Rigid Insulation: Secure rigid insulation by impaling over pins or anchors located not more than 3 inches from joint edges of boards, spaced not more than 12 inches on centers and secure with washers and clips. Spot weld anchor pins or attach with a waterproof adhesive especially designed for use on metal surfaces. Apply insulation with joints tightly butted. Neatly bevel insulation around nameplates and access plates and doors. Each pin or anchor shall be capable of supporting a 20 pound load. Cut off protruding ends of pins, after clips are sealed with coating compound for inside work or manufacturer's recommended weatherproof coating for outside work, and reinforced with open weave glass membrane.
B. Flexible Blanket Insulation: Apply insulation with all joints tightly butted. Secure insulation to ductwork with adhesive in 6 inch wide strips on 12 inch centers. Staple laps of jacket with outward clinching staples. Sealing shall be in accordance with paragraph 3.03 C below. For ductwork over 24 inches on horizontal duct runs, provide pins, washers and clips. Provide pins on sides of vertical ductwork being insulated. Space pins and clips on 18 inch centers and not more than 18 inches from duct corners. Carry insulation over standing seams and trapeze-type hangers. Install speed washers with pins and pin trimmed to washer. Sagging of flexible duct insulation will not be permitted. Cut off protruding ends of pins after clips are secured and sealed with coating compound for inside work. For warm air ducts, overlap insulation not less than 2 inches at joints and secure the laps with outward clinch staples on 4 inch centers. In cold air ducts, vapor seal all joints and staples as specified.
C. Insulation Finishes and Joint Sealing: Fill all breaks, punctures, and voids with vapor barrier coating compound for inside work or manufacturer's recom-mended weatherproof coating for outside service. Vapor seal all joints by embedding a single layer of 3-inch wide open weave glass membrane, 20 by 20 mesh maximum size between two 1/16-inch wet film thickness coats of vapor
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barrier coating compound. Draw glass fabric smooth and tight with a 1-1/2 inch overlap. At jacket penetrations such as hangers, thermometers, and damper operating rods, fill voids in the insulation with vapor barrier coating. Brush a coat of vapor barrier coating where required on HVAC ducts. Provide vapor barrier jacket continuous across seams, reinforcing, and projections. Where height of projections is greater than insulation thickness, carry insulation and jacket over the projection. For joints for heating only systems, provide insulation with two coats of fire resistant adhesive with glass fabric mesh embedded between coats.
D. Metal Jackets for Outside Ductwork: Ensure metal jacket side and end laps at least 2 inches wide, with the cut edge of the side lap turned under one inch to provide a smooth edge. Place horizontal laps to shed water. Seal vertical laps with insulation manufacturer's recommended weatherproof coating. Secure jackets in place with aluminum or stainless steel bands on 9 inch centers and aluminum or stainless steel screws on 5 inch centers. Where ducts penetrate exterior walls, continue the increased thickness required for ductwork exposed to weather and the metal jackets through the sleeve to a point 2 inches beyond the interior surface of the wall. Where metal jacket abuts an uninsulated surface, seal joints with a weatherproof mastic recommended by the insulation manufacturer. For rectangular ducts, provide corner angles to exposed corners of the insulation. Apply 2 coats of weatherproof coating recommended by the insulation manufacturer to the entire surface with a layer of glass cloth embed-ded between coats. Ensure glass cloth overlaps not less than 2 inches at joints and adjoining surface. Each coat weatherproof coatings shall be 1/16 inch aluminum thickness.
E. Exhaust Duct Insulation: For kitchen hoods, ovens, griddles, deep fat fryers, steam kettles, vegetable steamers, high pressure cookers, and mobile serving units, provide insulation with 3/4 inch wide, minimum 0.15 inch thick galva-nized steel bands spaced not over 12 inches on centers; or 16 gauge galvanized steel wire with corner clips under the wire; or with heavy welded pins spaced not over 12 inches apart each way. Do not use adhesives.
F. Access Plates and Doors: On acoustically lined ducts, plenums, and casings, provide insulation on access plates and doors. On externally insulated ducts, plenums, and casings, provide insulation-filled hollow steel panels and doors for access openings. Bevel insulation around access plates and doors.
3.04 FIBROUS DUCTBOARD FOR HVAC DUCTWORK
A. Duct shall be fabricated and installed in strict accordance with manufacturer's recommendations and SMACNA's Fibrous Glass Duct Construction Standards."
B. Closure system shall be UL 181 tested and recommended by manufacturer. Closure system shall be with pressure sensitive tape, mastic or heat sealable closure.
C. All longitudinal and traverse joints having a 1-1/2 inch staple flap shall be secured using outward clinch staples on 2-inch centers, and sealed with tape to provide a positive, air tight seal. Traverse joints not having staple flaps shall be
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secured with 8 inch long cross tabs running perpendicular to the seam of the joint on 12-inch centers. Cross tabs will be made from approved closure tape. The seam of the joint will then be sealed with an approved closure tape to provide an airtight seal.
D. Duct sections shall be additionally reinforced where necessary, according to manufacturer's and SMACNA's standards. Ductwork shall be supported as required on straight runs, at all turns, and at transitions to maintain proper alignment.
E. Hangers and supports shall be in strict accordance with manufacturer's and SMACNA's standards.
3.05 BOILER STACKS, BREECHING, AND DIESEL ENGINE EXHAUST INSULATION
A. Inside Boiler House or Mechanical Room: Bevel insulation neatly around openings and provide sheet metal insulation stop strips around such openings. Apply a skim coat of hydraulic setting cement directly to the insulation. Apply a flooding coat of adhesive over the hydraulic setting cement, and while still wet, press a layer of glass cloth or tape into adhesive and seal laps and edges with adhesive. Coat glass cloth with adhesive. When dry, apply a finish coat of adhesive at consistency so that when dry no glass weave shall be observed. Provide metal jackets for stacks, breeching, and exhaust pipes that are located up to 7 feet above finished floor and that pass through occupied spaces outside the boiler house or mechanical room. Apply metal jackets directly over insulation and secure with 3/4-inch wide metal bands spaced on 18 inch centers. Do not insulate nameplates.
B. Outside Boiler House and/or Room: Insulate smoke breeching between boiler house and/or room wall and stack as specified above except that in lieu of coating and finish, protect insulation with 24 gauge galvanized or stainless steel with raised seams made watertight.
3.06 EQUIPMENT INSULATION
A. General Procedures: Apply equipment insulation suitable for temperature and service in rigid block or semirigid board or flexible form to fit as closely as possible to equipment. Groove or score insulation where necessary to fit the contours of equipment. Stagger end joints where possible. Bevel the edges of the insulation for cylindrical surfaces to provide tight joints. Join sections of cellular glass insulation with bedding compound. After the cellular glass insulation is in place on areas to be insulated, except where metal-encased, fill joints, seams, chipped edges, or depressions with bedding compound to form a smooth surface. Fill mineral fiber joints with insulation cement. Bevel insulation around nameplates, ASME and access plates. For insulation on equipment that must be opened periodically for inspection, cleaning, or repair, construct insula-tion to be removable and replaceable without damage. Protect exposed insulation corners with corner angles, underwires and bands.
B. Heating Equipment (Except Pumps): Insulate shell and tube heat exchangers for the temperature of the shell medium indicated on the Drawings. Insulation on
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heads of heat exchangers shall be removable. Fabricate a male-female shiplap type joint for the removable section. On equipment with ribs such as boiler flue gas connection, draft fans, and fly ash or soot collectors, apply insulation over 6 by 6 by 12 gauge welded wire fabric spot welded to the equipment over the ribs. Secure insulation to the fabric with J hooks and 2 by 2 washers or wire loop insulation to the fabric. Use 16 gauge galvanized steel, stainless steel or copper wire or 3/4 inch wide 20 gauge stainless steel bands spaced on 12 inch centers. Seal joints with bedding compound for cellular glass or for mineral fiber with insulating cement and cover of insulation with a smoothing coat of insulating cement. Apply 2 coats of adhesive with a layer of glass cloth embedded between coats. The dry film thickness of the finish shall be 1/32 inch minimum.
C. Cold Equipment (Except Pumps): Secure insulation with 16 gauge, galvanized steel or copper clad wire or with 3/4-inch wide 20 gauge stainless steel bands spaced on 12-inch centers. Seal joints with joint sealer. Cover non-removable irregular surfaces such as corner angles with a smoothing coat of insulating cement. Provide removable heat exchanger head covers with a male-female shiplap type joint. Apply 2 coats of vapor barrier coating with a layer of glass cloth embedded between coats. The dry film thickness of the finish shall be 1/32-inch minimum.
D. Pumps: Insulate pumps used for hot service with 2-inch thick rigid mineral fiber insulation and pumps used for chilled water and brine service with 2 inch thick flexible unicellular sheet as follows: Insulate pumps by forming a box around the pump housing, drive shaft, and piping. Apply insulation to inside surfaces of 20 gauge galvanized, stainless steel or sheet metal boxes having openings for drive shaft and pipes. Construct the box by forming the bottom and sides using joints which do not leave raw ends of insulation exposed. Band bottom and sides to form a rigid housing that does not rest on the pump. Between top cover and sides, fit joints tightly forming a female shiplap joint on the side pieces and a male joint on the top cover to make the top cover removable. Secure insulation to the box with adhesive. Allow clearance for draining and adjustment of pump shaft seal.
3.07 INSULATION TABLES
A. See Tables I, II, III, and IV for insulation service, type and thickness. One or more of the tables may not be included if it was not applicable to the specific project.
3.08 PAINTING AND IDENTIFICATION
A. Paint in accordance with Section 15190, Mechanical Identification. Piping identification shall be as specified in Section 15190, Mechanical Identification.
3.09 FIELD INSPECTION
A. Visually inspect to ensure that materials provided conform to Specifications. Inspect installation progressively for compliance with requirements.
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TABLE I PIPING INSULATION WALL THICKNESS TUBE AND PIPE SIZE (INCHES)
Vapor Barrier
Service Type 1/4-1 1/4 1 1/2-2 2 1/2-5 6-10 11-36 Required Domestic Cold B3 1.0 1.0 1.5 1.5 1.5 Yes Water & Insula- ted Drains 0.5 0.75 1.0 1.0 1.0 Yes Domestic Hot B3 1.5 1.5 1.5 1.5 1.5 Yes Water & Recir- culating Piping 1.5 2.0 2.0 2.0 2.0 Yes Condensate Piping B3, L 0.5 0.75 1.0 N/A N/A Yes Refrigerant L 1.5 1.5 1.5 N/A N/A Yes Suction Piping Blower and Air B2, B3 2.0 3.0 4.0 4.0 4.5 Yes Compressor Discharge Piping, to 400°F NOTE: Insulation located outside shall be 1 inch thicker than that shown in table above. TABLE II INSULATION FOR DUCTWORK
*Thickness Vapor Barrier Service Type (Inches) Required HVAC Ductwork H3 2-1/2 Yes (Concealed or Exposed) HVAC Ductwork I1 1, 1-1/2, or 2 No Exposed I2, I3 1, 1-1/2, or 2 Yes Duct Liner Not Allowed HVAC Ductboard Not Allowed *NOTE: Insulation located outside shall be 1 inch thicker than that shown in table
above. Also, insulation located in an unconditioned attic space shall be 2 inches thicker than shown in table above.
END OF SECTION
***
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SECTION 15261
PROCESS PIPE INSULATION PART 1 GENERAL 1.01 WORK INCLUDED
A. The CONTRACTOR will furnish and install insulation on all process piping as indicated on the Drawings. The insulation thickness for cold process pipe insulation shall be 1 inch. The insulation thickness for hot process pipe insulation shall be 2 inches. The CONTRACTOR will provide all hardware, hangers and accessories necessary for a complete and airtight installation of the process pipe insulation system.
1.02 RELATED WORK
A. Plumbing Piping Insulation: Section 15260
B. HVAC Duct Insulation: Section 15260 1.03 SUBMITTALS
A. The CONTRACTOR will submit for review manufacturers shop drawings and technical literature. Literature will include description of materials construction and thermal conductivities (as a function of temperature). Samples of the products shall be submitted for inspection.
1.04 STORAGE AND HANDLING
A. Materials will be stored in manufacturer's unopened containers. Materials will be stored in such a manner as to prevent physical damage through construction operations or environmental exposure.
1.05 LEAK TESTING A. Leak testing of the systems to be insulated shall be performed prior to the
insulation being installed. 1.06 INSULATION A. Insulation shall not be applied until all surfaces are clean, dry, free of dirt,
grease, moisture, and generally any foreign element. PART 2 PRODUCTS 2.01 ELASTOMERIC INSULATION – COLD PROCESS PIPING
A. These Specifications are based on products and data of Armacell and designate the type and quality of work intended under this section. Products of other
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manufacturers will be considered. Proof of equality is the CONTRACTOR’S responsibility. Supporting technical data, samples, published specifications and the like must be submitted for comparison. The CONTRACTOR should warrant that proposed substitutions, if accepted, will provide performance equal to the materials specified herein.
B. Insulation material shall be flexible, closed-cell elastomeric insulation in tubular
or sheet form, Armstrong, AP Armaflex pipe insulation, AP Armaflex self-sealing pipe insulation, and AP Armaflex sheet and roll insulation (for piping larger than 6”).
C. Materials shall have a flame spread rating of 25 or less and a smoke developed
rating of 50 or less when tested in accordance with ASTM E84, latest revision. Sheet material with a thickness greater than 3/4” shall have a flame spread rating of 25 or less and a smoke developed rating of 100 or less when tested in accordance with ASTM E84, latest revision. In addition, the product when tested shall not melt or drip flaming particles, and the flame shall not be progressive. In addition, all materials shall pass simulated end-use fire tests.
D. Materials shall have a maximum thermal conductivity of 0.27 Btu-in/h-ft.2 F at
75 F mean temperature when tested in accordance with ASTM C177 or ASTM C518, latest revision.
E. Materials shall have a maximum water vapor transmission of 0.10 per-inches
when tested in accordance with ASTM E96 (Procedure A), latest revision. F. The material shall be manufactured under an independent third party
supervision testing program covering the properties of fire performance, thermal conductivity and WVT.
2.02 INSULATION – HOT PROCESSED PIPES
A. The insulation will be of rigid fiberglass capable of withstanding a temperature of 650 degrees Fahrenheit. The insulation will be made from flame attenuated glass fiber bonded with thermosetting resin. The insulation will be of a one piece hinged construction and have a maximum thermal conductivity of .34 Btu in./ft.2/hr. at a temperature of 250 degrees Fahrenheit. The insulation will possess the following properties:
Maximum Service Temperature 850ΕF Moisture Absorption 0.2% Alkalinity Less than 0.6% expressed as Na2 Corrosivity Does not accelerate Shrinkage None Resistance to Fungi Does not breed or promote Capillarity (after 24 hrs.) Negligible Surface Burning Characteristics Composite FHC 25/50 per ASTM E84, UL 723, NFPA 255, CAN/ULC S102-M88 Limited Combustibility NFPA 259
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B. The insulation will be Johns Manville Micro-Lok, or equal.
2.02 INSULATION JACKET
A. The insulation will be jacketed with a .16 inch aluminum jacket. The jacket will be factory applied and have a longitudinal seam closure with a 2-joint construc-tion for locking the insulation and jacket securely. Jacket sections will be butt joined with aluminum straps containing a permanent plastic sealing compound providing a weathertight circumferential seal. The insulation jacket will be Manville Metal-Lok, or equal.
PART 3 EXECUTION 3.01 PIPING A. Install pipe insulation by slitting tubular sections and applying onto piping or
tubing. Alternately, whenever possible, slide unslit sections over the open ends of piping or tubing. All seams and butt joints shall be adhered and sealed using Armstrong 520 adhesive. When using AP Armaflex SS only the butt joints shall be adhered using 520 adhesive.
B. Insulation shall be pushed on the pipe, never pulled. Stretching of insulation
may result in open seams and joints. C. All edges shall be clean cut. Rough or jagged edges of the insulation shall not
be permitted. Proper tools such as sharp knives must be used. D. On cold piping, insulation shall be adhered directly to the piping at the high end
of the run using a one inch strip of 520 adhesive on the ID of the insulation and on the pipe. All exposed end cuts of the insulation shall be coated with 520 adhesive.
E. Sheet insulation shall be used on all pipes larger than 6” IPS. Insulation shall not
be stretched around the pipe. On pipes larger than 12” IPS, adhere insulation directly to the pipe on the lower 1/3 of the pipe.
F. Seams shall be staggered when applying multiple layers of insulation. 3.02 VALVES, FLANGES AND FITTINGS A. All fittings shall be insulated with the same insulation thickness as the adjacent
piping. All seams and mitered joints shall be adhered with 520 adhesive. Screwed fittings shall be sleeved and adhered with a minimum 1 inch overlap onto the adjacent insulation.
B. Valves, flanges, strainers and Victaulic couplings shall be insulated using
Armaflex donuts that shall then be covered with sheet or oversized tubular insulation.
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3.03 HANGERS A. Standard and split hangers – Piping supported by ring hangers shall have
hangers insulated with the same insulation thickness as the adjacent pipe. All seams and butt joints shall be sealed with 520 adhesive. Ring hangers may be sleeved using oversized tubular insulation, on cold piping, insulation shall extend up the hanger rod a distance equal to 4 times the insulation thickness. Insulation tape may be used to a thickness equal to the adjacent insulation thickness.
B. Clevis hangers or other pipe support systems – Saddles shall be installed under
all insulated lines at unistrut clamps, clevis hangers or locations where the insulation may be compressed due to the weight of the pipe. Cold piping over 1-1/2 inch in diameter shall have wooden dowels or blocks, or a thickness equal to the insulation, inserted and adhered to the insulation between the pipe and saddle.
END OF SECTION
***
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SECTION 15310
DRY PIPE SPRINKLER SYSTEM, FIRE PROTECTION
PART 1 GENERAL
1.01 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Section, apply to this Section.
B. The following apply to the work of this section:
1. Fire Detection and Alarm Systems
2. 09900 Painting
1.02 SUMMARY
A. Scope: Provide a complete, code compliant dry-pipe sprinkler system, and associated equipment, ready for operation.
B. The work includes designing and installing an automatic dry-pipe fire extinguishing sprinkler system for Ordinary Hazard II and uniform distribution of water by hydraulic design to afford complete fire protection coverage thoughtout the contract area.
C. Authority Having Jurisdiction: Any reference in the specifications or applicable codes to the: authority having jurisdiction” shall be interpreted to mean the Kentucky Department of Housing, Buildings, and Construction (DHBC).
1.03 DEFINITIONS
A. FM: FM Global (Factory Mutual)
B. Furnish: To supply the stated equipment or materials
C. Install: To set in position and connect or adjust for use
D. NFPA: National Fire Protection Association
E. NICET: National Institute for Certification in ENGINEERING Technologies
F. Provide: To furnish and install the stated equipment or materials
G. UL: Underwriters Laboratories
1.04 SYSTEM DESCRIPTION:
A. The design shall conform to NFPA 13 and the requirements specified herein. Design of the automatic dry-pipe sprinkler system shall be for Ordinary Hazard II occupancy by hydraulic calculation. The design, equipment, materials,
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installation, workmanship, examination, inspection and testing shall be in strict accordance with NFPA 13, except as modified herein.
B. The system shall include all materials, accessories, and equipment inside and outside the building to provide a system complete and ready for use. Refer to Section 02610 Installation of Exterior Water Supply Main for Fire Protection Service.
C. Design and provide each system giving full consideration to obstructions, blind spaces, piping, electrical equipment, duct work and other construction and equipment in accordance with detailed drawings to be submitted for approval.
D. Equipment for fire protection service shall be UL listed for FM approved for use in dry pipe sprinkler systems.
E. In the NFPA publications referred to herein, the advisory provisions shall be considered mandatory.
1.05 PERFORMANCE REQUIREMENTS
A. Water Distribution: Distribution shall be uniform thoughtout the area which it is assumed the sprinkler heads will open. Variation in discharge from individual heads in the hydraulically most remote area shall be between 100 and 120 percent of the specified density.
B. Piping Restrictions: Piping is prohibited in the following areas, except when solely supplying sprinklers in such areas:
1. Transformer, switchgear, or similar rooms
C. Clearance From Electrical Equipment: Piping and automatic sprinklers and prohibited directly over:
1. Transformers
2. Substations
3. Switchboards
4. Motor control centers
5. Emergency generators
6. Bus Ducts
7. Electrical panels
D. If installing pipe over electrical equipment is unavoidable, provide drip pans under piping to protect electrical equipment.
E. Sprinkler systems shall be designed for earthquake protection in accordance with the requirement and recommendations of NFPA 13 and the Kentucky Building Code.
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F. Location of Sprinkler Heads: Heads in relation to the ceiling and the spacing of sprinkler heads shall not exceed their listed area of coverage for Ordinary Hazard II. Uniformly space sprinklers on the branch piping. Locate sprinkler heads in a consistent pattern with ceiling grid, lights, and supply air diffusers.
G. Sprinkler Discharge Area: The sprinkler discharge area shall be the hydraulically most remote areas as defined in NFPA 13.
H. Hose Allowances: System design shall include an allowance of 100 gpm (6.31 1/s) for inside hose stream, and 250 gpm (15.77 1/s) for total combined inside and outside hose streams.
I. Hydraulic Calculations: Hydraulic calculations shall be in conformance with NFPA 13 and the following requirements:
1. Margin of Safety: The sprinkler system shall be hydraulically designed so that the total water flow and pressure demand is at least 10% less than the available water flow and pressure at the site.
2. Friction Losses: Calculate losses in piping in accordance with the Hazen-Williams formula with “C” value of 100 for unlined ductile iron piping, 120 for steel piping, 140 for cement-lined ductile-iron piping, 150 for copper tubing and plastic piping.
3. Flow Velocity: Piping shall be sized so that the water flow velocity does not exceed 20 feet/sec (6.1 m/s) at any point in the system during maximum water flow (including inside hose demand). Flow velocity in each pipe segment is to be provided in the calculations.
4. Test Point: Calculations shall be brought back to the low test point.
5. Area of Coverage and Density: The area of coverage and density for each sprinkler shall be provided.
6. Equivalent Lengths: The equivalent lengths for all types of fittings and valves used shall be provided.
7. Supply and Demand Graph(s): A graph comparing the water supply and the sprinkler and hose stream demand for each remove area shall be provided. Pressure and flow values for the supply and demand curves are to be provided on N 1.85 graph paper.
1.06 SUBMITTALS
A. Partial submittals will not be acceptable. Any installation work performed prior to the approval of the submittal shall be at the CONTRACTOR’s own risk.
B. Before any work is commenced, submit manufacture’s data (with listing or approval), system calculations, and complete sets of working drawings.
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C. Manufactures’ Data: Annotate descriptive data to show the specific model, type and size of each item the CONTRACTOR proposes to furnish. Include data for proper installation of each system including:
1. Pipe and fittings
2. Dry pipe valves
3. Gate and check valves
4. Globe valves
5. Backflow preventers
6. Water motor alarms
7. Sprinkler heads
8. Pipe hangers and supports
9. Seismic bracing attachments and equipment
10. Pressure and waterflow switches
11. Tamper switches
12. Inspector’s test station
13. Retard chamber
14. Ball drip
15. Fire department connections
16. Lubrication compound/PTFE tape
17. Signs
18. Caps, chains
19. Cabinets
20. Hose valves
21. Drip pans
22. Air compressor
D. Shop Drawings: Shop drawings shall be submitted in accordance with the General Conditions, and shall consist of illustrations, schedules, performance charts, instructions, brochures, diagrams, and complete shop drawings of the sprinkler system and any other information required to illustrate the system has been coordinated, will function as a unit, and is in full compliance with the
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requirements of these specifications. Shop drawings shall conform to the requirements established for working plans prescribed in NFPA 13. The sprinkler system shall be hydraulically designed in accordance with NFPA 13. The CONTRACTOR’s submittal shall be signed and sealed by a Kentucky registered professional ENGINEER with two (2) years’ experience in fire suppression system design, Kentucky registered fire protection ENGINEER, or a Kentucky certified NICET Level III or IV fire suppression system layout technician. Qualifications and shop drawings shall be submitted to and accepted by the ENGINEER prior to submittal to the Department of Housing, Building and Construction (DHBC). The CONTRACTOR is responsible for submitting fire suppression system shop drawings to DHBC for approval after receiving the ENGINEER’s approval. Any system design changes required by the ENGINEER or DHBC shall be made at no additional cost to the OWNER.
E. As-Built (Record) Working Drawings: After completion, but before final acceptance of the work, furnish a complete set of as-built drawings for review and approval by the ENGINEER. Make all necessary corrections to the drawings and furnish four sets of as-built drawings for record purposes. All deviations from the approved shop drawings shall be highlighted on the as-build drawings.
F. Operation and Maintenance Manuals: Furnish four (4) instruction manuals containing complete operation and maintenance instructions for the specific make and model of all check valves, detector switches, backflow preventers, and other trim furnished. Serial numbers and ordering information shall be provided. Provide on copy of each instruction manual in a flexible, oil-resistant protective binder.
1.07 QUALITY ASSURANCE
A. The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. All publications listed below refer to the most current edition.
B. Manufactures Qualifications
1. American Society for Testing and Materials (ASTM) Publications:
a. A53 Pipe, Steel, Black and Hot Dipped, Zinc-Coated, Welded and Seamless
b. A135 Welded and Seamless Steel Pipe
2. Factory Mutual System (FM) Publications
a. Approval Guide
3. National Fire Protection Association (NFPA) Publications
a. 13 Standard for the Installation of Sprinkler Systems
b. 14 Standard for the Installation of Standpipe and Hose Systems
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c. 70 National Electrical Code
d. 72 National Fire Alarm and Signaling Code
e. 101 Life Safety Code
f. 291 Recommended Practice for Fire Flow Testing and Marking of Hydrants
g. 1963 Standard for Fire Hose Connections
4. International Code Council (ICC)
a. International Building Code
5. Underwriters Laboratories, Inc. (UL) Publications:
a. Fire Protection Equipment Directory
b. 262 Gate Valves for Fire Protection Service
c. 789 Indicator Posts for Fire Protection Service
6. American Society of Mechanical ENGINEERs (ASME)
a. A17.1 Safety Code for Elevators and Escalators
C. Qualifications Of Installer:
1. Prior to installation, submit data for approval by the ENGINEER, showing that the CONTRACTOR is a Kentucky licensed fire protection CONTRACTOR and has successfully installed automatic dry pipe fire extinguishing sprinkler systems of a least 200 sprinkler heads each, or there is a firm contractual agreement with a subcontractor having such required license and experience. The data shall include the names and locations of at least two installations where the CONTRACTOR or the subcontractor referred to above, has installed such systems. The CONTRACTOR shall indicate the type of design of each system and certify that each system has performed satisfactorily in the manner intended for a period of not less than 18 months.
2. Design (including hydraulic calculations) shall be by a Kentucky certified NICET Level III or IV Technician (in automatic sprinkler system design) or a Professional ENGINEER (P.E.), licensed in Fire Protection ENGINEERING in the State of Kentucky. Qualifications of the designer must be submitted to the ENGINEER for approval. The designer’s NICET or P.E. stamp shall be present on each sheet of the working drawings.
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1.08 DELIVERY STORAGE AND HANDLING
A. Deliver products to the project site in original, unopened packages with intact and legible manufactures’ labels identifying product and manufacturer, and shelf life if applicable.
B. Store materials inside, under cover, above ground, kept dry and protected from physical damage until ready for use. Remove from site and discard wet or damaged materials.
C. Automatic sprinklers must be kept in original packaging until they are installed. Loose carrying or storage is not permitted. Loose sprinklers shall be discarded immediately and replaced at CONTRACTOR’s expense.
1.09 COORDINATION
A. Coordinate sprinkler head layout with reflected ceiling plan and all ceiling – mounted equipment, including diffusers, lights, security cameras, fire alarm devices, exit signs, and other devices.
B. Coordinate major equipment and piping layouts with other trades to avoid obstructions and excessive changes in direction for piping.
1.10 WARRANTY
A. The CONTRACTOR shall guarantee labor, materials, and equipment provided under this contract against defects for a period of one year after the date of final acceptance of this work by the OWNER.
B. Final acceptance includes, but is not limited to, the receipt and ENGINEER approval of, Record Drawings and Operation and Maintenance Manuals.
1.11 EXTRA MATERIALS
A. Spare Sprinklers: The CONTRACTOR shall furnish spare automatic sprinklers in accordance with the requirements of NFPA No. 13 for stock of extra sprinklers. The sprinklers shall be packed in a cabinet and shall be representative of, and in proportion to, the number of each type and temperature rating of the sprinklers installed. The CONTRACTOR shall furnish no less than 4 special sprinkler-head wrenches, or at least 1 head wrench for each container or sprinkler box, whichever is greater.
PART 2 PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. All products are subject to the following listed acceptable manufacturers. If the product is not addressed herein the product shall be from a US based manufacturer and listed for fire protection use.
B. All products shall be FM approved/UL listed.
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C. Double Check Detector Backflow Preventer Assembly
1. Ames
2. Watts
3. Febco
4. Hersey
D. Fire Department Connections
1. Allenco
2. Elkhart Brass
3. Potter-Roemer Inc
4. Reliable Automatic Sprinkler Co.
E. Fire Protection Valves and Drain Assemblies
1. Tyco Fire & Building Products
2. Victaulic
3. Stockham
4. Kennedy
5. Jenkins
6. Reliable Automatic Sprinkler Co.
7. Viking Corporation
F. Sprinklers
1. Tyco Fire & Building Products
2. Reliable Automatic Sprinkler Co.
3. Viking Corporation
4. Victaulic Corporation
G. Valve Supervisory Switches
1. Potter Electric Signal
2. System Sensor
3. McWane, In. Kennedy Valve Div.
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2.02 ABOVEGROUND PIPING SYSTEMS
A. Provide fittings for changes in direction of piping and for all connections. Arrange piping so that it can be drained at the main riser. Make changes in piping sizes through standard tapered, reducing pipe fittings; the use of bushings is not permitted.
B. Jointing compound for pipe threads shall be polytetrafluoroethylene (PTFE) pipe thread tape only, applied on the male threads.
C. Use of pipe dope is not permitted.
D. Lubricant used on gaskets for mechanical fittings must be non-petroleum based and approved by OSHEM.
E. Run piping concealed in areas with suspended ceilings, except as noted on the drawings.
F. Sprinkler Pipe and Fittings: Provide in accordance with NFPA 13, except as modified herein. Steel piping shall be Schedule 40 per ASTM A53 for sizes less than 4 inches (101.6 mm) and Schedule 10 or 40 per ASTM A53 for sizes 4 inches (101.6 mm) and larger. ASTM A 135, Schedule 40 piping may be used for pipe sizes less than 2 ½ inches (63.5 mm).
1. Standard Installation:
a. Nominal pipe sizes 4 inches or larger: Schedule 10 or 40 Pipe meeting ASTM A-53, A-135 or A-795 with factory- or field-formed cut-grooved ends. Roll-grooved fittings are not permitted.
b. Nominal pipe sizes smaller than 4 inches: Schedule 40 Pipe meeting ASTM A-53, A-135, and A-795 with factory- or field-formed threaded ends.
c. For connections between 4 inch and larger pipes on risers, feed mains, cross-mains and drain lines, the requirements are as follows.
(1) Grooved pipe couplings and fittings for grooved pipe.
(2) Outlet coupling with screwed connection for grooved pipe.
d. For connections from risers, feed mains, cross-mains, or drains to branch lines, the requirements are as follows:
(1) Welded outlet with screwed connection or threaded couplings or fittings.
e. For connections to and between branch line pipes requirement is as follows:
(1) Threaded pipe couplings and fittings only.
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f. For connections between drain pipes requirement is as follows:
(1) Galvanized threaded or cut-grooved pipe couplings and fittings.
2. Underground piping: Shall comply with the requirements of NFPA 24 and shall be constructed of centrifugally case ductile iron or C900 polyvinyl chloride.
3. Pressure ratings: All fittings and gaskets shall meet or exceed maximum working pressures present within the system.
4. Corrosion protection: All piping and hangers where exposed to the weather or installed in a corrosive atmosphere shall be protected against corrosion.
5. Pipe and Hanger Supports: Provide pipe supports, hangers, and clamps conforming to NFPA 13 and listed by UL or approved by FM. Provide galvanized supports, hangers, and clamps for all galvanized piping.
6. Joint Construction
a. Plain-end fittings with mechanical couplings, hole-cut mechanical threaded outlet fittings, hole-cut mechanicals grooved outlet fittings, and hole-cut saddle clamp outlet fittings are not permitted on a case-by case basis when approved by the ENGINEER.
b. Procedures for welding outlets shall be in strict conformance with the welding requirements of NFPA 13, including submission of welding certifications.
c. Threaded Joints: Comply with NFPA 13 for pipe thickness and threads. Do not thread pipe with wall thickness less than Schedule 40.
d. Grooved Joints and Fittings: Assemble joints and fittings with listed coupling and gasket lubricant, and bolts from same manufacturer. Fittings and attached couplings shall be from the same manufacturer.
e. Steel Pipe: Square-cut piping as indicated. Use grooved-end fittings and rigid, grooved-end-pipe couplings unless otherwise indicated. Roll-grooved fittings are not permitted.
f. If the galvanized coating on piping is found to be chipped or cracked upon grooving of joint, two coats of liquid galvanizing material shall be applied to groove. The first coat shall be thoroughly dry prior to applying the second coat.
G. Use of restriction orifices, reducing flanges, unions, and plain-end fittings is not permitted.
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H. Flanged fittings shall be used in lieu of unions with the exception of drain lines.
I. The corrosion resistance ratio of pipe and fitting method shall not be less than 0.95.
J. Pipe Hangers and Supports: Provide in accordance with NFPA 13.
K. Identifications Signs: Attach properly lettered approved metal or polycarbonate signs conforming to NFPA 13 to each valve and alarm device. Polycarbonate signs shall be red with engraved white letters. Signs at valves shall describe the sprinkler zone it controls and state that the valve is to remain open. Permanently affix design data nameplate to the riser of each system.
L. Inspector’s Test Connection: Provide test connections no higher than 6 ft (1.83 m) above the floor for each sprinkler system or portion of each system and the control valve/drain assembly. Provide combination drain valve and test connection. Discharge shall be readily visible from the inspector’s test connection, either by direct observation of the discharge or thought a sight glass. Discharge shall be piped to either an open building drain or to the outside. Drainage and test valves shall be bronze globe, angle, or gate valves.
M. Drains: Provide drain piping to discharge at safe points outside the building or to sight cones attached to drains of adequate size to readily receive the full flow from each drain under maximum pressure. All drain piping and fittings are to be galvanized. Provide auxiliary drains as required by NFPA 13. Splash guards are to be provided where necessary at discharge outlets.
N. Pipe Sleeves and Seals. Provide where conduit or piping passes through walls, floors, roofs and partitions. Provide clearance between exterior of piping and interior of sleeve in accordance with NFPA 13. Penetration Firestopping, for sleeves and seals through fire-rated assemblies is required. Secure sleeves in proper position and location during construction. Provide sleeves of sufficient length to pass through the entire thickness of walls, floors, roofs, and partitions.
1. Sleeves in Masonry and Concrete Walls, Floors, and Roofs: Provide ASTM A53, Schedule 40, zinc-coated steel pipe sleeves. Sleeves in floors shall project 4 inches (101.6 mm) above finished floors to prevent seepage.
2. Sleeves in Partitions and Other than Masonry and Concrete Walls, Floors and Roofs: Sleeves shall be constructed from either zinc-coated schedule 40 steel pipe or zinc-coated 26 gauge steel sheet.
O. Escutcheon Plates: Provide one piece or split-hinge-type metal plates for piping passing through floors, walls, and ceilings in exposed and concealed areas. Provide chromium-plated or color-coordinated metal plates where pipe passes through finished ceilings. Securely anchor plates in proper position. Provide sprinkler escutcheon plates to match sprinkler head finish.
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2.03 BACKFLOW ASSEMBLIES
A. The backflow assemblies shall be of the Double Check Detector Assembly (DCDA) type with bypass meter assembly, two independently operated spring-loaded check valves, top mounted test cocks, and two UL FM OS&Y resilient seated gate valves.
B. Assemblies shall be listed for fire protection use.
C. An acceptable device installation must meet the requirements of the test procedure for a double check valve assembly outlined in the Manual of Cross-Connection Control published by the Foundation for Cross-Connection Control and Hydraulic Research of U.S.C. The device shall be tested by the above mentioned procedure in the presence of the ENGINEER’S representative.
D. A report of the test results shall be furnished by the OWNER and the ENGINEER.
2.04 DRY PIPE VALVE
A. Dry pipe valves shall include all trimming as required for a standard unit, that are UL listed or FM approved. Provisions shall be made to prevent excessive water accumulation. The dry pipe valve shall be fitted with an alarm bypass test connection so the waterflow device may be tested without opening the dry pipe valve.
B. Each dry pipe valve shall be equipped with an automatic air maintenance device, in addition to all other required components.
C. Provide an approved quick-opening device for dry pipe valves controlling systems having capacity of more than 500 gallons.
2.05 AUTOMATIC AIR COMPRESSOR
A. The automatic air compressor shall have a tank capable of maintaining the required operating pressure on the dry system and shall be capable of full recovery within 30 minutes. Provide all pressure switches, flow switches, supervisory switches, supervisory switches and low/high air pressure switches in accordance with NFPA and the manufacture’s recommendations.
B. The compressor shall operate on 208 V, 1 phase and shall have a horsepower rating of 1 or less. The starter shall be provided by the Fire Protection Contractor.
C. Where the building is provided with an emergency power system, the compressor shall be connected to emergency power circuits.
D. The automatic air compressor shall be UL listed for fire suppression system, General Air Products Model OL615100ACT, or equal.
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2.06 MANUAL RELEASE STATION
A. Stations shall be surface mounted and shall not be subject to operation by jarring or vibration. Break-glass-front stations will not be permitted; however a pull-lever, break-glass-rod type is acceptable. Display operating instructions on face of station in engraved or raised letters of a contrasting color. Provide permanent metal or engraved plastic signs mounted above or beside each station, indicating which system that the station controls. Lettering shall be a minimum of 1.5 inches high.
2.07 SPRINKLER HEADS
A. Provide quick response sprinklers in offices and all other areas where their use is listed or approved. Heads located within the air streams of unit heaters or other heat-emitting equipment or skylights shall be selected for proper temperature rating.
B. Heads shall have a nominal ½ inch (12.7 mm) orifice. Corrosion-resistant sprinkler heads shall be installed where they are exposed to the weather, moisture or corrosive vapors. Heads installed where they might receive mechanical injury or are less than 7 feet (2.13 m) above the floor level, shall be protected with approved guards in accordance with NFPA 13. Provide a non-corrosive finish.
2.08 VALVES
A. Provide valves as required by NFPA 13. Valves shall be UL listed or FM approved for fire protection service.
B. Gate valves: Gate valves shall be the outside stem & yoke (OS&Y) type, and open by counterclockwise rotation. Gate valves installed higher than 7 feet (2.1 m) above the floor shall be provided with a chain driver or permanently mounted ladder. Provide a gate valve beneath each alarm valve in each riser when more than one alarm valve is supplied from the same water supply pipe. For post indicator valves, provide operating nut location 3 feet above finish grade. Gate valves for use with indicator post shall conform to UL 262. Indicator posts shall conform to UL 789. Provide each indicator post with one coat of primer and two coats of red enamel paint.
C. Check valves: Check valves shall be clear-opening, swing-check type, with a bronze or stainless steel seat ring and an EPDM rubber clapper facing. Flanged check valves of size 4 inch (101.6 mm) and larger shall have flanged inspection and access cover plates.
D. Butterfly valve: Butterfly valves are permitted only for pipe sizes of 4 inches (100 mm) and smaller.
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2.09 FIRE DEPARTMENT CONNECTION
A. Fire department connection shall be in accordance with NFPA 13, with self-closing clapper valve in each inlet. The Siamese connection shall be polished bronze, with polished chromium finish.
B. Connection shall include a check valve, automatic drip (to drain to outside or building drain), caps and chains, 2 ½ inch (63.5 mm) female fire hose thread connections with National Standard threads, and nameplate.
C. Nameplate shall be positioned so it is clearly visible and shall state the type of connection and the system it serves.
2.10 ALARMS
A. Pressure Switch: Provide switch with circuit opener and closer for automatic transmittal of an alarm over the facility fire alarm system and connect into the fire alarm system per Section 283111. Alarm actuating device shall instantly recycle. Switches shall be compatible with the fire alarm system.
B. Low/High Air Pressure Alarm: Provide alarm for each sprinkler system. Alarm shall give a visual and audible alarm when air pressure in the system drops halfway from the normal pressure. Mount an alarm bell, light signal and cut-off switch for silencing the bell on the low air pressure alarm panel. Provide electrical power supply connections at the supply side of the building service panel with a separate fused safety-type switch for each connection with locked lever.
C. Electric Alarm Bell: Provide a weatherproof and guarded electric alarm bell, to sound on the flow of water in each corresponding sprinkler system. Mount alarm on the outside of the wall of the building at a location indicated on the drawings. Install a permanent sign next to the alarm stating the nature of the alarm and instructions for responding.
D. Valve Supervisory Switch: Valve supervisory switches shall be installed on all sprinkler control valves. The switches shall be mounted so as not to interfere with the normal operation of the valve and shall be adjusted to operate within two revolutions of the valve control or when the stem has moved no more than 1/5 of the distance from its normal open position. The entire installed assembly shall be tamper-proof and arranged to cause a switch operation if the housing cover is removed or if the unit is removed from its mounting. Devices shall be compatible with and connected to the fire alarm system.
2.11 CABINET
A. Furnish and install a metal cabinet containing a stock of spare sprinkler heads of all types and ratings installed. The cabinet shall be located near the alarm control valve and where the temperature will not exceed 100º F (37.8º C). The number of spare sprinkler heads shall be as required by NFPA 13.
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B. Provide a sprinkler head wrench for each sprinkler type present in the sprinkler head cabinet.
PART 3 EXECUTION
3.01 INSTALLATION
A. Equipment, materials, installation, workmanship, examination, inspection, and testing shall be in accordance with NFPA 13, except as modified herein. Install piping straight and true to bear evenly on hangers and supports. Install piping as close to the ceiling as possible, without interfering with other equipment and construction. Nipples shall be perpendicular to ceilings.
B. Accurately align sprinkler heads in suspended ceilings symmetrically with diffuser, lights, and ceiling tiles. Install sprinkler heads in the center of the ceiling tiles unless directed otherwise.
C. Keep the interior and ends of all piping affected by CONTRACTOR’S operations thoroughly clean of water and foreign matter by means of plugs or other approved methods. Inspect piping before placing into position. All pipe, fittings, and gaskets are to be cleaned of oil prior to installation.
3.02 FIELD CHANGES
A. Do not make field changes in the piping layout, pipe sizes, or type of equipment, without the prior approval of the ENGINEER.
3.03 FIELD PAINTING
A. Painting shall be per Section 09900, Painting, except as modified herein. The above-ground steel piping systems including valves, piping, pipe sleeves, conduit, hangers, miscellaneous metal work and accessories shall be cleaned, pre-treated, primed and painted.
B. Due care shall be exercised to avoid the painting of sprinkler heads or protective devices or allowing paint to drip or splatter on any equipment, artifacts, building structures, and floors. Materials which are used to protect sprinkler heads while painting is in progress shall be removed upon completion of painting.
C. The CONTRACTOR shall remove all sprinkler heads which are painted and provide new, clean sprinkler heads of the proper type at his own expense.
3.04 FIELD TESTNG AND FLUSHING
A. All testing shall be scheduled with the ENGINEER and Building Inspector.
B. An air pressure test shall be performed prior to filling the system with water. The test shall be conducted by raising the air pressure in the system to 40 psi (275.8 kPa) and allowing it to stand for 24 hours. There shall be no loss of air pressure greater than 1.5 psi (10.34 kPa) over the 24 hour period. Air pressure
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during this test shall be tracked via a graph over the 24 hour period by a pressure monitoring device or pressure monitoring gauge.
C. Hydrostatic tests shall be conducted at the greater of 200 psi (1379 kPa) or the normal system pressure plus 50 psi (345 kPa) for a 4 hour period with no leakage or reduction in gauge pressure. Hydrostatic test pressures shall not be maintained on the system overnight. Flush piping with potable water in accordance with NFPA 13.
D. Preliminary Tests and procedures: Test the alarms and other devices. Test the water flow alarms by flowing water through the inspector’s test connection. Prior to the hydrostatic test, perform an air test on the system. In areas where piping will be concealed by ceilings, walls, or other construction before the system is complete and ready for final testing, the preliminary hydrostatic test shall be conducted prior to piping being concealed. This test shall be witnessed by the Building Inspector and the ENGINEER. When all tests and procedures are completed and corrections made, submit a signed and dated certificate, similar to that specified in NFPA 13, with a request for formal inspection and tests.
E. Formal Inspections and Tests: At this time, all piping sprinklers, and other system components shall be in-place and all adjustments to the system completed. The ENGINEER and the Building Inspector shall witness all tests, and shall approve all systems before they are accepted. Submit a request for a formal inspection at least five working days prior to the date the inspection is to take place. A competent representative of the sprinkler installer shall be present during testing and inspection. As-built drawings shall be on-site for the inspection. At this inspection, the system shall be hydrostatically tested. Any or all of the required test shall be demonstrated that the systems comply with all contract requirements. The CONTRACTOR shall furnish all appliances, equipment, instruments, connecting devices and personnel for the test. Any costs incurred for repeat tests, due to the failure of the CONTRACTOR to adequately demonstrate that the system complies with the contract requirements, shall be borne by the CONTRACTOR.
END OF SECTION
***
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SECTION 15400
BUILDING DRAINAGE AND PLUMBING SYSTEM
PART 1 GENERAL
1.01 WORK INCLUDED
A. Furnish all labor, materials, equipment, and incidentals required and install a complete plumbing system as shown on the Drawings and as specified herein. More specifically, the work shall include, but not be limited to, the following:
1. Installation of sanitary, acid resisting waste, rainwater leader, and equipment drainage systems.
2. Installation of potable water systems.
3. Plumbing fixtures, wash-hose stations, emergency showers, eyewash fountains, emergency water alarm and floor drains.
4. Water mixers for showers and shower stalls.
5. Potable water heaters with temperature and pressure relief valves.
6. Water and drain outlets left for connections required by miscellaneous mechanical and process equipment.
7. Installation of toilet, drying, locker and janitor's room accessories furnished under Division 10.
8. All work necessary and required in conjunction with alteration to existing buildings as indicated on the Drawings.
9. All parts necessary to make a complete plumbing system ready for continuous operation.
B. The work of this Section shall also include the installation of valve tags fur-nished by the CONTRACTOR. All valves provided under this Section shall be tagged.
C. Demolition shall be as shown on the Drawings and shall be in accordance with the requirements of Division 2, Section 02050 of these Specifications.
1.02 RELATED WORK
A. All piping systems in the building other than the plumbing work specified in this Section.
B. Yard piping for sanitary and storm drains beyond 10 feet outside the building unless otherwise indicated.
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C. The following items are related work:
1. Small Plumbing Valves are included in this Division, Section 15100.
2. Hangers, Supports and Anchors are included in this Division, Section 15140.
3. Painting is included in Division 9, Section 09900.
4. Cutting and Patching are included in Divisions 3 and 4.
5. Manholes, Catch Basins, and Buried Pipe Encasement are included in Division 2.
6. Ductwork is included in this Division, Section 15890.
7. Toilet, Shower, Drying, Locker, and Janitor's Room Accessories are included in Division 10.
8. Electrical is included in Division 16.
9. Excavating and Backfilling is included in Division 2.
10. Concrete is included in Division 3.
11. Portable Fire Extinguisher is included in Division 10.
12. Mechanical Identification Markers, Tags and Plates are included in this Division, Section 15190.
13. Sewer and drain pipe is included in Division 2.
14. Pressure pipe is included in Division 2.
15. Firestopping is included in Section 15305.
1.03 SYSTEM DESCRIPTION
A. Mention herein or indication on the Drawings of equipment, materials, operation or methods shall require that each item mentioned or indicated be provided to make a complete system of plumbing ready for continuous operation.
B. The location of all equipment, fixtures and piping shall be considered as approximate only and the right is reserved by the ENGINEER to change at any time, before the work is installed, the position of such equipment and piping to meet structural conditions and to provide proper headroom clearance or for other sufficient causes and such changes shall be made without additional expense to the OWNER.
C. Attention is called to the necessity for elimination of transmission of vibration from mechanical equipment to building structures. All equipment, therefore, shall be carefully selected and installed to meet this condition and isolators shall be provided for all equipment with rotating parts.
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D. Instruct such persons as designated by the OWNER in the care and use of all plumbing equipment and piping systems installed.
1.04 DRAWINGS
A. All work shown on the Drawings is intended to be approximately correct to scale, but figured dimensions and detailed Drawings shall be followed in every case. The Drawings shall be taken in a sense as diagrammatic. Size of pipes and general method of running them are shown, but it is not intended to show every offset and fitting nor every structural difficulty that may be encountered. To carry out the true intent and purpose of the Drawings all necessary parts to make complete working systems ready for use shall be furnished without extra charge.
B. All piping shall be installed as closely as possible to walls, ceiling and other structural parts (consistent with proper spacing for covering, removal of pipe, and access to accessories, such as valves, strainers, etc.), so as to occupy the minimum space, and all offsets and fittings required to accomplish this shall be furnished without additional expense to the OWNER.
C. Refer to the Structural and Architectural Drawings which indicate the type of construction in which the work shall be installed. Locations shown on the Plumbing Drawings shall be checked against the general and detailed drawings of the construction proper. All measurements must be taken at the building.
1.05 REFERENCES
A. Kentucky Building Code
B. Kentucky State Plumbing Law, Regulations and Code
1.06 SUBMITTALS
A. Furnish to the ENGINEER for review, as provided in the General Conditions, shop drawings and technical literature covering details of all equipment, fixtures and accessories being furnished under this Section prior to fabrication, assembly or shipment.
1.07 CODES, ORDINANCES AND PERMITS
A. Comply with all the laws, ordinances, codes, rules and regulations of the local and State authorities having jurisdiction over any of the work specified herein.
B. Obtain all required permits, pay all legal fees and tap-on fees for the same and in general take complete charge and responsibility for all legal requirements pertaining to this Section of the work.
C. Requirements set forth in this Section and indicated on the Drawings shall be followed when in excess of the required or minimum regulations.
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D. If any work is performed and subsequent changes are necessary to conform to the regulations, such change shall be made as part of this work at no additional cost to the OWNER.
1.08 ACCEPTANCE OF INSTALLATION CONDITIONS
A. The Subcontractor shall be fully responsible for the proper execution and performance of the work described herein. It shall be his responsibility to inspect all installation conditions and bring to the attention of the ENGINEER via the CONTRACTOR any conditions which may affect his work adversely. He shall report via the CONTRACTOR to the ENGINEER, prior to commencing any portion of this work, any conditions unsuitable for the installation of his portion of the work.
PART 2 PRODUCTS
2.01 DRAINS
A. Floor Drains P-16
1. All floor and open ended drains as required shall be fitted with a deep seal cast iron "P" type trap.
2. All floor and open ended drain traps where exposed or accessible shall be fitted with bottom cleanouts and cleanout plugs or caps.
3. All floor drains shall have cast iron or acid resisting drainage flange, seepage control, clamping collar and inside caulk outlet.
4. In areas with finished floor covering (tile, etc.) floor drain shall be recessed 1-inch, and in areas with no floor covering recess shall be 1/4-inch.
5. Floor drains shall be Zurn-415, Wade, Ancon, or equal.
B. Indirect Waste Receptacles P-11
1. Furnish and install an open receptacle at the location shown on the Drawings. Receptacle shall have a 7-inch top, bottom outlet as noted on the Drawings.
2. Indirect waste receptacle shall be Zurn Z-566, Josam, Smith or equal.
C. Modular Trench Drain P-15
1. Modular trench drain shall have a 12-inch wide top, dura-coated cast iron deep sump body with bottom outlet.
2. Both the outlet module and extension module shall have an integral seepage pan and heel-proof grate with frame.
3. The modular trench drain shall be Zurn Model Z665 or equal.
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2.02 CLEANOUTS
A. Cleanouts in tile areas shall be heavy duty cast iron with square nickel bronze top recessed for tile and adjustable to finished floor. A membrane flange shall be provided. Cleanouts in tile areas shall be Zurn ZN-1400-5 or equal.
B. Cleanouts in vertical soil and waste stacks shall be cast iron ferrule and cadmium plated cast iron countersunk plug complete with nickel bronze square smooth wall access cover and frame. Cleanouts in vertical soil and waste stacks shall be Zurn Z-1440-3 or equal.
2.03 PLUMBING FIXTURES
A. Indoor Combination Shower/Eye-Wash Station P-1
1. Furnish and install combination corrosion resistant emergency shower/eyewash stations at the locations shown on the Drawings. The shower and eyewash shall be operated separately, the shower by a rigid pull-rod with triangular handle and the eyewash by hand control. The units shall be constructed of PVC, including the 1-1/2 inch pipe, floor flange, and all fittings. The shower valve and eye-wash valve shall be of the stay-open ball type. The eyewash fountain shall have an ABS plastic bowl and twin ABS plastic spray heads. The deluge shower shall have an 8-inch cycolac plastic head. Emergency identification signs shall be included with each unit. The combination shower/eyewash stations shall be Speakman SE-690-PVC, or equal.
2. Furnish and install a flow switch to actuate an alarm at a remote location.
B. Emergency Spray Unit P-14
1. Furnish and install a corrosion resistant emergency spray unit in the countertop at the location shown on the Drawings. The unit shall be operated by a polished chrome plated brass quick-opening squeeze lever valve and shall include an ABS plastic head with a flow rate capability of 7.0 gpm, polished chrome-plated hand grip with integral base, special positioning deck flange, metal hose guide bracket, 6 feet of pressure rated 7/8-inch hose, 1.65 gpm automatic flow compensation device, vacuum breaker, and an emergency identification sign.
2. Unit shall be mounted in a manner allowing concealment of hose below countertop when not in use.
3. Furnish and install a flow switch to activate an alarm at a remote location.
4. Emergency spray unit shall be Speakman Model SE-922, or equal.
C. Water Closets P-18
1. Furnish and install water closets for locations shown on the Drawings. Water closets shall be the water saving, siphon jet type with close-coupled tank and free standing elongated bowl. The tank, cover, and
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bowl shall be white vitreous china. All exposed metal surfaces shall be polished chromium plated.
2. Each water closet shall be equipped with bolt caps, flush valve, and float valve, trip lever, seat with cover, tank liner and tank supply assembly consisting of 3/8-inch angle valve, wheel handle, and flexible tube riser.
3. Water closet shall be American Standard Elongated Water Saver Cadet #2386.014 or equal. Water closet seat and cover shall be Olsonite 34 or equal.
D. Lavatories (Countertop) P-19
1. Furnish and install lavatories for locations shown on the Drawings. Lavatories shall be white vitreous china with an oval basin and front overflow, concealed hangers, and lavatory anchoring screws. All exposed metal trim and accessories shall be polished chromium plated. Drilling shall be for 8-inch lavatory faucet.
2. Each lavatory shall be equipped with a 1-1/4 inch adjustable cast brass "P" trap with cleanout and waste to wall; supply assembly consisting of 3/8-inch angle valves, wheel handles and flexible tube risers; and brass faucet and waste trim consisting of valves with renewable seats on 8-inch centers, 1/2-inch male threaded inlets, coupling nuts, aerator, grid drain, 1-1/4 inch tail piece, chrome handles, and 2-1/2 gpm flow restrictor.
3. Lavatories shall be American Standard Countertop Sink 0293.008, faucet and waste trim 6501.170, or equal.
E. Electric Water Heater P-8
1. Furnish and install an 80-gallon electric water heater at the locations shown on the Drawings.
2. The tanks shall be designed for 150 psi working pressure and unit shall meet or exceed requirements set forth in ASHRAE 90A for energy efficiency.
3. Heating elements shall be 4.5 kW, 480 volt, 3-phase. Recovery capacity for 100 degree temperature rise shall be 18 gph.
4. Electric water heater shall be A.O. Smith DEN-80.
F. Master Mixing Valve P-3
1. Furnish and install a master mixing valve at the location(s) shown on the Drawings. The unit shall be capable of providing 60 gpm of tempered water at 30 psi with a temperature range of 70 to 90 degrees Fahrenheit.
2. The unit shall employ 2 fully independent control mechanisms which split the flow in half, blending each half to the design temperature and then
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integrate each stream at the outlet. The unit shall be suitable for deluge shower or eyewash applications.
3. Each control mechanism shall employ a liquid-filled thermostatic motor to drive the valve without additional power requirements.
4. In the vent of interruption of the cold water supply each control mechanism shall close off all flow. In the event of interruption of the hot water supply, each control mechanism shall allow cold water to flow through both the fixed and variable bypass.
5. The master mixing valve shall be Speakman Model SE-350, or equal.
G. Mixing Valve P-13
1. Furnish and install a master mixing valve at the location(s) shown on the Drawings. The unit shall be capable of providing 7 gpm of tempered water at 30 psi with a temperature range of 70 to 90 degrees Fahrenheit.
2. The unit shall be suitable for single eyewash or facewash applications.
3. The control mechanism shall employ a liquid-filled thermostatic motor to drive the valve without additional power requirements.
4. In the event of interruption of the cold water supply, the control mechanism shall close off all flow. In the event of interruption of the hot water supply, the control mechanism shall allow cold water to flow through both the fixed and variable bypass.
5. The master mixing valve shall be Speakman Model SE-370, or equal.
H. Instantaneous Water Heater P-22
1. Furnish and install instantaneous water heaters at the locations shown on the Drawings. The unit shall be rated at 120V, 3.5 kW, 1 phase.
2. The demand for hot water shall activate a pressure differential switch that applies power to the heat exchanger at a slow steady rate with full power achieved in 12 seconds.
3. The instantaneous water heater shall be AccuMix Model MT004120T, manufactured by EEMAX, Inc., or equal.
I. Electric Water Heater P-10
1. Furnish and install a 15-gallon electric water heater at the locations shown on the Drawings.
2. The tank shall be designed for 150 psi working pressure and unit shall meet or exceed requirements set forth in ASHRAE 90A for energy efficiency.
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3. Heating element shall be 1.5 kW, 208 volt, single phase. Recovery capacity for 100 degree temperature rise shall be 12 gph.
4. Electric water heater shall be A.O. Smith DEL-15, or equal.
J. Compound Water Meter P-4
1. All meters furnished shall be manufactured by a registered ISO 9001 quality standard facility. Acceptable meters shall have a minimum of 15 years of successful field use. All specifications meet or exceed the latest revision of AWWA C701 and NSF/ANSI 61.
2. Compound meters shall consist of a combination of an AWWA Class II turbine meter for measuring high rates of flow and a nutating disc-type, positive displacement meter for measuring low rates of flow enclosed in a single maincase. An automatic valve shall direct flows through the disc meter at low flow rates and through the turbine meter at high flow rates. At high flow rates, the automatic valve shall also serve to restrict the flow through the disc meter to minimize wear.
3. The meters shall comply with the operating characteristics shown below:
Size
Normal Operating
Range (gpm)
Maximum Continuous Flow (gpm)
Maximum Loss of Head at
Maximum Cont. Flow (psi)
Maximum Intermittent Flow (gpm)
Low Flow (gpm)
2” 1/2-200 160 8 200 1/8 3” 1/2-450 350 8 450 1/8 4” 1-1000 700 8 1000 1/2 6” 1-1/2 – 2000 1400 8.5 2000 3/4
6” x 8” 1-1/2 – 2000 2000 10.5 2000 3/4
4. The maincase and cover shall be cast from an NSF/ANSI 61, Annex G and Annex F certified lead free high copper alloy containing a minimum of 85 percent copper. The size, model, NSF certification and arrows indicating direction of flow shall be cast in raised characters on the maincase or cover. The covers all contain a stainless steel calibration vane for the purpose of calibrating the turbine measuring element while the meter is inline and under pressure. A test plug shall be located in the maincase or the cover for the purpose of field testing of the meter.
5. Casing bolts shall be made of AISI Type 316 stainless steel.
6. Maincases shall be flanged. The 2-inch meters shall be oval flanged and 3-inch through 6-ilnch sizes shall be round flanged per Table 4, AWWA C702.
7. Separate magnetic-drive registers shall record the flow of the turbine and disc meters and their total will be the registration of the compound meter. The registers shall be permanently roll-sealed, straight reading
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indicating in cubic feet, gallons, or cubic meters. Registers shall include a center-sweep test hand, a low flow indicator, and a glass lens. The registers shall be serviceable without interruption of the meter’s operation. Registers shall be guaranteed for at least 10 years.
8. Register boxes and covers shall be of bronze composition. The name of the manufacturer shall be clearly identifiable and located on the register box covers.
9. Registers shall be affixed to the cover by means of a plastic tamperproof seal pin which must be destroyed in order to remove the register.
10. The meter serial number shall be imprinted on the meter flange or cover as well as the register box covers.
11. The turbine measuring chamber shall be a self-contained unit, attached to the cover for easy removal. The turbine shaft shall be tungsten carbide with tungsten carbide inserts and shall rotate in removable graphite bushings. Thrust bearings shall be tungsten carbide.
12. The nutating disc chamber shall be a self-contained unit mounted on the cover and easily removable from the cover. It shall conform to AWWA Standard C700 for the following sizes: 2-inch and 3-5/8” disc; 4-inch to 3/4-inch disc; 6-inch to 1-inch disc. The inlet to the disc chamber shall be a “single” opening of adequate size not to be susceptible to plugging and water restriction by waterborne debris.
13. The intermediate gear train shall be directly coupled from the turbine rotor and magnetically coupled to the register through the meter cover. The gear train shall be housed in the turbine measuring chamber. All moving parts of the gear train shall be made of a self-lubricating polymer or stainless steel for operation in water.
14. The automatic valve shall be of the spring-loaded, poppet type. All valve parts shall be made of lead free high copper alloy containing a minimum of 85 percent copper, stainless steel, or a suitable polymer with a replaceable semi-hard EPDM rubber seat. Only the cover must be removed to gain access to the valve for inspection or service.
15. The disc meter shall include a self-actuated valve that directs flow through the disc meter at low flow rates and through the turbine meter at high flow rates. At high flow rates, the self-actuated throttle valve shall restrict the flow through the disc meter to minimize wear.
16. A strainer shall be provided for the disc meter. It shall be easily removable and have and effective straining area of double the disc meter inlet.
17. Registration accuracy over the normal operating range shall be 98.5 percent to 101.5 percent. Registration at the crossover shall not be less than 95 percent with direct reading registers. Registration at the
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crossover shall not be less than 90 percent with absolute encoder or generator remote registers. Registration at the extended low flow rate shall not be less than 95 percent.
18. Acceptable meters shall be Neptune TRU/FLO® Compound with a Neptune Strainer, or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. All the items specified under PART 2 PRODUCTS, shall be installed according to the applicable manufacturer's recommendations, the details shown on the Drawings and as specified under this Section.
B. Completely caulk around fixtures where fixture meets the floor or wall to provide a water tight seal.
C. Where water piping is installed as copper tubing, all valves shall be copper solder end except as noted above to be threaded ends.
D. Control valves to all equipment and fixtures shall be installed, grouped and located so they will be easily operated, through access panels, doors, or adjacent to equipment.
E. Valves shall be installed in horizontal to upright position and shall not be installed in down position from the horizontal.
F. The sanitary system shall be extended to points of termination and installed as described as shown on the Drawings.
G. Provide all temporary metal supports to secure and maintain buried piping in correct alignment and slope.
H. When pipes run on a wall below a fixture or to a fixture, the supports for these pipes shall be cast pattern brass and where exposed shall be of same finish as the pipes they support.
I. All interior hot and cold water lines shall be insulated whether exposed or located in walls, pipe chases or above ceilings.
J. Insulation shall not be applied until pipes have been tested and accepted by all parties making inspection. All insulated covering shall be guaranteed for a period of one year.
K. Short exposed supply pipe at or immediately near regular plumbing fixtures shall not be insulated but shall be finished as trim for fixtures specified in PART 2 of this Section.
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L. Temperature and pressure relief valves shall be installed on the potable water heaters. Relief valves shall be ASME rated. Relief valves shall be piped to drain over floor drains or through wall to exterior of building as shown on the Drawings.
M. The flow switch as described above for emergency shower and eye wash units, shall be installed in the horizontal pipe line. It shall be on top of the pipe with the vane vertical. The flow switch shall be located not less than 6 diameters from any fitting that changes the direction of flow.
N. All work shall be installed in accordance with the manufacturer's printed instructions and shall be rigid, plumb and true to line, with all parts in perfect working order. Maintain protective covers on all units until final clean-up time and at that time remove covers and clean and polish all surfaces.
O. Installation of the fixtures and accessories shall meet the applicable require-ments of the American Disabilities Act.
P. Interior copper pipe shall show no dents or bends and joints shall present a neat appearance. Pipes shall be parallel to walls, floors and ceilings with unions and valves near beginning all runs and branches to facilitate dismantling and shutting off. Pipe shall be secured to walls and ceiling by clamps and rod hangers manufactured for the purpose. Perforated strap hangers are not acceptable. After installation, the pipe shall be tested and all leakage stopped.
Q. Wherever copper pipes pass through walls or floors, they shall have ductile or cast iron sleeves for easy removal. Pipes passing through structural beams shall be placed as near as possible to the top of the beam under the floor slab.
3.02 TESTING
A. The potable water supply and the entire soil and/or waste and vent system shall be tested in accordance with Article 815 KAR 20:150 of the Kentucky State Plumbing Code. The potable water line and appurtenances shall be installed and disinfected in accordance with the requirements of the Division of Water, Kentucky Natural Resources and Environmental Protection Cabinet.
B. All additional tests, methods or materials as may be required by the local ordinances and not specifically mentioned herein, shall be made as directed by the Local Inspection Authority.
C. Provide for any repeated test as necessary to make systems tight as required.
3.03 WATER FOR TESTING
A. The CONTRACTOR will provide air, steam, and water necessary for testing the piping systems. The Subcontractor shall make all connections for testing and remove all debris resulting therefrom. The water shall be used in an efficient and economical manner.
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B. Provide all apparatus and all other supplies or materials which may be necessary for testing the systems and operating the apparatus during the period while tests of any kind are being made, or for carrying out the work of the Contract.
3.04 CLEANING
A. At the completion of the work, all fixtures, equipment, apparatus and exposed trim for same included in this Section shall be clean and, where required, polished ready for use.
3.05 PROTECTION
A. Materials, fixtures, and equipment shall be properly protected at all times and all pipe openings shall be temporarily closed so as to prevent obstruction and damage. Work damaged during construction shall be replaced at no additional cost.
3.06 DISINFECTION
A. This requirement applies to the entire potable water system including the new underground service pipe and all interior potable hot and cold service piping.
B. Thoroughly flush the potable water system with clean potable water.
C. Fill the potable water system with a water/chlorine solution of 50 parts per million (50 mg/l) of chlorine, valve off and let stand for 24 hours. A chlorine residual test is required after filling line to ensure proper chlorine concentration.
D. Fill the system with a water/chlorine solution containing at least 200 parts per million (200 mg/l) of chlorine and allow to stand for 3 hours. A chlorine residual test is required after filling line to ensure proper chlorine concentration.
E. After the 3 hour period open all valves and faucets and flush the system with clean, potable water until the residual chlorine content is not greater than 0.2 parts per million.
F. When final flushing is complete, samples from at least 3 points in the system shall be taken for analysis at a State Certified Laboratory for certification that they are free of coliform bacteria contamination. One of the sampling points must be the furthest most fixture from the potable water service line building entry.
G. Laboratory certification that all samples are free of coliform bacteria contamination is required for system disinfection to be acceptable.
3.07 MISCELLANEOUS REQUIREMENTS
A. All final connections to mechanical equipment in all locations shall be preceded by union fitting and gate valve or globe valve.
B. Pump bases shall be drained whether shown on the Drawings or not from the tapping in the base to and over the nearest floor or open end drain.
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3.08 COORDINATION SKETCHES
A. It shall be the responsibility of the Subcontractor to have in his employ a competent coordinator of mechanical systems and as such to provide all coordination of drawings or sketches as may be required or deemed necessary by the ENGINEER to obtain the required ceiling heights and eliminate conflicts with all piping, ducts, and electrical installation.
END OF SECTION
***
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SECTION 15530
REFRIGERANT PIPING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials and services required to install refrigerant piping and specialties as shown on the Contract Drawings and as specified.
1.02 RELATED WORK
A. Special requirements for materials are given in Section 15010 and the General Conditions.
B. Refrigerant specialties are specified in Section 15535.
1.03 QUALIFICATIONS
A. The installing contractor shall have at least 3 years of successful installation experience on projects with refrigerant piping work similar to that required for this project.
B. Certify brazing procedures, brazers and operators in accordance with ASME standards (ANSI B31.5).
1.04 SUBMITTALS
A. Shop drawing and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Condi-tions.
B. At the project closeout, submit record drawings of installed refrigerant piping and accessories in accordance with Section 15010 and the General Conditions.
PART 2 PRODUCTS
2.01 GENERAL
A. Refrigerant piping shown on the Drawings, specified, or required for the air conditioning systems shall be type ACR, soft annealed temper copper.
B. Refrigerant fittings shown on the Drawings, specified, or required for the air conditioning system shall be wrought copper with solder joints.
C. Joints shall be brazed with silver solder, ANSI/ASTM B Grade 96 TS.
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2.02 LONG LINE REQUIREMENTS
A. Air conditioning liquid line solenoid (see Refrigerant Specialties Section 15535) shall be installed within 2 feet of outdoor unit with flow pointing toward outdoor unit.
B. An inverted vapor line trap shall be installed at indoor unit. The top peak of the trap shall be greater than the height of the indoor coil.
C. The above requirements provide protection against condensed refrigerant collecting in the vapor line and maintains a solid liquid during the off-cycle.
D. Maximum elevation between units shall be 50 feet. Maximum equivalent total line length shall be 175 feet.
2.03 INSULATION
A. Refrigerant suction piping shall be insulated with tubular flexible elastomeric insulation. Joints shall be sealed with a glue that is specifically for use with elastomeric insulation. Exterior insulation shall be protected with a UV and weather-resistant finish.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install all refrigerant piping as shown on the Contract Drawings.
B. Comply with applicable requirements of ANSI B31.5 and ANSI B31.5a, "Refrigeration Piping," pertaining to brazing of refrigerant piping for project site locations.
C. Comply with unit manufacturer's written recommendations of refrigerant piping installations.
D. Refrigerant piping shall be pitched in direction of oil return to compressor. Oil traps and double suction risers shall be provided where indicated, and where required to provide oil return.
E. Prior to initial operation, clean and test refrigerant piping in accordance with ANSI B31.5 and B31.5a, "Refrigeration Piping." Perform initial dry nitrogen, using soap solution to test all joints. Perform final test with 27-inch vacuum and then 200 PSI using halide torch. Systems shall be leak free.
END OF SECTION
***
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SECTION 15535
REFRIGERANT SPECIALTIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials and services required to install refrigerant specialties as shown on the Contract Drawings and as specified.
1.02 RELATED WORK
A. Special requirements for materials are given in Section 15010 and the General Conditions.
B. Refrigerant piping is specified in Section 15530.
1.03 QUALIFICATIONS
A. The installing contractor shall have at least 3 years of successful installation experience on projects with refrigerant piping work similar to that required for this project.
B. Certify brazing procedures, brazers and operators in accordance with ASME standards (ANSI B31.5).
1.04 SUBMITTALS
A. Shop drawing and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
B. At the project closeout, submit record drawings of installed refrigerant acces-sories in accordance with Section 15010 and the General Conditions.
PART 2 PRODUCTS
2.01 GENERAL
A. Moisture liquid indicators shall be forged brass, single port removable cap, polished optical glass, solder connections, UL listed, 200 degrees Fahrenheit temperature rating, 500 psi working pressure.
B. Solenoid valves (two way) shall be forged brass, designed to conform to ARI 760, normally closed, Teflon valve seat, NEMA 1 solenoid enclosure, 24 volt, 60 Hertz UL-listed, 1/2-inch conduit adaptor, 250 degrees Fahrenheit, and 400 psi work pressure. Valve coils shall have Class B insulation.
C. Filter dryers shall be liquid line flared fitting type sized according to unit manufacturer recommendations.
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D. Refrigerant specialties shall be ALCO Controls, Henry Valve Company, Parker-Hannifin Corporation, or Sporlan Valve Company.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install all refrigerant specialties as shown on the Contract Drawings and according to manufacturer's recommendation. Remove accessible internal parts before soldering or brazing replace after joints are completed and cooled.
B. Comply with applicable requirements of ANSI B31.5 and ANSI B31.5a, "Refrigeration Piping," pertaining to brazing of refrigerant specialties for project site locations.
C. Comply with unit manufacturer's written recommendations of refrigerant piping installations.
D. Prior to initial operation, clean and test refrigerant specialties along with refrigerant piping in accordance with ANSI B31.5 and B31.5a, "Refrigerant Piping." Perform initial dry nitrogen, using soap solution to test all joints. Perform final test with 27-inch vacuum and then 200 psi using halide torch. Systems shall be leak free.
END OF SECTION
***
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SECTION 15780
SPLIT SYSTEM AIR CONDITIONERS, FURNACES, AND HEAT PUMPS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install heating and air conditioning equipment as shown on the Contract Drawings and as specified herein. See equipment schedule in Contract Drawings for additional requirements.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Section 15010 and the General Conditions.
B. Electrical work is specified in Division 16.
C. Refrigerant piping is specified in this Division, Section 15530.
D. Electrical Control Devices are specified in this Division, Section 15950.
E. Refrigerant specialties are specified in this Division, Section 15535.
F. Insulation is described in this Division, Section 15260.
G. OWNER training for HVAC Equipment and Systems is specified in Section 15010 and the General Conditions.
H. Firestopping is included in Division 7, Section 07840.
1.03 QUALIFICATIONS
A. Coils shall be tested in accordance with the American Society of Heating, Refrigeration, and Air-Conditioning Engineers, Inc. (ASHRAE) Standard 33 "Methods of Testing Forced Circulation Air Cooling and Heating Coils."
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
B. Submit ladder-type wiring diagrams for power and control wiring required for final installation of equipment. Clearly differentiate between portions of wiring that are factory-installed and portions to be field-installed.
C. O&M instructions shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
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1.05 WARRANTY
A. Heat pumps and air conditioners, as standard, shall have a 1 year warranty against defects in materials and workmanship and hermetically sealed units shall have an additional 4 year warranty (parts only) on the compressor. Individual equipment specifications may require additional warranty periods by the manufacturer.
PART 2 PRODUCTS
2.01 INDOOR MULTIPOISE AIR HANDLER (2 TO 5 TONS)
A. Air Handler Unit
1. The cabinet of the AHU shall be of heavy gauge steel. The cabinet shall have a baked on electroplated paint finish.
2. The AHU shall contain the fan, cooling/heating coil, integral controls and resistance heating.
3. The blower shall be a statically and dynamically balanced direct drive unit. The performance of the blower shall conform to value indicated in the equipment schedule on the Drawings.
4. The heating/cooling coil shall be configured for flow as shown on the Drawings and integral to the fan coil unit.
5. The coil shall include a refrigerant metering system and have necessary refrigerant piping and service connections.
6. Install condensate trap per manufacturer’s requirements.
7. Install transformer and condensate pump, complete with piping, as called for in the equipment schedule.
8. Additional features shall include refrigerant charge and thermostatic expansion valve, factory-installed; heat packages; grooved copper tubing; lanced sine wave aluminum fin; fully wettable coil; high-impact thermoplastic condensate pan; primary and secondary drain connections with brass inserts; multipoise design; control board with built-in, replaceable 5 amp blade–type auto fuse; ECM motor for 2 to 5-ton units; time delay relay; high density R-4 insulation; and 40 VA, 208/230V transformer, UL and ARI listed/ certified.
9. Unit shall have a 5-year parts warranty on all parts. Unit shall utilize R-410a refrigerant
B. Resistance Heat Section
1. The resistance heat section shall be of size and capacity as described in the heat pump unit schedule on the Drawings.
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2. The heat section shall be mounted in the AHU.
3. Control and power wiring for the heat section shall connect to the AHU power and control wiring.
C. Capacity
1. Capacity of AHU shall be as listed on the Contract Drawings.
D. Manufacturer
1. The AHU shall be Carrier FE4ANF Infinity Series, or equal.
2.02 OUTDOOR HEAT PUMP UNIT (2 TO 5 TONS)
A. Air-cooled heat pump unit shall be designed for use with split system having a remote direct-expansion (DX) evaporator coil integral to the air handler unit. Capacities shall be as indicated on the Drawings. Unit shall utilize R-410a.
B. Cabinet shall be heavy gauge galvanized steel with baked on outside enamel. The entire cabinet shall be protected from rust and include support feet.
C. Compressor shall be 2-stage, scroll-type and hermetically sealed with overcurrent and temperature protection. The unit shall be provided with a thermostatically controlled crankcase heater to operate only when needed for protection of the compressor. The compressor shall be spring-mounted on rubber isolators. A high capacity dryer and high pressure limit switch shall also be an integral part of the unit.
D. Outdoor coils shall be constructed of precisely spaced ripple edged copper aluminum fins machine fitted to seamless copper tubes. Fins shall be equipped with collars to grip tubes. The entire coil shall be accessible for cleaning.
E. Outdoor fan shall be direct drive with vertical discharge. The fan motor shall be thermally protected and totally enclosed for maximum protection from weather, dust, and corrosion. The motor shall be equipped with a rain shield to provide additional protection from moisture. The fan shall be protected by a louvered steel fan guard.
F. The heat pump unit shall be provided with crankcase heater, internal pressure relief valve, solenoid operated switchover valve, high and low pressure limit switches, temperature/pressure actuated defrost control, refrigerant line connections with service valves and gauge ports, relays, contacts or any other components necessary to the efficient operation of the unit.
G. The heat pump unit shall be rated and sound tested in accordance with ARI Standards. The unit shall be UL listed.
H. The unit shall be Carrier 25HNB9 Infinity Series, or equal. See notes on equipment schedule which are in addition to and override any requirements in conflict in this Specification.
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I. If called for in the equipment schedule, the unit shall have low ambient cooling and include all accessories and incidentals required and recommended by the manufacturer for operations down to 20 degrees Fahrenheit.
J. Single-phase units shall have a 5-year limited compressor and parts warranty. Three-phase units shall have a 1-year limited parts warranty and a 5-year limited compressor warranty.
PART 3 EXECUTION
3.01 INSTALLATION
A. Heat Pump/Cooling Unit (Outdoor)
1. Install the unit on concrete pad as shown or noted on the Drawings, and in a location that will not restrict the air entry or discharge from the unit.
2. Install all refrigerant lines as recommended by the manufacturer taking care not to lose the refrigerant charge contained in the lines, allow air to enter the lines or equipment. Locate the lines in such a way as to not obstruct access to the unit or other equipment.
3. Provide electrical connections as required by the applicable codes. Provide control wiring required. All power wiring and control wiring shall be in water-tight conduit or flexible liquid-tight and located so as not to obstruct access to the unit or other equipment.
B. Air Handler/Fan Coil Unit (Indoor)
1. Install the unit as shown on the Drawings and as recommended by the manufacturer for the type of installation required. Installation shall be plumb and true, with clearance from combustible materials as recom-mended by the manufacturer and UL.
2. Connect power as required by the state and local codes, and secure their acceptance of the installation.
3. Operate the unit and test the safety controls, fan relay, overtemperature cutout, etc., for proper setting and operation.
4. Install clean filters in the unit.
5. Final connection of ductwork, if applicable, to unit shall be flexible. All duct connections at fan coil unit shall be airtight. Adhesive-backed tape shall not be used, either inside or outside of the ductwork, to cover or seal any openings or leaks.
6. Install (the expansion valve and) make the refrigerant connections as required and as recommended by the manufacturer. Test the refrigerant system for leaks and place in operation.
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7. Connect all controls and verify that they are functioning properly on heating and cooling.
8. Adjust the blower to match the air quantity called for in the Drawings.
END OF SECTION
***
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SECTION 15781
SELF-CONTAINED WALL MOUNTED VERTICAL AIR CONDITIONERS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install complete and operable air conditioning equipment as shown on the Contract Drawings and as specified herein. See the equipment schedule and Contract Drawings for additional requirements.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Section 15010 and the General Conditions.
B. Electrical work is specified in Division 16.
C. OWNER training for HVAC Equipment and Systems is specified in Section 15010 and the General Conditions.
1.03 QUALIFICATIONS
A. Equipment shall be UL listed and ARI certified.
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ENGINEER in accordance with Section 15010 and the General Conditions.
B. Submit ladder-type wiring diagrams for power and control wiring required for final installation of equipment. Clearly differentiate between portions of wiring that are factory-installed and portions to be field-installed.
C. O&M instructions shall be submitted to the ENGINEER in accordance with Section 15010 and the General Conditions.
1.05 WARRANTY
A. Air conditioners shall have a 1 year parts and labor warranty against defects in materials and workmanship and hermetically sealed units (compressors) shall have an additional 4 year parts only warranty. Submit written proof, by the manufacturer, of the primary and extended compressor warranties during shop drawing review.
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PART 2 PRODUCTS
2.01 PRODUCTS
A. General
1. Furnish and install a self-contained wall mount air conditioner suitable for outdoor use as described herein and noted on the Contract Drawings. The unit shall be as manufactured by Marvair or equal. The wall mount unit shall be completely factory assembled and tested, and shall include compressor, indoor and outdoor coils, fans, and motors as required, prewired controls, interconnecting refrigerant tubing, wiring, circuit breakers, and other necessary components mounted in a corrosion resistant cabinet. Unit shall be shipped from the factory with a full operating refrigerant and oil charge.
2. The complete package shall be ETL listed and tested to UL Standard 1995, latest edition, and CAN/CSA-C22.2 No. 236-95, latest edition. The unit shall be certified to Air Conditioning and Refrigeration Institute (ARI) Standard 210. For 6-ton, 3-phase units, the applicable standard is ARI 340/360. The manufacturer of the unit shall be ISO 9001 2000 certified.
B. Cooling Capacity
1. Total and sensible cooling capacity shall be as noted on the Drawings at ARI conditions of 67 degrees Fahrenheit wet bulb, 80 degrees Fahrenheit dry bulb entering indoor air, and condenser entering air temperature of 95 degrees Fahrenheit dry bulb.
C. Heating Capacity
1. Supplemental electrical resistance heat in the amount as noted on the Drawings shall be provided internally to the unit.
D. Cabinet
1. The weatherproof cabinet shall be constructed of zinc-coated, 20 gauge galvanized G60 steel. The conditioned air section shall be insulated with 1/2-inch, 2 pound dual density fiberglass. Two-inch throw away type filter shall be mounted internally, factory supplied, and accessible through a hinged type panel. Unit color shall be selected by the OWNER through the ENGINEER during shop drawing review. Submit color chart including non-standard optional colors. The cabinet shall include a sloped top and built-in mounting flanges.
E. Compressor/Refrigeration Circuit
1. The compressor, for all units except a one ton unit, shall be a 2-stage scroll type. One ton units shall be equipped with an immersion type self-regulating crankcase heater for use with a reciprocating compressor or if recommended by the manufacturer on various size scroll compressor units in low ambient applications. The refrigeration circuit shall contain a
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liquid filter dryer, suction and liquid access valves. The refrigeration circuit shall include high and low pressure switches with a lockout relay. The compressor motor shall be protected by an internal line break thermostat. Electrical wiring connections at the compressor shall be protected by receptacle housing.
F. Outdoor Section
1. The condenser coil shall be constructed of aluminum plate fins mechanically bonded to seamless copper tubes. Outdoor fan shall be direct driven, slow speed propeller type for quiet operation. The outdoor motor shall be equipped with a thermal protector.
G. Indoor Section
1. The evaporator coil shall be constructed of aluminum plate fins mechanically bonded to seamless copper tubes. Two direct driven indoor blowers shall be of centrifugal type, forward curved. The indoor motor shall be equipped with a thermal protector.
H. Control Circuit
1. The internal control circuit shall consist of a current limiting type trans-former to generate 24 VAC, switching devices to operate the compressor, indoor fan motor, and electrical heater(s). The control circuit shall incorporate a manual reset safety circuit to render the refrigerant system (compressor and outdoor fan motor) inoperative should there be a loss of air flow or refrigerant. System lockout condition shall be indicated by contact closure available at low voltage terminal block. The safety circuit shall be resettable at the wall thermostat.
2. A low ambient outdoor fan control shall be factory installed for operation of the air conditioner in the cooling mode down to zero degrees Fahrenheit. To prevent rapid compressor cycling and to delay startup of compressor on a call for cooling, an automatic resetting adjustable time delay circuit shall also be factory-installed. A timed low pressure bypass switch (Compac I A/C only) for startup of the air conditioner below 20 degrees Fahrenheit and down to 0 degrees Fahrenheit shall be factory-installed. Auto-reset low pressure control shall be factory-installed.
3. Unit shall have a factory-installed built-in circuit breaker or disconnect switch.
4. A hard-start kit shall be factory-installed for all single-phase reciprocating units. The kit is not required for units with scroll compressors unless recommended by the manufacturer for low ambient applications.
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I. Blank-Off Plate
1. The Compac I units shall have a blank-off plate installed to prevent any outdoor air from entering the conditioned space or an adjustable fresh air damper capable of being set to 0 percent outside air.
J. Supply/Return Grille
1. The supply grille shall be an adjustable aluminum, double deflection grille, factory provided. The return grille shall be an aluminum grille, factory provided.
K. Thermostat(s)
1. See the equipment schedule on the Drawings to determine which of the following thermostats are required.
a. Furnish and install a non-programmable electronic thermostat that does not require batteries and has a non-volatile program memory. It shall be an automatic change-over type with the following: System switch (heat, auto, cool, off), fan switch (auto, on), room temperature display, and selectable 5° cooling deadband.
b. The control of 1 or 2 air conditioning units shall be by the Marvair CommStat 3 or 4, as noted in the schedule, lead lag controller or equal. The CommStat controller shall be factory programmed with standard industry set points, but each of these set points shall have the capability to be changed in the field after installation. Instructions for programming the controller shall be printed on the front of the controller. Temperature display shall be in Fahrenheit. The lead lag changeover shall be adjustable from 1/2 day to 7 days in 1/2 day increments to ensure equal run time on each air conditioner. The controller shall allow the lag unit to assist upon demand. The cooling range shall be adjustable from 65 degrees Fahrenheit to 95 degrees Fahrenheit (18 degrees Celsius to 35 degrees Celsius). The heating range shall be adjustable from 50 degrees Fahrenheit to 80 degrees Fahrenheit (10 degrees Celsius to 27 degrees Celsius). The On/Off differential of each stage and the interstage differential of each stage shall be adjustable. The controller shall operate on 24 VAC and shall be insensitive to phasing of the air conditioners. The controller shall have LED’s to indicate control power from each air conditioner, function (heating or cooling), the lead unit and high or low refrigerant pressure lockout. A comfort button shall be readily accessible on the front of the controller to override the cooling and heating set points for 90 minutes. The temperature during the 90 minutes shall be user selectable—either 72 degrees Fahrenheit (22 degrees Celsius) or 77 degrees Fahrenheit (25 degrees Celsius). If one of the air conditioners loses power, the controller shall automatically advance the other unit to lead control. The controller shall indefinitely retain its settings on a power loss. The controller shall
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have dry contacts to provide remote alarm or notification. The relays shall be either normally open or normally closed. The controller shall have alarm relays for power to indicate a loss of power to the CommStat controller, low building temperature, high building temperature, refrigerant pressure lock out and a smoke alarm output. The controller shall have an input for a smoke detector. The enclosure of the controller shall be constructed of a non-corroding polycarbonate material.
L. Configuration and Manufacturer
1. See the equipment schedule on the Drawings to determine which of the following units (described below) are required. Units shall be ComPac I or ComPac II air conditioner units as manufactured by Marvair, or equal, as noted on the Drawings and described herein.
a. ComPac I A/C
(1) The ComPac I air conditioner shall have a factory-installed fresh air damper. The fresh air damper shall be manually adjustable to allow for ventilation of 0-15 percent of outside air. For equipment only cooling applications, damper shall be set to 0 percent outside air or a blank-off plate installed.
b. ComPac II A/C
(1) The ComPac II air conditioner shall have a factory-installed economizer. The economizer shall be factory-installed within the cabinet of the air conditioner. Slip-in or field-installed economizers are not acceptable. The economizer shall be designed to assure easy access to the air conditioning electrical controls. The economizer shall maintain a fixed supply air temperature of 50 degrees Fahrenheit (10 degrees Celsius) to 63 degrees Fahrenheit (13 degrees Celsius) during the “free” cooling operation by providing full range modulation for the outside return/air damper. The air conditioning unit shall include a method of pressure (exhaust) relief. The economizer shall be capable of introducing outside air and exhausting indoor air at a rate equal to the rated airflow of the air conditioner. The package shall be complete with necessary damper, linkage, and spring-return modulating damper motor. The economizer controls shall include an enthalpy sensor capable of controlling the damper by measuring the total heat content of the outside air. Field installed or removable economizer shall not be permitted.
M. See equipment schedule for specific requirements that override general requirements listed above. Fan motor shall be ECM. Unit shall utilize R-410a.
N. Unit shall be Marvair HVESA, or equal. One ton units shall be Model AVPA.
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PART 3 EXECUTION
3.01 INSTALLATION
A. Wall Mount Air Conditioner or Heat Pump
1. Install the unit as shown on the Drawings and as recommended by the manufacturer for the type of installation required. Installation shall be plumb and true, with clearance from combustible materials as recom-mended by the manufacturer and UL.
2. Connect power as required by the local codes, and secure their acceptance of the installation.
3. Operate the unit and test the controls for proper setting and operation.
4. Install clean filters in the unit when warranty starts and furnish 4 extra filters per unit for OWNER use.
5. All duct connections at unit shall be airtight. Adhesive-backed tape shall not be used, either inside or outside of the ductwork, to cover or seal any openings or leaks. Use duct sealing compound as required.
6. Connect all controls and verify that they are functioning properly on heating and cooling as well as in the economizer mode if equipped.
7. Verify wall type from the Contract Drawings and mount per manufacturer’s recommendations.
8. Keep combustible wall materials 3 inches away from supply duct through wall.
9. Use stainless steel mounting hardware for wall installation and caulk perimeter flange watertight.
10. Checklist, test, and startup with a report to the ENGINEER shall be performed by a technician from the manufacturer’s representative and the cost shall be included in the bid price.
END OF SECTION
***
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SECTION 15830
UNIT HEATERS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install unit heaters as shown on the Contract Drawings and as specified herein. Heating and air delivery capacities are specified in the heater schedule in the Drawings.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Section 15010 and the General Conditions.
B. Electrical work is specified in Division 16.
C. Controls are specified this Division, Section 15950.
D. OWNER training for HVAC equipment is specified in Section 15010.
1.03 QUALIFICATIONS
A. Manufacturer's shall be regularly engaged in manufacturer of unit heaters of types and capacities required, whose products have been in satisfactory use in similar service for not less than 3 years.
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
B. Submit ladder-type wiring diagrams for power and control wiring required for final installation of unit heaters. Clearly differentiate between portions of wiring that are factory-installed and portions to be field-installed.
C. O&M instructions shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
1.05 WARRANTY
A. Furnish manufacturer's one year warranty for each unit heater. Other warranty requirements are included in the equipment's description.
PART 2 PRODUCTS
2.01 ELECTRICAL HORIZONTAL UNIT HEATER
A. Heaters shall have electrical characteristics and capacities as shown in the heater schedule on the Contract Drawings.
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B. Unit heaters shall have a housing of 18 gauge die-formed steel, with a phosphate coating to resist corrosion, and finished with a baked-on enamel. The heater shall be of the pull-through air design or contain a heating element which fits the entire shroud to assure that all incoming air passes through the heating element. Heating elements shall be of the metal sheath finned type heat bank or cast aluminum heating grid with automatic reset thermal overheat protection. The product shall be guaranteed by the manufacturer for a period of 1 year under normal operating conditions. Fan motors shall be totally enclosed continuous duty with built-in thermal overload protection and shall be controlled by a fan delay switch to prevent cold drafts and distribute heat after element shuts off.
C. All heaters shall be equipped with front directional louvers for positive control of discharge air and shall be mounted to the wall utilizing a swivel type mounting bracket accessory.
D. Electric horizontal unit heaters shall be 5100 Series as manufactured by Markel or equal.
PART 3 EXECUTION
3.01 INSTALLATION OF ELECTRIC UNIT HEATERS
A. Install electric unit heater on support brackets furnished with the unit. Secure to structural support as required.
B. Locate heater so that clearance from combustible materials, as recommended by the manufacturer, is maintained.
C. Make all electrical connections for power and controls.
D. Check heater for proper operation, including safety controls.
END OF SECTION
***
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SECTION 15862
POWER VENTILATORS AND FANS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install Power Supply and Exhaust Ventilators as shown on the Contract Drawings and as specified herein.
B. Ventilators and fans shall have electrical characteristics and capacities as shown in the ventilation schedule on the Contract Drawings.
C. All belt drive type ventilators shall have automatic belt tensioners.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in the General Conditions
B. Electrical work is specified in Division 16.
C. Duct work and accessories is described in this Division, Section 15890. D. Controls are described in this Division, Section 15950.
D. OWNER training for HVAC equipment is specified in Section 15010.
1.03 QUALIFICATIONS
A. All ventilation equipment shall bear the AMCA certified rating seal and shall be listed in the latest edition of the AMCA Directory.
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
B. O&M instructions shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
1.05 WARRANTY
A. Furnish manufacturer's 1 year warranty for all power ventilators. See individual equipment descriptions and Section 15010 for additional warranty requirements.
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PART 2 PRODUCTS
2.01 GENERAL
A. Ventilators and fans shall have electrical characteristics and capacities as shown in the ventilation schedule on the Contract Drawings.
2.02 LAVATORY VENTILATORS
A. The power exhauster shall be of the direct drive type for ceiling mounting. The unit shall have an off-white decorative front of alloy reinforced polymeric material. The unit shall have peripheral air intake without griddle, one-piece polypropylene automatic back draft damper and 22 gauge steel housing, zinc-coated for corrosion protection. The unit shall have a noise rating not to exceed 6.0 sones.
B. The ventilator shall be controlled by the lighting switch for the lavatory, unless noted otherwise on the Contract Drawings. The ventilators shall be Loren Cook GC Series as manufactured by the Loren Cook Company of Springfield, MO, or equal.
2.03 EXHAUST UPBLAST VENTILATORS (CENTRIFUGAL TYPE)
A. Roof exhaust blowers shall be of the belt drive, upblast, vertical discharge type. Housing shall consist of heavy gauge aluminum construction. All spun parts shall have a rolled bead for added rigidity and shall be specially spun so as to seal the pores of the aluminum providing greater resistance against oxidation and deterioration.
B. The fan wheel shall be all-aluminum of the centrifugal blower type featuring backward inclined blades and a tapered inlet shroud. Wheels shall be statically and dynamically balanced. Inlet cone shall be aluminum and of the centrifugal blower type. Motor and drives shall be enclosed in a weathertight compartment, separate from the exhaust airstream. Air for cooling the motor shall be supplied to the motor compartment by way of an air tube from an area free of contaminated exhaust fumes. Motors shall be of the heavy duty, permanently lubricated, sealed ball bearing type. Drives shall be sized for 165 percent of motor horsepower capabilities and of the cast iron type, keyed to the fan and motor shafts. Variable pitch drives shall be standard. Fan shaft shall be of steel construction, turned, ground, and polished to precise tolerances in relationship to the hub and bearings. Drive belts shall be of the oil-resistant, non-static, non- sparking type with life expectancy of over 24,000 hours. Bearings shall be flanged and of the permanently lubricated, permanently sealed, ball bearing type capable of over 200,000 hours bearing life. The entire drive assembly and wheel shall be removable, as a complete unit, from the support structure without disassembling the external fan housing. The complete drive assembly shall be mounted on rubber vibration isolation. Belt-driven units shall have automatic belt tensioners.
C. All interior and exterior parts, including wheel, wheel hub, supporting posts, fan shaft, drive assembly, and all outside fasteners shall be of aluminum of
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non- ferrous construction. Fans shall be licensed to bear the AMCA ratings seal for air and sound performance. Fans shall be type ACRU as manufactured by the Loren Cook Company of Springfield, Missouri, or equal.
2.04 WALL TYPE EXHAUST VENTILATOR (EXTERIOR MOUNTED)
A. Wall type power exhausters for surface mounting on the wall exterior shall be of the centrifugal type with belt drive. The housing shall be of heavy gauge aluminum construction. All spun parts will have a rolled bead and be specially spun so as to seal the pores of the aluminum. The housing shall be weatherproof with special provision for draining water away from the wall.
B. The fan wheel shall be all aluminum of the centrifugal blower type with backward inclined blades and a tapered inlet shroud. Wheels shall be statically and dynamically balanced. The inlet cone shall be aluminum and of the centrifugal blower type.
C. The motor and drives shall be enclosed in a weathertight compartment separate from the exhaust air stream. Air for cooling the motor will be supplied to the motor compartment by way of an air tube from an area free of contaminated exhaust fumes. Motors shall be heavy duty, permanently lubricated with sealed ball bearings. Drives will be cast iron and keyed to the fan and motor shafts. Variable pitch drives shall be standard. Bearings shall be flanged ball-bearing type, permanently sealed and lubricated. The entire drive assembly and wheel shall be removable, as a complete unit, from the support structure without disassembling the external fan housing. The complete drive assembly shall be mounted for permanent maximum vibration isolation. Belt-driven units shall have automatic belt tensioners.
D. Fan shall be type ACW as manufactured by Loren Cook, or equal.
2.05 SUPPLY VENTILATOR (TIERED AIR SUPPLY PKG)
A. See note 17 on the fan equipment schedule for specific requirements. Unit shall be Type ASP-T by Loren Cook, or equal.
2.06 WALL TYPE EXHAUST VENTILATOR (INTERIOR MOUNTED)
A. Fan shall be a wall mounted, belt driven steel propeller exhaust fan with integral housing. Unit shall include exterior weatherhood with bird screen, heavy duty aluminum motorized discharge shutter, flanged wall collar, toggle disconnect, mounting angles, automatic belt tension device, and OSHA inlet guard. Shutter shall include transformer if required, depending on operator voltage.
B. Fan shall be manufactured at an ISO 9001 certified facility. Fan shall be listed by Underwriters Laboratories (UL 705) and UL listed for Canada (cUL 705).
C. The fan shall be of bolted and welded construction utilizing corrosion resistant fasteners. The motor, bearings and drives shall be mounted on a tubular steel power assembly. The power assembly shall be bolted to a minimum 14 gauge
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wall panel with continuously welded corners and an integral venture. Fan shall be enclosed in minimum 18 gauge galvanized steel wall housing with factory installed shutter and inlet guard. Unit shall bear an engraved aluminum nameplate. Nameplate shall indicate design CFM, static pressure, and maximum fan rpm. Unit shall be shipped in ISTA certified transit tested packaging.
D. All non-galvanized steel fan components shall be coated with an electrostatically applied, baked polyester powder coating. Each component shall be subject to a 5- stage, environmentally friendly wash system, followed by a minimum 2 mil thick baked powder finish. Paint must exceed 1,000 hour salt spray under ASTM B117 test method.
E. Propeller shall be a high-efficiency fabricated steel design with blades securely fastened to a minimum 7 gauge hub. The hub shall be keyed and locked to the fan shaft utilizing 2 setscrews. Propeller shall be balanced in accordance with AMCA Standard 204-96, Balance Quality and Vibration Levels for Fans.
F. Motor shall be heavy duty type with permanently lubricated sealed ball bearings and furnished at the specified voltage, phase and enclosure.
G. Bearings shall be designed and tested specifically for use in air handling applications. Construction shall be heavy duty regreasable ball type in a cast iron pillow block housing selected for a minimum L50 life in excess of 200,000 hours at maximum cataloged operating speed.
H. Belts shall be oil and heat resistant, non-static type. Drives shall be precision machined cast iron type, keyed and securely attached to the wheel and motor shafts. Drives shall be sized for 150 percent of the installed motor horsepower. The variable pitch motor drive must be factory set to the specified fan rpm.
I. Packaged wall exhaust fan shall be type (XLP, XLPH, XMP, XMPH) as noted in the equipment schedule and as manufactured by Loren Cook Company of Springfield, Missouri, or equal.
J. All belt drive type fans shall have an automatic belt tensioning device factory installed. If a proposed or equal manufacturer does not offer this option in their standard product design literature, it will not be considered as an equal if they offer to add this option at the factory. It must be an option offered in their marketing literature.
2.07 FIBERGLASS WALL EXHAUST FAN
A. Wall mounted fan housing shall be molded, shock resistant, sound absorbing, bonded-in color, reinforced fiberglass. Unit shall have a molded venturi type inlet.
B. Unit shall be direct connected with a 10-year lubricated motor mounted out of the airstream with ample air supply to the motor.
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C. Motor shall drive an extruded aluminum airfoil, epoxy-coated, backwardly inclined, non-overloading type blower wheel.
D. Motor shall have a standard toggle on/off power disconnect switch.
E. Motorized backdraft damper to be slightly remote from fan in a duct extension. Install transformer if required.
F. Fan shall be Fiber-Aire type (SA Series) as manufactured by Swartwout, or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install all required backdraft motorized dampers as called for in the fan schedule and check to make sure they are free to open and close.
B. Check rotation of all fans.
C. Adjust belt tensioners in belt drive units to properly load the belt(s). All fasteners shall be of non-magnetic stainless steel.
D. Install all curbs as required. See equipment schedule and fan curb detail, and note in schedule, for specific requirements.
END OF SECTION
***
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SECTION 15890
LOW PRESSURE DUCTWORK AND ACCESSORIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to install low pressure duct work systems as shown on the Contract Drawings and as specified herein.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in the General Conditions.
1.03 QUALIFICATIONS
A. The installing contractor shall have at least 3 years of successful installation experience on projects with low pressure ductwork systems work similar to that required for this project.
B. Systems shall comply with SMACNA "Low Pressure Duct Construction Standards" for fabrication and installation of low pressure ductwork.
C. Comply with ASHRAE Handbook and Product Directory, Equipment volume, Chapter 1 "Duct Construction for Fabrication and Installation of Low Pressure Ductwork."
D. Comply with ANSI/NFPA 90A "Standard for the Installation of Air-Conditioned and Ventilating Systems" and ANSI-NFPA 901 "Standard for the Installation of Warm Air Heating and Air Conditioning Systems."
E. Have available at project field office, copy of SMACNA "Low Pressure Duct Construction Standards - latest edition."
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
B. At the project closeout, submit record drawings of installed ductwork, duct accessories, and outlets and inlets in accordance with the General Conditions.
PART 2 PRODUCTS
2.01 GENERAL
A. Duct work shown on the Drawings, specified, or required for the heating, ventilating and air conditioning systems shall be constructed and erected in a first class, workmanlike manner. Duct work shall be fabricated from materials as
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indicated on the Contract Drawings. Ducts, unless otherwise accepted by the ARCHITECT/ENGINEER, shall conform accurately to the dimensions indicated on the Drawings. Duct sizes indicated on Drawings represent clear inside dimensions.
2.02 VENTILATION AIR AND CONDITIONED AIR DUCTS - SHEET METAL
A. Ventilation and conditioned air ducts shall be rectangular and the sheetmetal thickness shall be a minimum of:
Longitudinal Fittings Spiral Seam Spiral Seam Galvanized Galvanized Duct Diameter Galvanized Steel Steel Steel (Inches) (Inches) (Inches) (Inches) Up to 12 28 (0.1019) 26 (0.022) 26 (0.022) 13 to 18 26 (0.022) 24 (0.028) 24 (0.028) 19 to 28 24 (0.028) 22 (0.034) 22 (0.034) 29 to 36 22 (0.034) 20 (0.040) 20 (0.040) 37 to 54 20 (0.040) 18 (0.052) 18 (0.052)
B. Longitudinal seams shall be ACME lock grooved system. Transverse joints shall be beaded sleeve type fabricated of the same gauge of material as the duct and be a minimum of 4 inches in length. Each section of the duct shall be fastened to the joint sleeve with a minimum of 3 fasteners.
C. Ductwork for ventilation systems serving chemical storage and/or feed areas, designated as “H” area occupancies by the inclusion of a break-glass type emergency off control switch in the fan equipment schedule, shall be constructed according to Section 510 of the International Mechanical Code. Reference the requirements in the code or the summary information noted in the general mechanical notes applicable to all HVAC shown on the Contract Drawings.
2.03 DUCT INSULATION
A. Air handling ducts shall be insulated with fiberglass all service FSK faced duct wrap insulation. Insulation shall be a thickness of 2.5 inches and have an R value of 8.6. All cold air supply and outside air intake ducts, as well as return ducts in unconditioned spaces or which handle outside air shall be insulated.
B. Insulation exterior to the building shall be 2 inch thick glass fiberboard or blanket type with vapor seal mastic, reinforced with open-mesh glass fabric to provide adequate protection against mechanical damage and weather.
C. The insulation characteristics shall be fire-retarding and meet the requirements of the National Fire Protection Association Standard 90A.
D. Joints and laps in the insulation must be tightly sealed.
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E. All duct insulation shall be installed in strict adherence to manufacturer's recommended installation instructions.
F. See Specification Section 15260 for additional requirements.
2.04 FLEXIBLE DUCT
A. Flexible duct may be used only where indicated on the Contract Drawings. Flexible duct shall be Hart & Cooley F-246, or equal. Thermal conductance (C) shall not exceed 0.17 (R-6). The duct shall be commercial series, metalized polyester jack reinforced with fiberglass scrim, high pressure, corrugated aluminum core. Duct shall meet UL 181 and be Greenguard Level 4 highly microbial resistant.
B. All flexible duct shall be installed in strict adherence to manufacturer's recommended installation instructions.
C. The length of flexible duct shall be limited to 4 feet unless noted otherwise on the Contract Drawings.
D. Flex duct shall be fully extended and well supported at maximum 2-foot intervals to minimize pressure losses. The bend radius shall not be greater than one times the duct diameter.
2.05 DAMPER HARDWARE
A. Dampers shall be furnished and installed in the air conditioning/heating duct systems at the locations shown on the Drawings.
B. Dampers shall be full duct size of fabricated, reinforced galvanized steel and have a continuous shaft through the duct. The end bearing shall accommodate a 3/8-inch hot rolled rod and shall be finished with a gasket. The regulator shall be self-locking consisting of 3 precisely fitted die castings, a flat spring and a heavy locking nut, complete with heavy steel handle and gasket. The regulator shall accommodate a 3/8-inch hot rolled rod.
2.06 TURNING VANES
A. Furnish and install turning vanes in ALL rectangular elbows and tees in the ventilation and air conditioning/heating duct system. Vanes shall be of a non-corrosive material of the same material as the ductwork, and conform with SMACNA, Inc., Low Velocity Duct Construction Standards.
2.07 FIRE DAMPERS
A. The CONTRACTOR shall furnish and install fusible link fire dampers as indicated on the Drawings. All equipment and hardware necessary for proper installation shall be provided by the CONTRACTOR. Dampers shall be installed in accordance with the manufacturer's instructions and all applicable codes. All dampers shall conform to the Underwriters' Laboratories (UL) Standard of Safety UL 555 and have a listing as noted on the Contract Drawings but not less than 1.5 hours. Dampers shall be approved for installation in fire partitions in
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accordance with UL building materials listings. All dampers shall meet NFPA 90A construction requirements.
B. The dampers shall be actuated by a fusible link. Dampers and frames shall be installed in framed wall sleeves with retaining angles. Sleeves shall be connected to duct work by breakaway connections. Sleeve material shall be according to the following schedule:
Duct Dimension (Diameter of Either Sleeve Minimum Sleeve Thickness* Rectangular Dimension) Gauge Uncoated Steel 12" 26 .018" 13"-30" 24 .024" 31"-54" 22 .030" 55"-84" 20 .036" 85" 18 .0474 *Sleeve thickness must not be less than duct gauge or that specifically required by a recognized authority.
C. All dampers shall be provided with access doors large enough and located such that maintenance and resetting of dampers is permitted. Access door type and installation shall be consistent with the construction and pressure classification of the system.
D. Each fire damper shall be provided with 3 extra accessory fusible links.
E. Fire dampers shall be as manufactured by Metal-Fab, Ruskin, or equal. See the equipment schedule and the Contract Drawings for additional requirements.
2.08 ACCESS DOORS (DUCTWORK)
A. Provide access doors for access to dampers, splitters, fire dampers, coils, chambers, cleanouts, etc. as required.
B. Access doors in ductwork shall be at least 16-inch by 16-inch or larger if noted on the Drawings. Doors shall be as large as possible when duct will not accommodate 16-inch x 16-inch.
2.09 SUPPLY AIR DIFFUSERS (CONDITIONED AIR)
A. Air diffusers shall be installed at the locations shown on the Drawings, and shall be of the size and core pattern indicated on the Drawings. The diffusers shall have a flange frame, complete with 1/4-inch gasket, for ceiling mounting and removable steel core. The frame and core shall be factory painted in baked off-white enamel. The noise criteria for the diffusers shall not exceed as noted on schedule. Each diffuser shall be equipped with an opposed blade damper which can be regulated through the face of the diffuser. Supply air diffusers shall be manufactured by Titus or equal.
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2.10 RETURN AIR GRILLE (CONDITIONED AIR)
A. Return air grilles shall be installed at the locations shown on the Drawings. The grille sizes and core patterns shall be as indicated on the Drawings. Each grille shall be equipped with an opposed blade damper where indicated on the Drawings. The damper shall be regulated by an adjusting lever. Return air grilles shall be as manufactured by Titus or equal.
2.11 SUPPLY/EXHAUST GRILLES (VENTILATION)
A. The supply/exhaust grilles shall be as required on the Contract Drawings. The grilles shall be Titus or equal.
2.12 COMBINATION FIRE AND SMOKE DAMPER
A. See Note 1 on RGD equipment schedule and sheet notes on drawing plan view.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install all ductwork generally as shown on the Contract Drawings and as recommended by the SMACNA Manual.
B. Low pressure ductwork and fittings shall be made tight for minimum air leakage. Large or noisy leaks will not be accepted. Duct tape shall not be used to seal duct joints, transitions, or for any other reason.
END OF SECTION
***
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SECTION 15910
LOUVERS AND VENTS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment, and services required to install louvers and vents as shown on the Contract Drawings and as specified herein.
B. CONTRACTOR shall coordinate all louver and vent openings with the Architectural/Structural Drawings. Should a conflict be discovered between the Architectural/Structural Drawings and the Mechanical Drawings, the CONTRACTOR shall notify the ARCHITECT/ENGINEER immediately. No additional costs will be allowed to the CONTRACTOR should he fail in properly coordinating louver locations with Architectural Drawings.
C. See the Drawings and/or equipment schedule for additional requirements.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in the General Conditions.
B. Electrical work is specified in Division 16.
C. Controls are described in this Division, Section 15950.
D. Low leak dampers for use in air distribution systems are described in Section 15890.
1.03 QUALIFICATIONS
A. All equipment in this Section shall bear the AMCA certified rating seal and shall be listed in the latest edition of the AMCA Directory.
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Drawings and these Specifications shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
B. O&M instructions shall be submitted to the ARCHITECT/ENGINEER in accordance with Section 15010 and the General Conditions.
C. Submit manufacturer's certified test data, where applicable, and installation instructions for required products including finishes.
1.05 WARRANTY
A. Furnish manufacturer's 1 year warranty for all louvers and vents.
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PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Louvers and vents shall be manufactured by Ruskin Manufacturing Company, or equal.
2.02 EXTRUDED ALUMINUM LOUVERS
A. Horizontal drainable blade louvers shall be designed to collect and drain water to exterior at sill by means of gutters on front edges of blades, and channels in jambs and mullions. Furnish units with extrusions not less than 0.081 inches thick of depth and sizes indicated, complying with the following performance requirements:
1. Units shall not have less than 50 percent free area for 48-inch x 48-inch size units.
2. Static pressure loss shall not be more than 0.052 oz. per square foot of free area at an airflow of 1,000 fpm free area velocity.
B. Units shall have fabricated screen frames with insect or bird screens as required in the equipment schedule or notes.
2.03 MOTORIZED COMBINATION LOUVER/DAMPER
A. The unitized louver/damper shall be 6 inches deep and assembled completely by welding. Stationary blades shall be 12 gauge (.081 inch) extruded aluminum alloy 6063-T52. The adjustable blades and frame will be 8 gauge (.125 inch) extruded aluminum, alloy 6063-T52. Adjustable blades shall pivot in nylon bearings on 1/2-inch diameter aluminum pins with operating mechanism in each jamb frame. The louver/damper shall have drainable blades with downspouts in jambs and mullions. All materials shall be factory finished after assembly. See equipment schedule for required factory finish.
B. The louver/damper shall bear AMCA certified rating seals for air performance, water penetration and air leakage ratings. Air leakage will not exceed 2.8 scfm/ft2 of louver area at a static pressure of 1.5-inch w.g. Water penetration shall be no more than .025 ounces per square foot of free area at an air flow of 1,000 fpm free area velocity when tested for 15 minutes per AMCA standard 500. The louver shall provide a minimum of 7.88 square feet of free area in a 4-foot x 4--foot section. The section shall pass 1,200 fpm free area velocity at a pressure drop not exceeding .15-inch w.g.
C. The louver/damper shall be equipped with a factory-mounted electric operator with auxiliary switch and spring return and will be complete with all linkage and mounting hardware required. The motor shall be Barber-Colman 400 Series, or equal, unless required to be otherwise based on service or control requirements noted or shown in the Drawings. See electrical drawings for voltage requirements.
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D. A mesh aluminum insect or 16 B&S gauge x 3/4-inch diamond pattern expanded aluminum bird screen with removable frame as noted on the ventilation schedule will be fitted to the unit. Other accessories will be as indicated on the ventilation schedule on the Drawings.
E. Combination louver/dampers shall be manufactured by the Ruskin Manufacturing Company, or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. Locate and place louver units plumb, level, and in proper alignment with adjacent work.
B. Use concealed anchorages wherever possible. Provide brass or lead washers fitted to screws where required to protect metal surfaces and to make a weathertight connection.
C. Protect galvanized and non-ferrous metal surfaces from corrosion or galvanic action by application of a heavy coating of bituminous paint on surfaces which will be in contact with concrete, masonry, or dissimilar metals.
D. Caulk all perimeter with silicone to make edge insect proof and watertight.
E. Use non-ferrous stainless steel fasteners for all exterior applications.
F. Test operation and adjust the counterbalance to the proper air pressure for gravity dampers.
G. CONTRACTOR shall install appropriate lintels as described in the structural section of the Contract Drawings. If not described, submit request for lintel sizing during shop drawing review.
END OF SECTION
***
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SECTION 15990
BALANCING, TESTING, AND ADJUSTING OF HVAC SYSTEMS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment and services required to test, balance, and adjust installed HVAC systems and equipment as shown on the Contract Drawings and as specified herein.
B. After the systems have been completely installed, all equipment shall be carefully tested, balanced, and adjusted. Adjust all dampers, registers and air diffusers for air flow and make an accurate velometer test of air quantities delivered and removed from each opening. Any readjustments in the motor, drives, units, controls and other equipment found to be necessary shall be made without additional cost and the entire system shall be placed in a satisfactory operating condition.
C. Equipment that does not perform as specified shall be adjusted per the manufacturer’s instructions by the CONTRACTOR and retested. This includes all equipment where the capacity exists for adjustment such as multi-speed direct drive motors and belt driven equipment. Proof of these adjustments shall be noted in the report.
D. All chilled/hot water system piping shall be balanced by adjusting valves, balance cocks, etc. to match scheduled GPM requirements.
E. See the general mechanical notes applicable to all HVAC in the Contract Drawings for additional requirements.
1.02 QUALIFICATIONS
A. The testing firm shall have at least 3 years of successful testing, adjusting, and balancing experience on projects with testing and balancing requirements similar to those required for this project, who is not Installer of systems to be tested and is otherwise independent of project. The firm shall be certified by Associated Air Balance Council (AABC) or the National Environmental Balancing Bureau (NEBB) in those testing and balancing disciplines similar to those required for this Project. The ENGINEER may pre-approve a test and balance firm not certified by AABC or NEBB, but only prior to the bid opening.
B. Measurements, instruments, testing, adjusting, and balancing shall comply with the American Society of Heating, Refrigeration and Air-Conditioning Engineers, Inc. recommendations for such testing.
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1.03 SUBMITTALS
A. Submit certified test reports signed by Test and Balance Supervisor who performed TAB work. The reports shall include identification and type of instruments used and their most recent calibration date with submission of final test report.
B. Reports shall contain the following general data in a format selected by the balancing contractor.
1. Project Number 6. Test & Balance Agency 2. Contract Number 7. Test & Balance Engineer 3. Project Title 8. General Contractor 4. Project Location 9. Mechanical Subcontractor 5. Project Architect/ 10. Dates Tests were Performed
Engineer 11. Certification
C. Test data typical to each category of equipment shall be reported in a format in accordance with AABC or NEBB guidelines but as a minimum shall include the following items as applicable:
1. Static Pressure 11. Serial number 2. Airflow velocity and CFM 12. Sheave make, diameter, bore, 3. GPM distance 4. Name plate data 13. Filter size 5. Multi-speed motor setting 14. Model number 6. Equipment tag 15. Diffuser/grille size 7. Motor size (HP) 16. Location/area/room served 8. Motor amperage 17. Design data/performance 9. Motor RPM 10. Fan RPM D. The CONTRACTOR shall provide access to all HVAC equipment to accomplish
the scope of work described in this Section. A notation of “equipment not accessible” in the report is not acceptable. The CONTRACTOR shall provide a means to make all equipment accessible to the T & B contractor.
PART 2 EXECUTION
2.01 JOB CONDITIONS
A. Do not proceed with testing, adjusting, and balancing work until work has been completed and is operable. Ensure that there is no latent residual work still to be completed.
B. Do not proceed until work schedule for testing, adjusting, and balancing is clean and free from debris, dirt and discarded building materials.
C. Patch holes in insulation ductwork and housings which have been cut or drilled for test purposes, in manner recommended by original Installer.
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D. All equipment settings shall be marked to show final settings at completion of TAB work.
E. Prepare a report of recommendations for correcting unsatisfactory mechanical performances when system cannot be successfully balanced; including where necessary, modification which exceed requirements of Contract Documents for mechanical work. Retest, adjust, and balance systems subsequent to significant system modification and resubmit test results at no additional cost to OWNER.
END OF SECTION
***
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SECTION 16010
GENERAL ELECTRICAL REQUIREMENTS PART 1 - GENERAL 1.01 WORK INCLUDED
A. Work included in this section of the Specifications includes the furnishing of all labor, material, tools, approvals, excavation, backfill, and other equipment and services necessary to install the electrical system as shown on the Contract Drawings and as specified herein. It also includes the connection of all equipment included in this Contract but furnished by other contractors or suppliers.
B. The Contractor shall furnish and install all conduit, wire, safety switches and miscellaneous material to make all electrical connections to all items of equipment or wiring devices indicated in the Drawings or Specifications except as otherwise specified.
C. All devices and items of electrical equipment, including those shown on
the Contract Drawings but not specifically mentioned in the Specifications or those mentioned in the Specifications but not shown on the Contract Drawings, are to be furnished under this section of the Specifications. Any such device or item of equipment, if not defined in quality, shall be equal to similar equipment and/or devices specified herein.
D. Bidders are required to visit the construction site prior to submitting a bid
and carefully examine the Contract Drawings and Specifications so that he/she may fully understand what is to be done and to document existing conditions. Any discrepancies, questions, or omissions must be brought to the attention of the Engineer at least 10 days prior to the bid opening date. Extras will not be approved for work that the Contractor should have seen beforehand by visiting the site prior to bidding.
E. It is the general intent that all motors shall be furnished with the
particular object of equipment it drives by the supplier furnishing the equipment. Motor controls and related equipment shall be furnished by the Division 16 supplier unless specifically noted otherwise in these Specifications or on the Drawings.
F. Where wiring diagrams are not shown on the Contract Drawings, they
shall be provided by the supplier of the equipment served and such diagrams shall be adhered to except as herein modified.
1.02 RELATED WORK
A. Division Zero and 1: Contractors bidding work under this Contract shall read and understand Division Zero and Division 1 - General Requirements. If any discrepancies are discovered between the Basic Electrical
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Requirements and the above-mentioned documents, the above-mentioned documents shall overrule this section. The General Electrical Requirements are intended as a supplement to the above-mentioned documents. The Contractor shall bid as outlined in the above mentioned Specifications and shall be governed by any alternates or unit prices called for in the form of proposal.
B. Contractor shall carefully examine the entire set of Contract Drawings and all Divisions of the Specifications.
1.03 SUBMITTALS
A. Shop Drawings including descriptive literature and/or installation, operation and maintenance instructions shall be submitted in the amount of copies per the General Conditions for this Division. All Shop Drawings shall be submitted in loose-leaf three-ring cardboard reinforced vinyl binders. A shop drawing submittal shall be prepared for each Section of this Division.
B. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Non-applicable catalog data shall be marked out. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles/configurations represented on the literature. For example: Device boxes – Styles shall be listed as: For masonry walls, for electrical devices, for ceiling mounted light fixtures, etc. Proposed options must be highlighted, underlined, etc.
C. The Engineer reserves the right to make modifications to motor control
and power distribution equipment ratings after equipment Shop Drawing review, if the equipment Shop Drawings are submitted prematurely (prematurely meaning submitted before all utilization equipment has been reviewed and accepted). Cost of modifications shall be the Contractor’s responsibility.
D. O&M manuals must be submitted for all equipment. The O&M manuals
shall be assembled in three-ring binders with front and binder-edge labels. The first and last few pages shall have sheet hole protectors to prevent the pages from tearing out. O&M manuals must include the following information:
1. Vendor and contractor information, addresses, phone numbers,
email, websites, etc. 2. Equipment cutsheets with detailed model number breakdown
suitable for procuring replacement equipment. It is best to insert the approved shop drawing cutsheets into the O&M manuals, unless field changes necessitate otherwise. Non-applicable information must be marked out, and selected options must be highlighted.
3. Operation instructions
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4. Maintenance instructions 5. Drawings, wiring diagrams, etc. 6. Copy of required testing results 7. Copy of inspection certificates 8. A compact disc holder with compact disc containing a PDF format
copy of all O&M information. At Contractor’s option, a CD can be submitted (in the quantity required for O&M manuals) containing the O&M information for the entire electrical system rather than with each O&M manual.
E. AutoCAD floor plans are available in electronic format for a fee of $100
per sheet. Contact the Engineer to obtain these floor plans.
1.04 SYMBOLS AND ABBREVIATIONS
A. The symbols and abbreviations generally follow standard electrical and architectural practice; however, exceptions to this shall be as shown on the Contract Drawings.
1.05 COORDINATION WITH OTHER TRADES
A. The Contractor shall coordinate the electrical work with that of other trades to ensure proper final location of all electrical equipment and/or connections. The Contractor shall verify door swings to see that light switches are located properly.
1.06 CODES
A. The minimum standard for all work shall be the latest revision of the Kentucky Building Code (KBC) and the National Electrical Code (NEC). Whenever and wherever state and/or local laws or ordinances and/or regulations and/or the Engineer’s design require a higher standard that the current NEC or KBC, then these laws and/or regulations and/or the design shall be followed.
1.07 INSPECTIONS AND PERMITS
A. Inspection of the electrical system on all construction projects is required. It is the Contractor’s responsibility to pay for and obtain all permits, pay all fees, and coordinate the activity of inspections. The Contractor shall notify the electrical inspector in writing, immediately upon notice to proceed, and a copy of the notice shall be submitted to the Engineer. No work shall be concealed unless acceptable to the inspector.
B. At the time of completion of the project, there shall be furnished to the
Owner a certificate of compliance, from the agency having jurisdiction pursuant to all electrical work performed. The Engineer shall also receive a copy in the O&M manual submittal.
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1.08 STORAGE
A. All work, equipment, and materials shall be protected against dirt, water, or other injury during the period of construction.
B. Sensitive electrical equipment such as light fixtures, motor starters,
control panels, and panelboards, delivered to the job site, shall be protected against injury or corrosion due to atmospheric conditions or physical damage by other means. Protection is interpreted to mean that equipment shall be stored under roof, in a structure properly heated in cold weather and ventilated in hot weather. Provision shall be made to control the humidity in the storage area to 50 percent relative. The stored equipment shall be inspected periodically, and if it is found that the protection is inadequate, further protective measures shall be employed. Electrical equipment other than boxes and conduit shall not be installed until the structure is under roof with doors and windows installed.
C. No light fixtures or device plates shall be hung or installed until after
painting is completed. 1.09 ERRORS, CORRECTIONS, AND/OR OMISSIONS
A. Should a piece of equipment be supplied of a different size or horsepower than shown on the Contract Drawings, the Contractor shall be responsible for installing the proper size wiring, conduit, starters, circuit breakers, etc., for proper operation of that unit and the complete electrical system at no extra cost to the Owner.
B. It is the intent of these Specifications to provide for an electrical system
installation complete in every respect, to operate in the manner and under conditions as shown in these Specifications and on the Contract Drawings. The Contractor shall notify the Engineer, in writing, of any omission or error at least 10 days prior to opening of bids. In the event of the Contractor’s failure to give such notice, he/she may be required to correct work and/or furnish items omitted without additional cost. Further requirements on this subject may be found in the General Requirements.
C. Necessary changes or revisions in electrical work to meet any code or
power company requirement shall be made by the Contractor without additional charge.
1.10 GUARANTEES AND WARRANTIES
A. The Contractor shall guarantee all work including equipment, materials, and workmanship. This guarantee shall be against all defects of the electrical system or improper equipment operation. It shall last for the
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period of time specified in the General Conditions of the Contract, but not less than one year from the date of substantial completion.
B. Repair and maintenance for the guarantee period is the responsibility of the Contractor and shall include all repairs and maintenance other than that which is considered as routine. (That is oiling, greasing, etc.) The Engineer shall be the judge of what shall be considered as routine maintenance.
C. Certain equipment is required to have longer warranty periods than that
specified in the General Conditions. See the individual sections for these warranty requirements.
1.11 POWER COMPANY COORDINATION
A. The Contractor is responsible for coordinating all activities onsite by the power company.
B. All power company metering equipment shall be electrically located
“upstream” of any manual/automatic transfer equipment on projects requiring onsite emergency power generation equipment.
C. Any special provisions required by the serving electrical utility shall be as
outlined on the Contract Drawings or as advised by the utility at the time of construction, and work required by these special provisions shall be executed with no extra cost to the Owner.
1.12 TEMPORARY ELECTRICAL POWER AND LIGHTING
A. The Contractor shall be responsible for providing temporary electrical power and lighting as required during the course of construction and shall remove the temporary service equipment when no longer required. Temporary power is also addressed in general and special requirements.
1.13 TRAINING
A. All manufacturers supplying equipment for this division shall provide the Owner’s operations staff with training in the operation and maintenance on the equipment being furnished. The training shall be conducted at the project site by a qualified representative of the manufacturer. Refer to individual equipment specifications for training requirements.
1.14 RECORD DRAWINGS
A. The Contractor shall maintain 1 set of the Contract Drawings on the job in good condition for examination at all times. The Contractor’s qualified representative shall enter upon these drawings, from day to day, the actual record of construction and/or alteration progress. Entries and notes shall be made in a neat and legible manner and these drawings
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delivered to the Engineer after completion of the construction, for use in preparation of Record Drawings.
B. Specific attention shall be given to the exact location of any underground
lines installed under this Contract. These lines shall be dimensioned to easily identifiable points on permanent structures.
1.15 MAINTAINING CONTINUOUS ELECTRICAL SYSTEM AND SERVICE
A. Existing service(s) continuity shall be maintained at all times. In no way shall the installation and/or alteration of the electrical work interfere with or stop the normal operation of the existing facilities, except where acceptable to the Owner and prior arrangements have been made.
B. When additions and taps to existing service(s) require electrical outages,
arrangements shall be made in advance for such outages. All outages shall be held to an acceptable minimum. If necessary, cuts shall be performed on premium time. If performed at night, requiring a general outage, the Contractor shall furnish an auxiliary source of light and power as required. Under no circumstances shall an electrical outage of any duration be initiated until the Owner and Engineer have concurred, and as far as possible in advance.
1.16 SERVICE ENTRANCE
A. Conductors and terminations for service entrances shall be furnished and installed by the Contractor. Voltage, phase, and number of wires shall be as shown on the Drawings. Clearances for overhead entrance wires shall be per Power Company, NEC, and NESC requirements.
B. Any details not shown on the Drawings or written in the Specifications
pertaining to the service entrance shall be per power company requirements. It is the Contractor’s responsibility to contact the utility prior to bidding and obtain any special requirements they will be imposing. Owner will pay directly the K.U. utility fee for service tap. Do not include this in the bid.
C. On underground service entrances from pad mounted transformers, the
Contractor shall be responsible for furnishing and installing all primary, secondary, and metering conduits, as well as secondary service/metering conductors. The Contractor shall be responsible for furnishing pull wires in primary conduits for use by the power company. The Contractor shall be responsible for fabricating the required concrete pad that the transformer will be mounted on. The Contractor shall also mount the meter base or C.T. cabinet when furnished by the power company.
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1.17 CONTRACTOR LICENSING
A. The Contractor performing the electrical work on this project shall be a licensed electrical contractor in the state of Kentucky.
1.18 RECEIPTS
A. Some sections of the Specifications call for equipment, materials, accessories, etc. to be provided and “turned over to the Owner” or like requirements. The Contractor shall obtain a receipt for each item turned over, signed by the Owner or his representative. A copy of this receipt shall be transmitted to the Engineer.
B. When a question arises concerning whether items have been turned over
to the Owner, and there is no signed receipt, it may be assumed that the items were not provided.
1.19 DEFINITIONS
A. Furnish – Procure equipment/materials and deliver and unload at the project site.
B. Install – Enter the equipment/materials permanently into the project and
make operational. C. Provide – Furnish and Install
D. NEC – National Electrical Code
1.20 HAZARDOUS LOCATIONS
A. Electrical materials and equipment for installation in hazardous locations,
as defined in the NEC and as indicated on the Drawings, shall be specifically approved by UL or FM for the particular Class, Division and Group of the location involved.
1.21 EQUIPMENT CONFIGURATION/PROGRAMMING
A. Any equipment furnished by the Contractor is required to be configured or programmed by the Contractor or his subcontractor/vendor. Any necessary studies or engineering necessary to configure or program this equipment shall be provided by the Contractor as needed to place the equipment into successful operation. Engineer or Owner will not be responsible for equipment configuration or programming.
B. If a manufacturer or manufacturer’s representative is required to
startup/commission the equipment in these Specifications, then it is required that the Contractor provide the services of the manufacturer to configure/program the equipment. This includes the provision of any
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necessary studies or engineering necessary for the configuration/programming.
PART 2 - PRODUCTS 2.01 MATERIALS
A. All materials used shall be new and at least meet the minimum standards as established by the NEC and/or National Electrical Manufacturers Association (NEMA). All materials shall be UL listed for the application, where a listing exists. All equipment shall meet applicable FCC requirements and restrictions.
B. The reuse of salvaged electrical equipment and/or wiring will not be
permitted unless specified herein or indicated on the Contract Drawings.
C. All salvaged or abandoned electrical materials shall become the property of the Contractor and shall be removed from the job site upon completion of the project, unless otherwise noted on the Contract Drawings or specified herein.
D. Existing fluorescent light fixtures to be abandoned and removed this
Contract, shall be assumed to be equipped with PCB filled ballasts. Light fixtures shall be disassembled and the ballast removed prior to salvage and/or disposal. Ballasts containing PCB’s shall be disposed per requirements of the Toxic Substances Control Act (TSCA). Manifests shall be submitted to the Owner documenting proper transportation and disposal of PCB contaminated ballasts.
E. All materials must be rated for the temperature range expected to be
encountered in the application indicated on the Drawings. If there are any questions regarding the temperature range, contact the Engineer 10 days prior to bid opening date. No extras will be allowed for materials proposed that do not have an acceptable temperature range.
2.02 OVERCURRENT AND OVERLOAD PROTECTION
A. Circuit breakers or fused switches shall be the size and type as written herein and shown on the Contract Drawings. Any additional overcurrent protection required to maintain an equipment listing by an authority having jurisdiction shall be installed by the Contractor at no extra cost to the Owner.
B. The Contractor shall submit actual nameplate data from motors shipped
to the site, stating motor identification as well as characteristics. Overload relay thermal unit selection tables shall accompany the motor data. The Contractor shall select and highlight thermal unit sizes from this data and shall include this information in the O&M Manuals.
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2.03 STEEL COVER PIPE
A. Steel cover pipe shall be furnished and installed as a sleeve to protect conduits that travel under roads or in boring/jacking installations. Pipe shall be plain end steel pipe with yield strength of 35,000 psi minimum and tensile strength of 60,000 psi minimum. It shall be manufactured per API-5L specifications. Minimum wall thickness shall be .188” under 10” size and .25” for 10” or 12” size.
PART 3 – EXECUTION 3.01 GENERAL ELECTRICAL INSTALLATION
A. Equipment connections shall be made with flexible or rigid conduit as required. Controllers for motors, safety switches, and all control, protective and signal devices for motor circuits, except where such apparatus is furnished mounted and connected integrally with the motor driven equipment, shall be installed, connected and left in operating condition. The number and size of conductors between motors and control or protective apparatus shall be as required to obtain the operation described in these Specifications, and/or by the Contract Documents, and/or as shown in manufacturer-furnished Engineer reviewed Shop Drawings.
B. All raceways and wiring shall be firestopped where required by code and/or indicated in the Contract Drawings.
3.02 CUTTING AND PATCHING
A. Cutting and patching shall be held to an absolute minimum and such work shall be done only under the direction of the Owner’s representative. The Contractor shall be responsible for and shall pay for all openings that may be required in the floors or walls, and he shall be responsible for putting said surfaces back in their original condition. Every attempt shall be made to avoid cutting reinforcing steel bars when an opening is required in a reinforced concrete wall or floor slab.
B. Prior to cutting of any floors or walls, all conduits must be located prior to
the cutting through the use of sounding test equipment. Such equipment is readily available through local electrical companies and other sources. If a pipe or electrical circuit is damaged during cutting/demolition the Contractor shall repair the damaged item back to original condition. Absolutely no extras will be allowed for the replacement of damaged electrical conduits, pipes, etc. in floors walls, and ceilings that are to remain.
3.03 CLEANUP
A. Cleanup shall be completed as soon as possible after the electrical installation is complete and as required throughout the project construction by the Owner. All equipment supplied under this Division
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shall be free of shipping tags, dust, stickers, shavings, filings, drill cuttings, etc. All painted equipment shall be left free of scratches or other blemishes, such as splattered or blistered paint, etc. Surplus material, rubbish and equipment resulting from the work shall be removed from the job site by the Contractor upon completion of the work. All existing equipment must be thoroughly cleaned by the Contractor in the vicinity of the construction area.
B. During construction, cover all Owner equipment and furnishings subject
to damage or contamination in any way. 3.04 EXCAVATION AND BACKFILL
A. Excavation for conduits shall be of sufficient width to allow for proper jointing and alignment of the type conduit used. Conduit shall be bedded on original ground. Where conduit is in solid rock, a 6-inch earth cushion must be provided. Conduit shall be laid in straight lines between pull boxes and/or structures unless otherwise notes on the Contract Drawings. The cost of solid rock excavation shall be included in the lump sum bid with no extra pay allowed (unclassified).
B. Backfill shall be as detailed on the Drawings. Dirt within 6” of the
conduits shall be hand placed, loose granular earth. It shall be free of rocks over ½ inches in diameter. Above 6”, large rocks may be included but must be mixed with sufficient earth to fill all voids.
3.05 SLEEVES, CHASES AND OPENINGS
A. Sleeves shall be required at all points where exposed conduits pass through new concrete walls, slabs, or masonry walls. Sleeves that must be installed below grade or where subject to high water conditions must be installed watertight.
B. Wiring chases shall be provided where shown on the Contract Drawings.
The Contractor shall have the option of installing chases below surface mounted panelboards provided all structural requirements are met.
C. It is the Contractor’s responsibility to leave openings to allow installation
of the complete, operational electrical system. Openings required but not left shall be cut as outlined under cutting and patching. The Contractor shall coordinate all holes and other openings with necessary diameters for proper firestopping.
3.06 GROUNDING AND BONDING
A. All metallic conduit, cabinets, equipment, and service shall be grounded in accordance with the latest issue of the National Electrical Code. All supporting framework and other metal or metal clad equipment or materials which are in contact with electrical conduit, cable and/or enclosures, shall be properly grounded to meet the code requirements.
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3.07 ANCHORING/MOUNTING
A. Electrical conduits and/or equipment shall be rigidly supported. Anchors used shall be metallic expansion type, or if appropriate to prevent spalling concrete, epoxy set type. Plastic or explosive type anchors are prohibited.
B. Contractor shall provide all necessary supports in accordance with KBC
Seismic requirements. 3.08 ELECTRICAL COMPONENT MOUNTING HEIGHTS
A. Unless otherwise indicated, mounting height for components shall be as defined on the Drawings.
3.09 TESTING
A. After the wiring system is complete, and at such time as the Engineer may direct, the Contractor shall conduct an operating test for acceptance. The equipment shall be demonstrated to operate in accordance with the requirements of these Specifications and the Contract Drawings. The test shall be performed in the presence of the Engineer or his authorized representative. The Contractor shall furnish all instruments and personnel required for the tests, as well as the necessary electrical power.
B. Before energizing the system, the Contractor shall check all connections
and set all relays for proper operation. He/she shall obtain all necessary clearances, approvals, and instructions from the serving utility company and/or equipment manufacturers prior to placing power on the equipment.
C. Tests may be performed by the Engineer to determine integrity of
insulation on wiring circuits selected by the Engineer at random.
D. Cost of utilities for testing done prior to beneficial occupancy by the Owner shall be borne by the Contractor.
3.10 BORING OR JACKING
A. Boring or jacking shall be provided where indicated on the Drawings. It may be allowed at other locations with permission of the Engineer. Boring or jacking shall be performed by mechanical means and accurate vertical and horizontal alignment must be maintained. Steel cover pipe shall be used and shall be installed inside bored holes concurrently with boring or jacking. All joints shall be solidly welded. The weld shall be such that the joint shall be of such strength to withstand the forces exerted from boring and jacking operation as well as the vertical loading imposed on the pipe after installation. The weld shall also be such that it provides smooth, nonobstructing joint in the interior of the pipe. Backfill and
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bedding at ends of bore shall be as indicated on the Drawings. Spacers on 5’ centers shall be installed to separate the conduits from the cover pipe. No greater than ½” of movement is acceptable after spacers are installed.
3.11 DEMOLITION
A. For equipment indicated to be demolished, remove all conduit, boxes, wiring, switches, and controls associated with the equipment. Concealed conduit may be abandoned in place. All walls, floors, ceilings, and surfaces must be patched and painted to match surrounding surface after demolition is complete.
END OF SECTION
***
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SECTION 16060
SECONDARY GROUNDING PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Grounding shall be provided in accordance with the NEC, as described in these Specifications, and as shown on the Contract Documents.
1.02 RELATED DOCUMENTS
A. Section 16010 – General Electrical Requirements
1.03 SUBMITTALS A. Submittals are required on all grounding equipment in accordance with Section 16010.
1.04 QUALITY ASSURANCE
A. Codes and Standards 1. NEC Compliance: Grounding must conform to NEC requirements.
2. UL Compliance: Comply with applicable requirements of UL
Standard No. 467 “Electrical Grounding and Bonding Equipment” and No. 869, “Electrical Service Equipment.” All grounding and bonding products shall be UL listed and labeled for their intended usage.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Grounding equipment shall be Cadweld, Thomas and Betts/Blackburn, Erico, Copperweld Bimetallics Group, Cathodic Engineering Equipment Co., or equal.
2.02 GROUND RODS
A. Ground rods shall be copper-clad steel with minimum diameter of ¾” and
length of 10’. They shall confirm to UL467 requirements. 2.03 GROUND CONDUCTORS
A. Conductors shall be copper and sized as indicated on the Drawings. If size is not indicated than the conductors shall be sized according to the NEC.
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2.04 GROUND MESH / EQUIPOTENTIAL BONDING GRID A. Provide a prefabricated mesh constructed of #8awg (minimum) copper on
12” x 12” grid. The mesh shall be Erico, or equal. Connections shall be via exothermic welding process. The use of rebar may be utilized in lieu of the mesh if the rebar is laid on 12” centers or less, is tied or bonded together, and is located within 3” of the surface of the concrete.
2.04 GROUNDING ACCESSORIES
A. Provide all grounding accessories necessary for a complete, functional, code-compliant grounding system. This includes but is not limited to the following: connectors, lug terminals, electrodes, bonding jumpers, surge arresters, tape, heat-shrink tubing, exothermic welding materials, bonding straps, etc.
2.05 GROUND ENHANCEMENT MATERIAL
A. Ground enhancement material shall be GEM by Erico Products, Powerfill by Cathodic Engineering Equipment Company, or equal.
B. The ground enhancement material must be permanent and maintenance
free (no recharging with salts or chemicals which may be corrosive) and maintain its earth resistance for the life of the system. It must set up firmly and not dissolve or decompose, or otherwise pollute the soil or local water table. The material shall be capable of being applied dry or in a slurry form, and shall reduce resistance by at least 40 percent.
C. Basic components of this material shall be carbon, hydraulic cements, and
hydrous aluminum silicates. Minimum 4-inch diameter holes shall be used with ground rod installations, with depth 6" shorter than length of rod, completely filled with the material. Trenches for grounding electrode conductor shall also utilize this material the full length from electrode to building, in accordance with manufacturer installation recommendations, except trench depth shall allow buried conductor to be at least 2'-6" deep.
PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. Grounding shall utilize a supplemental driven ground rod system in a bed to achieve the design ground resistance.
B. The ground system shall be continuous with all structures on a common
ground. This can be accomplished by bonding all conduits together and bonding to the ground bus at each motor control center. Bonding jumpers shall be required at all pull boxes, and at all motor casings. A separate grounding conductor shall be pulled in all conduits in addition to wire counts shown on Drawings.
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C. Where multiple rods are driven, they shall be separated by at least 10 feet
to assure maximum effect.
D. Ground resistance between ground and absolute earth shall not exceed 5 ohms.
E. All grounding and grounding electrode systems shall be as required by
the NEC as for types of electrodes utilized and sizing of grounding conductor to service equipment from the electrode system. These shall include footer rebar, buried metal water pipe, buried bare copper conductor, etc.
F. All grounding electrode system connections shall be made using
exothermic welds, Cadweld, or equal. No splices are allowed in the grounding electrode conductor.
G. Where indicated, an insulated, isolated ground shall be run from the
service entrance to panels serving computers.
H. Should ground rods be impractical for use due to rocky conditions, then grounding electrode plates may be used after acceptance by the Engineer on a case by case basis.
I. Ground mesh/equipotential grids shall be installed prior to pouring final pavement/concrete and shall be located not less than 2” or more than 3” from top of slab. Install per NEC article 680 or 682 provisions as applicable. The grid must extend at least 3’ horizontally from the metal structure that it surrounds, and must be bonded with a minimum #8 conductor to the grounding electrode system for the structure.
3.02 FIELD QUALITY CONTROL
A. Testing
1. The Contractor shall provide all labor, tools, instruments, and materials as necessary to perform testing of the grounding electrode system. Results shall be submitted in writing to the Engineer. The testing shall be done to determine the effectiveness of the selected grounding scheme and to see that it conforms with resistance specified (5 ohms maximum).
2. The testing should be done using a fall-of-potential method test at
the point of grounding electrode conductor connection to main power distribution equipment and at each separately derived system or MCC. The test shall be performed no sooner than 48 hours after a rainfall event.
3. The written report should contain the following information:
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a. Type of ground scheme used, i.e., building steel, driven rod, mat, etc.
b. Type of instrument used.
(1) Manufacturer (2) Model Number (3) Confirm fall-of-potential test (4) *Serial Number (5) *Where instrument was obtained
*These 2 items are required so that the same instrument may be utilized should reproduction of the test be necessary due to unsatisfactory readings/instrument miscalibration.
c. Ground resistance readings obtained at various test
distances.
d. Ground resistance/distance curve.
e. Value of Grounding Electrode Resistance at knee of curve.
f. Sketch showing setup of instrumentation and location of grounding electrode and test probes.
g. Proposed method to achieve the specified resistance, should
an unacceptable reading be obtained.
h. Ground resistance readings obtained (if applicable) after modifications incorporated.
3.03 GROUND ENHANCEMENT MATERIAL
A. Where indicated on the Drawings or as deemed necessary by the Contractor to achieve design grounding electrode system resistance, a ground enhancement material shall be utilized, in accordance with manufacturer’s recommendations.
END OF SECTION
***
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SECTION 16070
SUPPORTING DEVICES PART 1 - GENERAL 1.01 SCOPE OF WORK
A. All electric equipment shall be rigidly mounted and installed using supporting devices as indicated on the Contract Drawings, as required by the work, and as described herein.
1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
1.03 SUBMITTALS
A. Submittals are required in accordance with Section 16010 requirements. 1.04 QUALITY ASSURANCE
A. Electrical components shall be listed and labeled by UL, ETL, CSA, or similar.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Strut: “Kindorf,” “Unistrut,” “B-Line,” “Allied Tube & Conduit,” or equal. 2.02 STRUT
A. Epoxy-Painted: ASTM A1011 (Fittings – ASTM A1018) 33,000 psi minimum yield, coated with water-borne epoxy deposited via cathodic electro-deposition. Accessory hardware shall be ASTM B633 zinc-plated.
B. Galvanized: Either pre-galvanized, ASTM A653 with G90 coating, or hot-dip galvanized per ASTM A123. Accessory hardware shall be ASTM B633 zinc-plated.
C. Aluminum: Extruded alloy 6063-T6. Accessory hardware shall be stainless
steel type 18-8 or 304. D. Stainless Steel: AISI Type 304 or 316. Accessory hardware shall be
stainless steel type 18-8, 304, or 316. E. Fiberglass resin strut shall be used in chemical areas and areas exposed
to chlorine gas. Hardware shall be 316 stainless steel.
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2.03 HARDWARE A. All hardware for interior applications shall be zinc-plated.
B. All hardware for exterior applications shall be stainless steel type 18-8 or 304.
C. All hardware for NEMA 4X areas, chemical areas, or otherwise wet/corrosive areas shall be stainless steel Type 316.
PART 3 - EXECUTION 3.01 ANCHORING CABINETRY
A. All free standing equipment shall be anchored to its foundation using expansion bolts of the size and number recommended by the equipment manufacturer.
3.02 ANCHOR METHODS
A. Concrete: Expansion anchors, preset inserts, or purpose made anchors. B. Hollow Masonry: Toggle bolts or expansion anchors.
C. Wood Surfaces: Wood screws (#10 min) or lag bolts.
D. Metal Surfaces: Machine screws or bolts.
3.03 STRUT INSTALLATION A. Table of Acceptable Usage:
AREA STRUT MATERIALS
Commercial Interior Epoxy-Painted, Galvanized, Aluminum Commercial Exterior Aluminum, Stainless
Industrial Interior Galvanized, Aluminum, Stainless Industrial Exterior Aluminum, Stainless
NEMA 4X (non-chemical) Areas
Stainless or Fiberglass
NEMA 4X Chemical Areas Fiberglass Resin B. The only exception to the above shall be anchor bolts for area lightpoles
which shall be allowed to have galvanized threads and galvanized nuts.
C. Epoxy-painted strut, where cut in the field, must have ends filed smooth and painted the same color as the strut.
D. Galvanized strut, where cut in the field, must have ends filed smooth and
cold galvanized.
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E. All field-cut strut shall have ends filed smooth and free of burrs or sharp edges. Any strut installed within 7 feet above finished floor must have protective foam edging applied to prevent injury to personnel.
END OF SECTION
***
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SECTION 16075
ELECTRICAL IDENTIFICATION PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Provide electrical identification of equipment, boxes, and conductors as specified herein.
1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
1.03 SUBMITTALS A. Submittals are required for electrical identification products in accordance
with Section 16010 requirements. PART 2 - PRODUCTS 2.01 MANUFACTURERS
A. Brady, Safety Sign Company, Seton or equal.
2.02 ELECTRICAL IDENTIFICATION PRODUCTS
A. Engraved, Plastic Laminated Labels and Signs: Shall be engraved stock
melamine plastic laminate, 1/16 inch minimum thickness, and shall have white plate with black letters.
B. Vinyl self-adhesive signs: Shall warn of “High Voltage” (state the specific
voltage). The type of labels to be used shall have orange as the basic color to conform with OSHA requirements, and letters shall be black. The labels shall be of proper size to fit flatly on the surface of the enclosure to make for a neat appearance and not interfere with the operating function of the device it is attached to.
C. Colored Adhesive Marking Tape for Wires and Cables: Self-adhesive, vinyl
tape not less than 3 mils thick by 1 inch in width. D. Conductor Labels: Shall be machine printed, heat-shrink type. E. Underground line marking tape: Permanent, red-colored, continuous
printed, not less than 6 inches wide and 4 mils thick. Tape shall have metal-backing suitable for tracing.
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PART 3 - EXECUTION 3.01 EQUIPMENT LABELING
A. All starters, feeder units in panelboards, disconnects, instruments, etc. shall be marked to indicate the motor, outlet, or circuit they control. Marking is to be done with engraved laminated nameplates and shall bear the designation shown on the Contract Drawings where this information is given. Nameplates shall be fastened to equipment with stainless steel screws, minimum of one each side. In no way shall the installation of mounting screws void the NEMA enclosure rating of the equipment in which they are installed. Nameplate background color shall be white, with black engraved letters, unless otherwise noted. Typical panelboard label:
“Panel PP1 225A 480Y/277 3PH 4W Fed From Panel MCP” Typical Safety Switch Label: “AHU-5 480V 3PH Fed From Panel PP1” Typical Instrument label: “PIT-501 High Service Discharge Pressure” B. All cabinets, disconnect switches, control panels, transfer switches,
panelboards etc. shall be additionally labeled with orange OSHA-compliant vinyl self-adhesive signs that list the maximum voltage contained inside the cabinet or panel.
C. Branch circuits in lighting panels shall be typed on a card suitable for the
card frame furnished with the panel. The card shall bear the panel designation listed on the Contract Drawings where this information is given, as well as indicate what each circuit controls. The Contractor shall retype new cards for all existing panelboards modified.
D. Submersible pumps shall be furnished with a spare nameplate which shall
be installed inside the MCC or starter enclosure. E. All mechanical equipment on the project that has electrical service shall
be labeled and the equipment labels must match the breaker labels. Coordinate with Divisions 2, 11, and 15.
3.02 BOX LABELING
A. Label each box with the voltage and circuit numbers contained.
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3.03 CONDUCTOR LABELING A. Label each conductor to match the circuit number or manufacturer’s shop
drawing wiring diagrams. 3.04 ARC-FLASH HAZARD LABELING
A. Electrical equipment shall be labeled with Arc-Flash hazard warning labels as required by the N.E.C. Labeling shall comply with ANSI Z535.4.
3.05 AVAILABLE FAULT CURRENT LABELING
A. Service equipment shall be labeled with the maximum available fault
current and date of calculation as required by the NEC. Contact Engineer to obtain available fault current value.
END OF SECTION
***
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SECTION 16120
CONDUCTORS, CABLES, AND CIRCUITS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Provide conductors, cables, and circuiting as indicated and as specified herein for a complete, functional electrical system.
B. Building wire #12 - #1 shall be applied based on a 60 degree Celsius
temperature rise. Building wire larger than #1 may be applied at its 75 degree Celsius temperature rise.
1.02 RELATED WORK
A. Section 16010 – Basic Electrical Requirements
B. Section 16075 – Electrical Identification
C. Division 17 – Instrumentation/SCADA
1.03 SUBMITTALS
A. Submittals are required on all cables and conductors in accordance with Section 16010 requirements.
B. Submittals are required on cable supports.
C. Submit test results as specified herein. 1.04 QUALITY ASSURANCE
A. All wire and cable shall conform to the latest requirements of the NEC and shall meet all ASTM/UL specifications. Wire and cable shall be new; shall have size, grade of insulation, voltage rating and manufacturer’s name permanently marked on the outer covering at regular intervals. Complete descriptive literature shall be submitted to the Engineer for review and acceptance prior to installation.
1.05 DELIVERY, STORAGE AND HANDLING
A. Wire and cable shall be suitably protected from weather and damage during storage and handling and shall be in first class condition when installed.
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PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Building Wire (type “THWN”) - “Collyer,” “Rome,” “American,” “Carol,” or equal.
B. Flexible Cords and Cables (Types “SO” (600V) “SJO” - 300V) “Collyer,”
“American,” “Carol,” or equal.
C. Power cables, for conduit installation or direct-burial (600V, 5KV or 15 KV) - “Anaconda,” “Okonite,” “Triangle PWC,” or equal.
D. Self Supporting Aerial Power Cables (600V, 5KV, or 15 KV) - “Okonite,”
“American,” “Collyer,” or equal.
E. Control Cables (Shielded or unshielded) 600V max. - “Belden,” “Eaton-Dekoron,” “Okonite,” or equal.
F. Instrumentation Cables (Shielded) 600V mx. - “Eaton-Dekoron,”
“Manhatton,” “American,” “Belden,” “Okonite,” or equal. G. Fire Alarm Cables – See Fire Alarm Specification. H. Cable Supports – Hubbell/Bryant or equal.
2.02 GENERAL
A. In general, all conductors shall be 98 percent conductive, annealed copper unless otherwise noted on the Contract Drawings.
B. Conductors with high temperature rated insulations and special construction shall be used where required in connecting to light fixtures or appliances that have special requirements.
C. Aerial power cables, telecommunications, fire alarm, and data cabling
shall be as specified in applicable sections.
2.03 GENERAL BUILDING WIRE
A. Conductors shall be type THWN-2 insulation. Conductor size shall be AWG (American Wire Gauge) Standard. Minimum conductor size shall be AWG number 12 except branch circuits in excess of 75 feet from panel to first outlet not smaller than no. 10 AWG. Minimum voltage rating shall be 600 volts. Conductors for small power may be solid (i.e. lighting, receptacles), but conductors for control work shall be stranded.
B. Metal Clad (MC) Cable – Shall comply with NEC and UL 1569.
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C. Conductors inside control panels, that do not extend outside the cabinet, shall be Type MTW with a minimum size of 18 gauge and a minimum voltage rating of 600V. Each conductor shall be terminated with a ferrule and a wire label.
2.04 INSTRUMENTATION CABLE
A. Instrumentation cable shall have individually shielded and twisted pairs or triads. Conductors shall be tinned copper, and the cable shall include a separate drain conductor. Voltage rating shall be 600 Volt. Conductor colors shall be black and white. Shielding shall be a combination braid/foil with 100% coverage. Insulation shall be PVC or XLPE. Conductors shall be #18AWG minimum, but no smaller than the size indicated on the Drawings.
B. All signal lines should be constructed of individually twisted pairs (6 to 10
twists per foot), including thermocouple extension leads. Cables should be made of twisted pairs, with all lays and pairs twisted in the same direction for maximum flexibility.
C. Insulation resistance at 68 degrees Fahrenheit between conductors and
between conductors and ground should be at least 500 megohms per 1,000 feet.
D. Multi-pair cable should be jacketed with poly-vinyl-chloride, polyethylene
or Teflon at least 0.045" thick. Voltage rating shall be 600 volts. 2.05 MULTICONDUCTOR CONTROL CABLE
A. Shall be concentrically cabled No. 14 AWG stranded copper conductors with saturated interstitial fillers; overall binder of nylon or similar material; and PVC jacket. Quantity of conductors shall be as indicated on the Drawings, with 25% spare minimum. Conductor insulation shall be 20 mils of polyethylene with 10 mils PVC, rated 600V.
B. Color coding shall be ICEA, Method 1.
2.06 SUBMERSIBLE PUMP POWER CABLE
A. Power cables for submersible pumps shall be of the extra hard usage type suitable for submerged duty and able to withstand common corrosive agents found in water and wastewater. They shall be provided with high grade non-magnetic stainless steel relief cable grips installed at the pump end and high grade non-magnetic stainless steel support cable grips anchored to the wet well structure where they enter the wet well. All submersible pump cable shall be listed for Class I Div. I Group D areas.
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2.07 CABLE SUPPORT GRIPS
A. The strain relief and support cable grips shall be as manufactured by Hubbell/Bryant or equal. They shall be the “heavy-duty” stainless steel type 302, 304, or 316 and shall be listed by a third party such as U.L. or E.T.L.
PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. General
1. Conductors shall be continuous from outlet to outlet and no splices shall be made except accessible in junction or outlet boxes. Wire connectors of insulating material or solderless pressure connectors, properly taped, shall be used for all splices in wiring, wherever possible.
2. Feeder conductors shall be color coded in accordance with the
following schedule:
480/227V 208/240V 120/240, Single 3 Phase 3 Phase Phase
Phase A Brown Black Black Phase B Orange Red Red Phase C Yellow Blue Neutral (Grounded) White or White or White or Light Gray Light Gray Light Gray 3-Way Tracers Blue Grounding Green Green Green Remote Energized Control Conductors Yellow Standard Control Red
3. Conductors shall be pulled into raceways in strict accordance with manufacturer’s recommendations.
4. Ample slack conductors shall be allowed at each terminal point,
and pull or junction box, to permit installation with ease and without crowding.
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5. All conductors terminating at terminal blocks shall be identified with numbers and/or letters identical to circuit or control identification.
6. No conductors shall be drawn into conduits until all work which
may cause wire or cable damage is completed. Wire pulling shall be accomplished utilizing machinery and accessories intended for the purpose.
7. All connections and splices shall be made in accordance with
conductor manufacturer’s recommendations, and as written herein.
8. If the size and number of conductors in a conduit on the Drawings
is not shown, then it shall be assumed to be 4#12, 3/4" C. 9. All interior primary branch wiring shall be located above slabs. 10. An equipment grounding conductor, sized per NEC, shall be
installed in each power, signaling, or instrumentation circuit whether indicated or not.
B. Feeders
1. Wire (up to and including #6 AWG) shall be factory color coded for
each phase and neutral, with green used for the ground conductor. Larger conductors shall be identified with tape per Section 16075 requirements. As far as practical, all feeders shall be continuous from origin to panel termination without running splices in intermediate pull boxes.
C. Metal-Clad (MC) Cable Installation
1. MC cable shall only be used for lighting circuits accessible above
suspended acoustical tile ceilings. A junction box fed with conduit shall be installed in the plenum space above each room for conversion from conduit to MC cable. The use of MC cable in walls, slabs, or to jump between rooms is prohibited. MC Cable shall not be installed in the wall cavity between face brick and block.
2. MC cable termination shall be prepared using a pre-engineered
fitting designed specifically for the purpose. D. Instrument Cable
1. Instrumentation cable must only be installed in dedicated conduits
with other instrumentation cable. Installation with power conductors is prohibited.
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2. Low level analog (less than 500 millivolt d-c): Use twisted pairs which may be cabled with other pairs carrying similar voltage levels. Foil wraps or equivalent shielding is required for each cable with the shield insulated from ground.
3. High level analog (greater than 500 millivolt d-c or 0-10 VDC or 4-
20 mAdc): Use twisted pairs which may be cabled with other pairs carrying similar voltage levels and current levels less than 100 ma. Shielding is required.
4. All shields must be grounded at one point only as close as possible
to the signal source.
5. A minimum separation of 12 inches between analog signal leads and a-c power leads should be maintained. For a-c power leads carrying 100 amps or greater, a 24 inch separation should be maintained. Parallel runs should be limited to less than 500 feet. Perpendicular runs may be as close as 6 inches.
3.02 FIELD TESTING
A. Megohm meter testing is required on circuits with #4 and larger conductors. Prior to energizing, check with 1000V megohm meter to determine insulation resistance levels to assure requirements are fulfilled. Minimum acceptable reading is 100 megohms held at a constant value for 15 seconds. A certified copy of megohm meter tests shall be submitted to the Engineer and included in the O&M manuals. Test results shall include ambient temperature and humidity at time of testing.
END OF SECTION
***
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SECTION 16130
RACEWAYS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. This section of includes all raceways for accommodation of electrical conductors, communications conductors, sleeves for underground electrical installations, conduit stubs for future installations, fittings and accessories.
B. All raceways and fittings shall be painted to match existing or
surrounding surfaces except in mechanical spaces. 1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
B. Division 9 – Paint
1.03 SUBMITTALS
A. Submittals are required on all raceways and fittings in accordance with Section 16010 requirements.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Tubular Raceways
1. Steel, Galvanized, Electric-Metallic-Tubing (EMT) - “VAW,” “Triangle,” “Allied Tube & Conduit Corp,” or equal.
2. Steel, Intermediate Metal Conduit (IMC, Electro-Galvanized, Rigid,
Threaded - “Allied Tube and Conduit Corp.,” “Triangle,” “Wheatland Tube Co.,” or equal.
3. Plastic (PVC); Type 80 (or Schedule 80) (Heavy -Wall) - “Robin-Tech,”
“Carlon,” or equal. 4. Aluminum, Rigid, Heavy-Wall, Threaded - “VAW,” “Alcoa,”
“Reynolds,” or equal.
5. Steel, Galvanized, Rigid, Heavy-Wall, Threaded - “Wheatland Tube Co.,” “Triangle,” “Allied Tube & Conduit Corp.,” or equal.
6. Flexible Metal Conduit - “AFC,” “Alflex,” or equal.
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7. Liquidtight Flexible Metal Conduit - “Carol Cable Co., Inc.,”
“Superflex,” “OZ Gedney,” or equal. 8. Factory Coated Aluminum Conduit - Alumax “ALX-1", or equal.
B. Wireways
1. “Square-D,” “Hoffman,” or equal.
C. Raceway Fittings
1. Conduit fittings - “Crouse-Hinds,” “Appleton,” “OZ Gedney,” or
equal.
2. Non-metallic conduit fittings - “Robin-Tech,” “Carlon,” “Scepter,” or equal.
3. Flexible conduit fittings - “Raco,” “T & B,” “OZ Gedney,” or equal.
D. All raceways shall be marked with the manufacturer’s name or trademark
as well as type of raceway and size. This marking shall appear at least once every 10 feet and shall be of sufficient durability to withstand the environment involved. All raceways shall be furnished and installed as outlines under Part 3 of this Specification.
2.02 MATERIALS
A. Aluminum Conduit
1. Aluminum conduit shall be extruded from alloy 6063 and shall be the rigid type, non-toxic, corrosion resistant, and non-staining. It shall be manufactured per UL standards as well as listed/labeled by same.
2. Fittings, boxes, and accessories used in conjunction with aluminum
conduit shall be die cast, copper free type. They shall be resistant to both chemical and galvanic corrosion. All covers shall have neoprene gaskets.
3. Aluminum conduit proposed for concrete slab or underground
applications shall be UL listed for the purpose and factory pre-coated. Corrosion-resistant taping is allowed for stubouts out of the ground.
B. Rigid Steel Conduit
1. Rigid steel conduit and fittings shall be of mild steel piping,
galvanized inside and out, and shall conform to UL standards. The conduit and fittings hall be listed and labeled by UL as well. The
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galvanized coating of zinc shall be of uniform thickness applied by the hot-dipped process, and shall be applied also to the threads. It shall be further dipped in a chromic acid bath so as to chemically form a corrosion resistant protective coating of zinc chromate which has a characteristic yellow-green color. Each piece of conduit shall be straight, free from blisters and other defects, cut square, and taper reamed. It shall be delivered with plastic protectors on the threads.
C. Polyvinychloride (PVC) Conduit
1. PVC conduit and fittings shall be Schedule 80 heavy wall, as
indicated in these Specifications manufactured to conform to UL standards. It shall be listed and labeled by UL. It shall have at least the same temperature rating as the conductor insulation. Expansion joints shall be used as recommended by the manufacturer in published literature. PVC systems shall be 90 degrees Celsius minimum UL rated, have a tensile strength of 7,000 psi @ 73.4 degrees Fahrenheit, flexural strength of 11,000 psi and compressive strength of 8,000 psi.
2. PVC conduit support clamps shall be non-metallic, non-corroding and specially designed for expansion and contraction. Adapters shall be provided for use with strut. Provide IPEX Scepter or equal.
D. Electrical Metallic Tubing (EMT)
1. EMT shall be high grade steel with an exterior galvanized coating
of zinc applied uniformly by the electro-galvanized process. The interior surface shall be uniformly coated with aluminum lacquer or enamel. After galvanizing, it shall be dipped in a chromic acid bath to chemically form a protective coating of zinc chromate. The conduit shall conform to UL standards and be listed as well as labeled by UL.
E. Intermediate Metal Conduit
1. Intermediate metal conduit (IMC) shall be made of high
performance steel and given extra strength by a special electroweld forming process, and shall have a larger internal diameter than rigid steel conduit. IMC conduit shall be listed and labeled by UL. Exterior surfaces shall be hot-dip galvanized in the smaller sizes and electro-galvanized in the larger sizes and then chromated. All threads shall be galvanized after cutting. The interior wall shall be coated with a silicone epoxy-ester lubricant. Each piece of conduit shall be straight, free from blisters and other defects, cut square, and taper reamed.
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F. Flexible Conduit
1. Flexible metallic conduit shall be constructed from flexibly or spirally wound elecro-galvanized steel. Connections shall be by means of galvanized malleable iron squeeze type fittings, or tomic twist-in type in sizes not exceeding 3/4 inch. Liquidtight conduit shall be light gray in color and have sealtight fittings, type UA. It shall be sunlight resistant and suitable for minimum temperature range of -22°F to 140°F.
G. Conduit Fittings
1. Rigid Steel and IMC Conduit Fittings
a. Standard threaded couplings, locknuts, bushings, and
elbows made only of steel or malleable iron are acceptable. Integral retractable type IMC couplings are acceptable also.
b. Locknuts: Bonding type with sharp edges for digging into
the metal wall of an enclosure.
c. Bushings: Metallic insulating type, consisting of an insulating insert molded or locked into the metallic body of the fitting. Bushings made entirely of metal or nonmetallic material are not permitted.
d. Erickson (union-type) couplings: Approved for use in
concrete are permitted or use to complete a conduit run where conduit is installed in concrete.
e. Sealing fittings: Threaded cast iron type. Use continuous
drain type sealing fittings to prevent passage of water vapor. In concealed work, installed fittings in flush steel boxes with blank coverplates having the same finishes as that of other electrical plates in the room.
f. Compression fittings are NOT acceptable for use with Rigid
conduit. All connections are required to be threaded. 2. Rigid Aluminum Conduit Fittings
a. Standard threaded locknuts and bushings shall be malleable
iron, zinc-plated steel or aluminum alloy materials. Bushings/hubs shall have insulated throats. Elbows, couplings, hubs, and connectors shall be aluminum. Aluminum fittings containing more than 0.4 percent copper are prohibited.
b. Set screw or compression fittings: Not permitted for use
with aluminum conduit.
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3. Electrical Metallic Tubing Fittings
a. Only material of steel or malleable iron is acceptable.
b. Couplings and connectors: Concrete tight and rain tight,
with connectors having insulated throats. Use gland and ring compression type couplings and connectors for all conduit sizes.
c. Set screw indent type connectors or couplings are
prohibited.
d. Die-cast or pressure-cast zinc-alloy fittings or fittings made of “pot metal” are prohibited.
4. Expansion and Deflection Couplings
a. Accommodate 1.9 cm (0.75 inch) deflection, expansion, or
contraction in any direction, and allow 30 degree angular deflections.
b. Include internal flexible metal braid sized to guarantee
conduit ground continuity and fault currents in accordance with UL, and the NEC code tables for ground conductors.
c. Watertight, seismically qualified, corrosion-resistant,
threaded for and compatible with rigid or intermediate metal conduit.
d. Jacket: Flexible, corrosion-resistant, watertight, moisture
and heat resistant molded rubber material and stainless steel jacket clamps.
K. Corrosion-Protection Tape: The corrosion protection tape shall be
Scotchrap 51 or equal with 20mil thickness PVC tape and high-tack adhesive. Degreasing and priming of the conduit is required prior to applying the corrosion-protection tape.
L. Duct Seal: Sealant shall be UL-listed electrical duct seal, Gardner Bender
#1003 or equal. Caulk is not acceptable. Sealant shall be asbestos-free, permanently soft/non-hardening, FDA/USDA approved non-toxic, non-corrosive, non-irritant, and paintable. Temperature range shall be -30°F to 175°F, minimum.
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PART 3 - EXECUTION 3.01 PREPARATION
A. Underground metallic conduits shall be degreased, primed, and wrapped with all-weather corrosion-resistant tape to 6” above finished grade. The tape shall be 50% overlapped such that there is an effective 2-layers of tape protecting the conduit.
3.02 INSTALLATION
A. Conduit
1. Conduit shall not be installed in wall cavities between face brick and block. The only time this will be allowed is for serving an exterior receptacle or light fixture.
2. Underground raceways (conduit) shall be provided with steel
sleeves where they pass over or under obstructions, such as: sidewalks; roadways; piping; etc.
3. All conduit shall have an insulated ground wire pulled to all equipment and receptacles.
4. All raceway runs are shown diagrammatically to outline the general
routing of the raceway. The installation shall be made to avoid interference with pipes, ducts, structural members or other equipment. Should structural or other interference prevent the installation of the raceways, or setting of boxes, cabinets, or the electrical equipment, as indicated in the Drawings, deviations must be approved by the Engineer, and after approval, shall be made without additional charges and shown on the Record Drawings.
5. Fire Stop: Where conduits, wireways, and other electrical raceways
pass through fire partitions, fire walls, smoke partitions, or floors, install a fire stop that provides an effective barrier against the spread of fire, smoke and gases, with UL listed sealants only. Completely fill and seal clearances between raceways and openings with the fire stop material
6. Assure conduit installation does not encroach into the ceiling
height head room, walkways, or doorways.
7. No conduit shall be run exposed across roofs without first obtaining permission from the Engineer.
8. Conduit may be run inside concrete slabs as long as the slab is at
least 6-inches thick and conduit will have at least 1 ½-inches of cover on both sides.
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9. No conduit shall be run exposed across floors.
10. Electrical conduits and/or equipment shall be rigidly supported. Anchors used shall be metallic expansion type, or if appropriate to prevent spalling concrete, epoxy set type.
11. Contractor shall provide all necessary supports in accordance with KBC Seismic requirements.
12. All conduit shall be installed in a first-class workmanship manner.
It shall be installed in horizontal and vertical runs in such a manner as to ensure against trouble from the collection of trapped condensation and shall be arranged so as to be devoid of traps wherever possible. Special care shall be used in assuring that exposed conduit runs are parallel or perpendicular to walls, structural members, or intersections of vertical planes and ceilings. No open wiring is allowed.
13. Fittings or symmetrical bends shall be required wherever right
angle turns are made in exposed work. Bends and offsets shall be avoided wherever possible, but where necessary, they shall be made with an approved conduit bending machine. All conduit joints shall be cut square, reamed smooth and drawn up tight, using couplings intended for the purpose.
14. Conduits shall be securely fastened to all sheet metal outlets,
junction and pull boxes with double galvanized locknuts and insulating-grounding bushings as required by the NEC, except for penetrations in NEMA 4/4X areas which shall utilize Myers sealing hubs. Conduit crossings in insulating roof fill will require both conduits to be secured to the roof deck, and these crossings can only be made where the insulating fill is a minimum of 3 inches deep. Runs of exposed conduit shall be supported in accordance with the NEC using cast aluminum or malleable iron one hole pipe straps with spacers to provide an air space behind the conduit. Stainless steel minerallaac, one piece conduit clamps shall be acceptable where located such that building occupants are not in danger of inadvertent contact, since this type fitting has several sharp edges. In general terms, they may be considered in areas such as on or above ceilings, or high on walls. All conduit in walls and slabs shall be securely braced, capped (wooden plugs are prohibited), and fastened to the forms to prevent dislodgement during vibration and pouring of concrete.
15. During construction, all conduit work shall be protected to prevent
lodgement of dirt, plaster or trash in conduits, fittings or boxes. Conduits which have been plugged shall be entirely freed of accumulations or be replaced. All conduits in floors or below grade shall be swabbed free of debris and moisture before wires are pulled. Crushed or deformed conduit shall not be permitted.
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16. All open conduit work through floor slabs shall be made watertight
by grouting around conduit. Provide coating where conduit comes in contact with all concrete.
17. Where IMC or GRS conduit penetrates a floor slab the conduit shall
be painted with 2 coats of Carboline 888 epoxy paint or equal to a point 6 inches above the penetration.
18. The final section of conduit connecting each motor or piece of
utilization equipment subject to vibration shall be of the flexible type. Type “UA” shall be used in all process areas and in outdoor or wet locations. Flexible conduit to space heaters shall be long enough to allow swivel action.
19. All underground conduits entering a building shall be sealed
against water/condensate entering around the conductors with duct seal.
20. In certain situations, conduit expansion joints shall be required to
ensure against conduit and/or cable damage due to settling or thermal expansion and contraction. These expansion joints shall be required where required by the manufacturer or the Contract Drawings and shall be installed per manufacturer’s instructions.
21. Motor control centers, meter panels, computer panels, switchgear,
etc., mounted in a building with a basement or pipe gallery below, shall have the conduit opening left in the slab sealed to prevent moisture, dust, etc., from entering the panel. Utilize duct seal.
22. All conduit work in the finished space of each new structure shall
be concealed except for conduits to lighting fixtures in buildings with precast roof slabs, or excepted as noted on the Contract Drawings. All conduit work below ground floor level in each structure shall be exposed. Conduits entering from underground into buildings shall be watertight through the wall, both inside and outside.
23. Where PVC conduit is installed, underground transition shall be
made to GRS conduit at bends where wire pulling could cut conduit.
24. Aluminum conduit shall not be used underground, in chemical or
chlorine storage/feed areas, or placed in concrete slabs, unless it is UL listed for the purpose and factory pre-coated.
25. Conduit stubs, for future use, extended through outside walls shall
be capped with threaded pipe caps and coated to prevent corrosion. Stubs shall extend 5 feet beyond the walls from which
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they are stubbed unless otherwise indicated on the Contract Drawings.
26. All metal raceway systems shall be grounding conductive, solidly
bonded throughout and grounded in accordance with NEC requirements and/or as noted on the Contract Drawings. In addition, all raceway systems shall be provided with separate grounding conductors.
27. Minimum conduit size shall be 3/4 inch.
28. The following table shows the minimum burial depth required for
all exterior conduit or cable:
Direct Burial Cable (Suitable for that use) 30" Rigid Metal Conduit 30" Schedule 80 PVC 30"
29. Wire pulling shall be facilitated by the use of a UL approved pulling compound in pulls over 30 feet in length or where there are 2 or more 90 degree bends. Only polypropylene, nylon, or manila pulling ropes will be permitted. Standard industry recognized wire pulling equipment shall be used.
30. All conduits entering and leaving exterior enclosures shall be
sealed around the wires with duct seal. All underground conduits or exterior conduits shall be sealed with duct seal where they penetrate into an interior enclosure.
31. All conduits for emergency lighting systems shall be separate from
other building power conduits.
32. Areas of use for each type of conduit:
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PVC EMT GRS IMC Aluminu
m Exterior Underground X X X Exposed X Office Areas/Buildings - Interior Under/In Floor Slab X X X Interior Exposed (Elec/Mech Rm) X X X X Interior Concealed X X X X Industrial Buildings - Interior Under/In Floor Slab X X X Interior Exposed X Interior Concealed X X X X Elec/Mech Rm X X X X NEMA 4X Areas/Chemical Rooms Interior Concealed X Interior Exposed X Medium Voltage Conc. Encased X
3.03 SERVICE ENTRANCE
A. Conductors and terminations for service entrances shall be furnished and installed by the Contractor. Voltage, phase, and number of wires shall be as shown on the Drawings. Clearances for overhead entrance wires shall be per Power Company, NEC, and NESC requirements.
B. Any details not shown on the Drawings or written in the Specifications
pertaining to the service entrance shall be per power company requirements. It is the Contractor’s responsibility to contact the utility prior to bidding and obtain any special requirements or costs they will be imposing. Those costs shall be included in the bid.
C. On underground service entrances from pad mounted transformers, the
Contractor shall be responsible for furnishing and installing all primary, secondary, and metering conduits, as well as secondary service/metering conductors. The Contractor shall be responsible for furnishing pull wires in primary conduits for use by the power company. The Contractor shall be responsible for fabricating the required concrete pad that the transformer will be mounted on. The Contractor shall also mount the meter base furnished by the power company.
END OF SECTION
***
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SECTION 16131
BOXES PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Outlet/device boxes, pull boxes, junction boxes, and underground boxes shall be furnished and installed where indicated on the Contract Drawings, and\or as required by the work in accordance with the NEC.
B. Manholes shall be provided where indicated. 1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
B. Section 16900 – Control Panels
1.03 SUBMITTALS
A. Submittals are required on all boxes and cabinets in accordance with
Section 16010 requirements. PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Boxes - “Wiegmann,” “Appleton,” “Raco,” “Crouse-Hinds,” “Hoffman,” “Robroy Industries,” “Cloud Concrete Products,” “Carlon,” or equal.
B. Floor Boxes, Fittings, Poke-throughs - “Hubbell”, “OZ Gedney,” or equal. C. Cabinets – “Hoffman,” “Wiegmann,” “Rittal,” or equal.
2.02 GENERAL
A. Outlet/Device Boxes: 1. Exposed Steel Conduit: Provide cast or malleable iron, zinc-
electroplated outlet boxes finished with aluminum lacquer or enamel. Provide cast metal covers with neoprene gaskets for NEMA 4 areas and stamped steel covers for NEMA 12 and undesignated areas.
2. Exposed PVC Conduit: Provide PVC boxes and covers.
3. Exposed Aluminum Conduit: Provide copper free, cast aluminum boxes. Hardware shall be stainless steel.
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4. Concealed Conduit: Provide galvanized coated flat-rolled sheet
steel outlet wiring boxes of dimensions required by NEC. Boxes shall be flush mounted.
5. Exceptions to the above shall include NEMA 4X areas, where stainless or non-metallic boxes are required, and NEMA 6, 7, or 9 areas in which the boxes should be listed for use in the applicable environment.
B. Junction and Pull Boxes
1. Exposed Steel Conduit, up to 50 cubic inches: Provide cast or
malleable iron, zinc-electroplated outlet boxes finished with aluminum lacquer or enamel. Boxes shall have drilled external, cast mounting extensions (bossed to provide at least 1/8" between back of box and mounting surface for drainage). Provide cast covers with neoprene gaskets.
2. Exposed PVC Conduit, up to 50 cubic inches: Provide PVC boxes and covers.
3. Exposed aluminum conduit, up to 50 cubic inches: Provide copper
free, cast aluminum boxes. Hardware shall be stainless steel.
4. Exposed Conduit, Larger than 50 cubic inches: Provide sheet metal boxes with hinged covers and appropriate gaskets and NEMA rating. NEMA 1, 3R, 4 and 12 areas shall be painted steel or aluminum. NEMA 4X non-chemical areas shall be stainless type 304. NEMA 4X chemical areas shall be fiberglass. Padlock hasps shall be provided in areas accessible to the public.
5. Exceptions to the above shall include NEMA 6, 7, and 9 areas in
which the boxes shall be listed for use in the applicable environment.
C. Underground junction or pull boxes or handholes shall be constructed of
reinforced concrete cast-in-place or pre-fabricated as detailed on the Contract Drawings. Strength of manholes, handholes, and pullboxes and their frames and covers shall conform to the requirements of IEEE C2. Precast-concrete manholes shall have the required strength established by ASTM C 478, ASTM C 478M. Frames and covers shall be made of gray cast iron and a machine-finished seat shall be provided to ensure a matching joint between frame and cover. Cast iron shall comply with ASTM A 48/A 48M, Class 30B, minimum. Handholes for low voltage cables installed in parking lots, sidewalks, and turfed areas shall be fabricated from an aggregate consisting of sand and with continuous woven glass strands having an overall compressive strength of at least 10,000 psi and a flexural strength of at least 5,000 psi. Pullbox and handhole covers in sidewalks and turfed areas shall be of the same
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material as the box. Concrete pullboxes shall consist of precast reinforced concrete boxes, extensions, bases, and covers.
D. Junction boxes for use in wet-wells and other hazardous areas shall be
watertight, rustproof and corrosion resistant, and explosionproof with threaded conduit openings (5 ½ full threads - minimum) and provided with rustproof hardware.
E. Explosion proof sealing fittings shall be furnished and installed in
accordance with NEC requirements. PART 3 - EXECUTION 3.01 INSTALLATION, APPLICATION, AND ERECTION
A. General
1. Boxes shall be installed in the locations shown on the Contract Drawings. The Contractor shall study the general building plans in relation to the space surrounding each outlet, in order that his work may fit the other work required by these Specifications. When necessary, the Contractor shall relocate devices so that when fixtures or other fittings are installed, they will be symmetrically located according to room layout and will not interfere with other work or equipment.
2. All supports for outlet boxes shall be furnished and installed by
the electrical trades.
B. Concealed Work
1. All outlet boxes shall be 4” x 4” standard galvanized steel type at least 1½ inches deep. Exceptions shall be noted on the Contract Drawings. Provide two-inch single plaster ring for single devices in all CMU walls.
2. Standard deep type outlet boxes (concrete rings with appropriate
covers) shall be used in floor slab construction so concealed conduits entering sides of boxes can clear reinforcing rods.
3. Outlet boxes for concealed telephone and signaling systems shall
be the 4-inch square type, unless otherwise noted or required by the telephone company.
4. See details on Drawings for box requirements.
C. Interior Pull and Junction Boxes
1. Interior pull and junction boxes are not shown but shall be used as
needed.
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D. Manholes, Handholes, and Pullboxes - Exterior Underground
1. General
a. Manholes, handholes, and pull boxes for exterior
underground work are shown on the Contract Drawings and are the minimum number required. Others may be added at the Contractor’s option, but no extra pay shall be allowed. See detail on the Contract Drawings.
b. Manholes shall be constructed approximately where shown.
The exact location of each manhole shall be determined after careful consideration has been given to the location of other utilities, grading, and paving. The location of manholes that are not indicated on the drawings shall be approved by the Engineer prior to construction. Manholes shall be the type noted on the Drawings and shall be constructed in accordance with the applicable details as indicated. Top, walls, and bottom shall consist of reinforced concrete. Walls and bottom shall be of monolithic concrete construction. The Contractor may at his option utilize monolithically constructed precast-concrete manholes having the required strength and inside dimensions as required by the drawings or specifications. In paved areas, frames and covers for manhole and handhole entrances in vehicular traffic areas shall be flush with the finished surface of the paving. In unpaved areas, the top of manhole covers shall be approximately 1/2 inch above the finished grade. Where existing grades that are higher than finished grades are encountered, concrete assemblies designed for the purpose shall be installed to elevate temporarily the manhole cover to existing grade level. All duct lines entering manholes must be installed on compact soil or otherwise supported when entering a manhole to prevent shear stress on the duct at the point of entrance to the manhole. Duct lines entering cast-in-place concrete manholes shall be cast in-place with the manhole. Duct lines entering precast concrete manholes through a precast knockout penetration shall be grouted tight with a portland cement mortar. PVC duct lines entering precast manholes through a PVC endbell shall be solvent welded to the endbell. A cast metal grille-type sump frame and cover shall be installed over the manhole sump. A cable-pulling iron shall be installed in the wall opposite each duct line entrance.
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2. Electric Manholes a. Cables shall be securely supported from walls by hot-dip
galvanized cable racks with a plastic coating over the galvanizing and equipped with adjustable hooks and insulators. The number of cable racks indicated shall be installed in each manhole and not less than 2 spare hooks shall be installed on each cable rack. Insulators shall be made of high-glazed porcelain. Insulators will not be required on spare hooks.
3. Communications/Data/Instrumentation Manholes
a. The number of hot-dip galvanized cable racks with a plastic
coating over the galvanizing indicated shall be installed in each manhole. Each cable rack shall be provided with 2 cable hooks.
4. Handholes
a. Handholes shall be located approximately as shown.
Handholes shall be of the type noted on the drawings and shall be constructed in accordance with the details shown.
5. Pullboxes
a. Pullbox tops shall be flush with sidewalks or curbs or placed 1/2 inch above surrounding grades when remote from curbed roadways or sidewalks. Covers shall be marked "Low-Voltage,” “Communications,” or “Instrumentation” as applicable and provided with 2 lifting eyes and 2 hold-down bolts. Each box shall have a suitable opening for a ground rod. Conduit, cable, ground rod entrances, and unused openings shall be sealed with mortar.
6. Ground Rods
a. A ground rod shall be installed at the manholes, handholes
and pullboxes. Ground rods shall be driven into the earth before the manhole floor is poured so that approximately 4 inches of the ground rod will extend above the manhole floor. When precast concrete manholes are used, the top of the ground rod may be below the manhole floor and a No. 1/0 AWG ground conductor brought into the manhole through a watertight sleeve in the manhole wall.
E. Openings in Electrical Boxes
1. All openings in electrical equipment, enclosures, cabinets, outlet
and junction boxes shall be by means of welded bosses, standard
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knockouts, or shall be sawed, drilled, or punched with tools specially made for the purpose. The use of a cutting torch is prohibited. Unused openings shall be plugged per the NEC.
END OF SECTION
***
587-15-C-13 (81) (7/17)
16140-1
SECTION 16140
WIRING DEVICES PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Wiring devices shall be provided where indicated on the Contract Drawings.
1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
B. Section 16130 - Boxes 1.03 SUBMITTALS
A. Submittals are required on all wiring devices in accordance with Section 16010.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. “Hubbell,” “Bryant,” “Eagle,” “General Electric,” “Wiremold,” “P&S,” “Leviton,” “Daniel Woodhead,” or equal.
2.02 EQUIPMENT
A. General
1. Ranges, sump pumps, and air conditioners shall be equipped with the proper cord and plug for receptacles. Range cord shall be 50 amp, 6 foot, with 2#6 and 2#8 conductors, and standard 4-prong plug.
2. Switch and receptacles for sump pump motors shall be rated at 20
amps at 125 volts and shall be equipped with a manual motor starting switch in lieu of toggle switch, as specified elsewhere this Division.
B. Wiring Device Colors shall be Ivory
C. Receptacles
1. General – All receptacles shall be heavy duty specification grade
duplex receptacle, NEMA 5-20R, 20A, 125V, 3-wire. Provide
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weatherproof-in-use cover where indicated on the Drawings. Duplex outlet (interior) - “Hubbell” catalog series 5362, or equal.
2. Single outlet – Hubbell series 5361 single receptacle, or equal.
3. Special purpose outlet - Per equipment requirements.
4. Range outlet - 50 amp, 4-wire grounded, 125/250 VAC - “Hubbell”
cat. no. 9450, or equal.
5. Ground fault interrupting receptacles shall be required where shown on the Contract Drawings, and shall be indicated by the abbreviation “GFI” beside the circuit symbol on the Contract Drawings. They shall be rated 20 amps (125 volts) and shall be of the duplex, feed through type, capable of protecting all downstream receptacles on the same circuit. They shall be UL listed and shall comply with UL 943 and interrupt the current between 4-6 milliamps of ground fault leakage. Appropriate plates shall be furnished and installed. The 20 ampere rating shall apply not only to device internals but to the faceplate as well. Receptacle shall be Hubbell GFI 5352, or equal.
D. Plates and Covers
1. Furnish and install plates of the appropriate type and size for all
wiring and control devices, signal and telephone outlets.
2. All plates on surface mounted boxes shall be of 302 stainless steel (nonmagnetic) with rounded or beveled edges, except in NEMA 3R and 4/4X areas, then weatherproof-in-use covers shall be installed. All plates on flush mounted boxes shall be 302 stainless steel. All device plate screws shall be stainless steel with countersunk heads. Screwheads shall be colored to match the plates. Plates shall be installed vertically and with an alignment tolerance of 1/16 inch. Device plates shall be of the one-piece type, of suitable shape for the devices to be covered. Plates shall have a smooth finish with no crevices to collect dirt. Oversize plates are not acceptable.
3. Covers for boxes serving equipment where flexible conduit is to be
tapped into cover plates shall be sheet metal drilled for conduit. Gaskets shall be required as well as all special adapters for mounting.
4. Weatherproof covers shall be Hubbell WP series, Thomas and Betts
2CKG, or equal. They shall be weatherproof-in-use with cast aluminum construction. Mounting screws shall be stainless. Protection shall be NEMA 3R.
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E. Wall Switches (Tumbler Type)
1. General – Switches shall be industrial grades, 120/277VAC, 20A Single pole - “Hubbell” cat. series 1221, or equal.
2. Single pole (exterior) - “Hubbell” cat. no. 1222-gray, or equal, and
Bryant 7420 or equal plate.
3. Switch and pilot light (interior) - “Hubbell” cat. no. 1221-IL (with lighted switch handle), or equal.
4. Switch and pilot light (exterior) - “Hubbell” cat. no. 1221-PL, or
equal.
5. 3-way switches (interior) - “Hubbell” cat. no. 1223, or equal.
6. Double-pole (interior) - “Hubbell” cat. no. 1222, or equal.
7. 4-way switches (interior) - “Hubbell” cat. no. 1224, or equal.
8. Key switches or lock type shall be “Hubbell” cat. no. 1221-L, 1222-L, 1223-L, 1224-L. Provide 20 extra matching keys in addition to one for each switch.
9. Combination Light Switches (2 handles that fit within the same
space as one), 2 single pole “Pass & Seymour” Cat. No. 670-I, suitable for 120/277 volt systems.
10. Weatherproof switch covers shall be Hubbell 7420 series, or equal,
with stainless mounting screws, cast aluminum construction and wet location rating.
F. Break-Glass Emergency Switch
1. Surface Mount NEMA 4/4X – Provide Allen-Bradley Bulletin 800T
series or equal red push-button station with two NO and two NC contacts rated 120V minimum. The contacts shall operate when the glass is broken with the attached accessory tool. A “STOP” legend plate shall be included. Switch must be field-labeled with appropriate label to indicate what system it controls.
G. Fan Motion Switch
1. Provide a switch rated 120V, 1/3HP minimum suitable for
controlling a fan when motion is sensed within the coverage area. The coverage shall be up to 1200 square feet. The switch shall mount in a standard 2x4 device box and shall include an override button. The switch shall have an adjustable time delay of 20 seconds to 30 minutes to allow the fan to continue running after the room is no longer occupied.
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PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. Wall Switches
1. Wall switches shall be mounted at a height as indicated on the Drawings, unless otherwise noted on the Contract Drawings.
B. Receptacles
1. Outlets shall be located as shown on the Contract Drawings. Where
located in special interior finishes, they shall be properly centered. Boxes shall be of the type noted and accepted for the specific installation.
2. Furnish and install receptacle circuits where called for on the
Contract Drawings and/or by these Specifications. Circuits shall be installed in conduit from panel to receptacle, with flush mounted boxes except as noted on the Contract Drawings.
3. Receptacles and lighting circuits shall not be combined on the
same overcurrent device. For runs over 75 feet or for 30 amp receptacles, minimum wire size shall be AWG No. 10.
4. Receptacles for specific devices (e.g., air conditioner), shall be
rated at the correct voltage and amperage for that unit.
5. The minimum free length of conductor at each box for the connection of a fixture, switch or receptacle shall be 8 inches. All connections shall be made mechanically and electrically secure.
6. Mounting heights shall be as indicated on the Drawings. Utilize
medium mounting height for receptacles in locations subject to flooding.
7. Receptacles over workbenches or countertops or at medium or
high mountings shall be mounted so that the grounding slot is below the neutral and hot. All other receptacles shall be mounted with the grounding slot above the neutral and hot.
END OF SECTION
***
587-15-C-13 (81) (7/17)
16150–1
SECTION 16150
WIRE CONNECTIONS AND CONNECTING DEVICES PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Wire connection and connecting devices shall be as herein specified. 1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
1.03 SUBMITTALS
A. Submittals are required in accordance with Section 16010.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Connectors, Lugs, etc. - “T & B”, “Anderson”, “Burndy”, or equal.
B. Ties and Servings - “T & B”, “Panduit”, or equal.
C. Termination and splice connectors - “3M Scotchlok”, “Anderson”, “T & B”, “Burndy”, or equal.
2.02 MATERIALS
A. Wire Splicing and Terminations (600 Volts and Below)
1. Electrical Terminal and Splice Connectors (#22 - #4 AWG)
a. Terminals and splice connectors from #22 - #4 AWG shall be compression types with barrels to provide maximum conductor contact and tensile strength. Performance, construction, and materials shall be in conformance with UL standards for wire connectors and rated for 600 volts and 105 degrees Celsius.
b. Connectors shall be manufactured from high conductivity
copper and entirely tin plated. Terminal barrels shall be serrated on the inside surface and have a chamfered conductor entry. Terminals shall have funnel entry construction to prevent strand fold-back. All barrels shall be brazed seam or seamless construction.
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c. Spade type terminals shall be sized for the appropriate stud and shall be locking type that snap firmly onto studs with a close fit for maximum retention. Spade type terminals shall be insulated with an insulation suitable for maintaining a high dielectric strength when crimped and be made form nylon, PVC, or equal.
2. Electrical Lugs and Connectors (#6 AWG - 1000 Kcmil)
a. Lugs and splice connectors from #6 AWG - 1000 Kcmil shall
be compression types with barrels to provide maximum conductor contact and tensile strength. They shall be manufactured from high conductivity copper and entirely tin plated. They shall be crimped with standard industry tooling. The lugs and connectors must have a current carrying capacity equal to the conductors for which they are rated and must also meet all UL requirements. All lugs above 4/0 AWG shall be 2 hole lugs with NEMA spacing. The lugs shall be rated for operation through 35 KV. The lugs shall be of closed end construction to exclude moisture migration into the cable conductor.
3. Twist-on Wire Connectors (#22 AWG - #10 AWG)
a. All twist-on wire connectors must have a corrosion resistant
spring that is free to expand within a steel jacket. The steel jacket must be insulated with a flexible vinyl jacket capable of withstanding 105 degrees Celsius ambient temperatures and of sufficient length to cover wires that are inadvertently overstripped.
b. Each connector size must be listed by UL for the intended
purpose and color coded to assure that the proper size is used on the wire combinations to be spliced. The connectors must be compatible with all common rubber and thermoplastic wire insulations.
4. Solderless/re-usable lugs shall be used only when furnished with
equipment such as control panels, furnished by others, where specification of compression type lugs is beyond the Contractor’s control. In the event their use is necessary, the Contractor shall be responsible for assuring that they are manufactured to NEMA standards, with proper number and spacing of holes and set screws.
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PART 3 - EXECUTION 3.01 INSTALLATION, APPLICATION, & ERECTION
A. Insulation of Splices and Connections
1. Connections/splices with a smooth even contour shall be insulated with a conformable 7 mil thick vinyl plastic insulating tape which can be applied under all weather conditions and is designed to perform in a continuous temperature environment up to 105 degrees Celsius. The tape shall have excellent resistance to abrasion, moisture, alkalis, acids, corrosion, and varying weather conditions (including sunlight). The tape shall be equal to Scotch 33+ and shall be applied in conformance with manufacturer’s recommendations. In addition, it shall be applied in successive half-lapped layers with sufficient tension to reduce its width to 5/8 of its original width. The last inch of the wrap shall not be stretched.
2. Connections/splices with irregular shapes or sharp edges
protruding shall be first wrapped with 30 mil rubber tape to smooth the contour of the joint before being insulated with 33+ insulating tape specified in the previous paragraph. The rubber tape shall be high voltage (69 KV) corona-resistant based on self-fusing ethylene propylene rubber and be capable of operation at 130 degrees Celsius under emergency conditions. The tape must be capable of being applied in either the stretched or unstretched condition without any loss in either physical or electrical properties. The tape must not split, crack, slip, or flag when exposed to various environments. The tape must be compatible with all synthetic cable insulations. The tape must have a dissipation factor of less than 5 percent at 130 degrees Celsius, be non-vulcanizing, and have a shelf life of a least 5 years. The rubber tape shall be applied in successive, half-lapped wound layers and shall be highly elongated to eliminate voids. Other manufacturer’s recommendations on installation shall be adhered to. The rubber tape shall be equal to Scotch 23 or 130C electrical splicing tape.
3. Splices made in wet or damp locations shall be made submersible
and watertight with special kits made for the application and compatible with type of cables employed.
B. Connection Make-up
1. Connections of lugs to bus bars, etc., shall be made up with
corrosion resistant steel bolts having non-magnetic properties with matching nuts, and shall utilize a Belleville spring washer (stainless steel) to maintain connection integrity. Connections shall be torqued to the proper limits. Prior to bolting up the connection,
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electrical joint compound shall be brushed on the contact faces of the electrical joint.
2. All motor lead connections shall be made up to match the type of
lead furnished on the motor. If the lead is not lugged, then twist-on wire connectors may be used. To prevent possible vibration problems, twist-on connectors shall be taped after installation.
3. All lugged motor lead connections (excluding motors over 200
horse-power) shall be made up using ring tongue compression lugs with proper size stainless steel nuts and bolts. Belleville type spring shall be used to maintain tension on the connections. The connections shall then be insulated using the procedure described for irregular shapes, utilizing rubber tape in conjunction with vinyl electrical tape.
4. At the time of final inspection, the Engineer may request the
Contractor to disassemble 3 randomly selected motor lead connections in the Engineer’s presence, to assure conformance with these Specifications.
5. The Contractor shall include all necessary tools, materials, and
labor in his bid for disassembly of the connections and for remaking them with new insulating materials after inspection.
END OF SECTION
***
587-15-C-13 (81) (7/17)
16220-1
SECTION 16220
MOTORS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Motors are to be furnished with driven equipment except where otherwise noted on the Contract Drawings or elsewhere in this Division of the Specifications. All motors shall conform to the following Specifications and any special requirements of the driven equipment. Special requirements of the driven equipment shall take precedence over these Specifications should a discrepancy occur. Starting torque and slip ratings shall conform to the requirements of the driven equipment.
B. Polyphase motors shall be of the squirrel cage induction type and single
phase of the capacitor start-induction run type except as otherwise noted. Conduit boxes shall be tapped for the size conduit shown on the Contract Drawings.
C. All motors shall be manufactured and installed in accordance with
applicable NEMA standards and NEC provisions, latest revisions. 1.02 RELATED WORK
A. Division 11 B. Section 16010 – General Electrical Requirements
1.03 SUBMITTALS
A. Submittals are required in accordance with Section 16010 requirements. 1.04 DELIVERY, STORAGE, & HANDLING
A. All electrical motors shall be protected against the accumulation of moisture, dust and debris and physical damage during the course of installation of the job.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Motors - “General Electric”, “Westinghouse”, “U.S. Motors”, “Gould Century”, “Lincoln”, “Baldor”, “Marathon”, “Reliance”, “Magnatek”, “Siemens”, or equal.
587-15-C-13 (81) (7/17)
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2.02 EQUIPMENT
A. Motors 200 Horsepower and Under for Service Under 600 Volts
1. Ratings and Electrical Characteristics
a. Time: All motors shall be rated for continuous duty.
b. Temperature: Based on NEMA standards for a maximum ambient temperature of 40 degrees Celsius and an altitude of 3,300 feet or less, according to service factor and insulation class employed.
c. Voltage: All single-phase motors shall be rated
115/208/230 volts and all polyphase motors 230/460 volts. Submersible polyphase motors to be operated at 460 volts may take exception to the dual voltage requirement. All motors shall be capable of normal operation at balanced voltages in the range of ±10 percent from rated winding voltage.
d. Frequency: All a-c motors shall be rated for 60 Hz.
operation. All motors shall be capable of normal operation at frequencies 5 percent above or below the nominal rating of 60 Hz.
e. Horsepower: Horsepower of the motors shall be as given in
the Specification Division on the driven equipment or as shown on the Contract Drawings. Submersible motors shall be allowed to be furnished even though the horsepower rating may not be in accordance with standard NEMA assignments. In many cases, the horsepower specified is a minimum requirement and certain alternate manufacturers may require larger horsepower motors. The larger motor shall be furnished at no extra cost to the Owner.
f. Locked Rotor Current: Locked rotor current shall be in
accordance with NEMA standards.
g. Efficiency and Power Factor: Efficiency and power factor shall be given consideration during Shop Drawing review. The ratings at full, ¾, and ½ load shall be compared to similar motors manufactured by acceptable suppliers listed in these Specifications. Excessive variation shall be considered grounds for rejection.
h. Speed: Synchronous speed of motors shall correspond to
standard NEMA ratings. Actual speed shall be as given in the Specification Division on the driven equipment. Slip shall not exceed 5 percent at full load.
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i. Service Factor: The service factor shall be 1.15 unless
requirements of the driven load necessitate a higher service factor.
j. Insulation Class: Insulation shall be NEMA Class B, except
as otherwise noted. Submersible motors shall be Class F, and motors to be operated at variable speed shall be Class F. Class F insulated motors shall operate at a Class B rise at nameplate horsepower loading.
k. Design Level: Motors shall be NEMA design B, except as
otherwise noted.
l. Enclosure: Motors for process equipment 2 HP and smaller shall be totally enclosed. All motors for process equipment larger than 2 HP shall be TEFC (totally enclosed fan cooled), suitable for use indoors or outdoors, except as otherwise noted. Totally enclosed non-ventilated (or air-over) motors may be used for ventilators and other auxiliary equipment that by virtue of the load are provided with more than adequate ventilation. ODP (open dripproof) motors may be used for ventilators where the motor is outside the air stream yet still protected from the weather. Division 15 of the Specifications and the HVAC Contract Drawings will detail the type of enclosure required for ventilators. Submersible motors shall be air or oil filled and of watertight construction. Motors used in classified atmospheres shall be properly rated for that hazard. Motors for potable water wells shall be water-filled/lubricated.
m. Frame Size: Frame designations shall be in accordance with
NEMA standards.
n. Winding Overtemperature Sensors: All motors 15 to 200 HP shall be provided with motor winding thermostats. The devices shall be hermetically sealed, snap-acting thermal switches, actuated by a thermally responsive bi-metallic disk. A minimum of 1 per phase is required, with switches wired into the control circuit of the starter to provide de-energization should overheating threaten. All submersible motors shall be equipped with motor winding thermostats regardless of size. Also all motors 0-200 HP operated by adjustable frequency drives shall have motor winding thermostats.
o. All submersible pump/motor assemblies shall be equipped
to detect presence of moisture and alarm at the controller.
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2. Mechanical Characteristics
a. Integral Horsepower Motor Construction
(1) Motor frames for horizontal motors shall be cast iron, heavy fabricated steel, or cast aluminum (alloy 356 or 360). A steel insert ring shall be set into the aluminum alloy endshield when cast to minimize wear of the bearing support. Aluminum alloy motors shall not be used in areas where exposed to chlorine gas.
(2) Motor frames for vertical motors shall be cast iron,
heavy fabricated steel, or extruded aluminum (alloy 6063-T4 or 6063-T6). Endshields for vertical motors must be cast iron.
(3) If an aluminum frame is used, the endshields and/or
all other steel hardware must be plated with zinc or cadmium and coated with grease before assembly to minimize the galvanic action between the steel and aluminum.
(4) Motor frames and endshields shall be of such design
and proportions as to hold all motor components rigidly in proper position and provide adequate protection for the type enclosure employed. Lifting lugs of all motors shall conform to NEMA standards.
(5) Windings shall be random or form wound, adequately
insulated and securely braced to resist failure due to electrical stresses and vibration. If the windings are aluminum, there shall be a cold welded aluminum-copper transition joint at the termination of the windings to permit the use of standard copper to copper connection techniques by the electrician and to prevent galvanic action between the copper power wires and the aluminum windings.
(6) The motor shaft shall be made of high grade machine
steel or steel forging of size and design adequate to withstand the load stresses normally encountered in motors of that particular rating. Bearing journals shall be ground and polished.
(7) Rotors shall be made from high grade steel
laminations adequately fastened together and to the shaft. Rotor cage windings may be cast aluminum of bar type construction with brazed end rings.
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(8) Integral horsepower motors shall be equipped with cone, roller, or ball bearings made to AFBMA standards, Grade 1 and shall be of ample capacity for the motor ratings. The bearing housing shall be large enough to hold sufficient lubricant to minimize the need for frequent relubrication (ten years normal operation without lubrication), but facilities shall be provided for adding new lubricant and draining out old lubricant without motor disassembly. The bearing housing shall have long, tight running fits or rotating seals to protect against the entrance of foreign matter into the bearings or leakage of lubricant out of the bearing cavity.
(9) See the specification division relating to each piece of
motor driven equipment for additional motor requirements to those listed above.
b. Fractional Horsepower Motor Construction
(1) Motor and shell shall be rigid welded steel designed
to maintain accurate alignment of motor components and provide adequate protection. End shields shall be reinforced, lightweight, die cast aluminum. Windings shall be of varnish insulated wire with slot insulation of polyester film and baked on bonding treatment to make the stator winding strongly resistant to heat, aging, moisture, electrical stresses, and other hazards. Motor shafts shall be made from high grade, cold rolled, shaft steel with drive shaft extensions carefully machined to standard NEMA dimensions for shaft coupled drive connection. Bearings shall be carefully selected precision ball bearings with extra quality, long life grease and large reservoir providing 10 years normal operation without relubrication, AFBMA Grade 1.
c. Submersible Motor Construction
(1) See Equipment Specifications.
3. Tests, Nameplates, and Shop Drawings
a. Tests
(1) Tests shall be required on integral horsepower
motors only. A factory certified test report of “electrically duplicate motors previously tested” shall be supplied on all motors under 200 horsepower. The test shall be certified by the factory and shall
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contain a statement to the effect that complete tests affirm the guaranteed characteristics published in the manufacturer’s catalogs or descriptive literature.
(2) Tests will be in accordance with IEEE test procedures.
b. Nameplates
(1) Each motor shall have a permanently affixed
nameplate of brass, stainless steel, or other metal of durability and corrosion resistance. The data contained on the nameplate shall be in accordance with NEMA standards.
(2) Submersible pump motors and other motors in
difficult-to-access locations shall be furnished with a spare nameplate for mounting inside the MCC or starter enclosure.
c. Shop Drawings
(1) Shop Drawings shall consist of motor dimensions,
nameplate data from each motor and tests as outlined above. Also included shall be efficiency and power factor at 100, 75, and 50 percent load. Operation, maintenance, and lubrication information (including bearing catalog numbers) shall be submitted with Shop Drawings for review.
4. Efficiency Requirements
a. NEMA premium efficiency or IEC 60034-30 Level IE3
efficiency levels shall be the minimum acceptable levels as follows.
Minimum Efficiency Requirements (%)
Nominal 1200 RPM
Nominal 1800 RPM
Nominal 3600 RPM
1 82.5 85.5 77.0 1.5 87.5 86.5 84.0
2 88.5 86.5 85.5 3 89.5 89.5 86.5 5 89.5 89.5 88.5
7.5 91.0 91.7 89.5 10 91.0 91.7 90.1 15 91.7 92.4 91.0 20 91.7 93.0 91.0 25 93.0 93.6 91.7
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Minimum Efficiency Requirements (%)
Nominal 1200 RPM
Nominal 1800 RPM
Nominal 3600 RPM
30 93.0 93.6 91.7 40 94.1 94.1 92.4 50 94.1 94.5 93.0 60 94.5 95.0 93.6 75 94.5 95.4 93.6
100 95.0 95.4 94.1 125 95.0 95.4 95.0 150 95.8 95.8 95.0 200 95.8 96.2 95.4
B. Motors Over 200 Horsepower for Service Under 600 Volts
1. Motors specified in this section shall comply with the requirements
of preceding Section 2.02, Subarticle A unless otherwise noted herein. Motors shall be furnished by the pump supplier to be installed by the Contractor. Terminal housings shall be as specified in Sub-article D which follows, and extra long motor leads shall be provided to accommodate the large terminal housing.
2. Motors shall be NEMA Design B, and shall be especially suitable
both electrically and mechanically to drive the equipment specified in other divisions. The speed, horsepower, torque, base, bearings, shaft and motor tolerances shall be coordinated closely with the equipment manufacturer’s requirements so as to provide a satisfactory, efficient drive without overloading, overheating, or abnormal vibration.
3. Motors shall meet the NEMA temperature rise as defined for Class
B insulation. Service factor shall be 1.15 and the motor shall be tested for temperature rise at its service factor load above a 40°C ambient. All motors shall be dynamically balanced and vibration shall be measured per NEMA methods. Critical speed of the shaft and motor assemble shall be above the operating speed of the motor by at least 10 percent.
4. Motor enclosure shall be TEFC unless specified otherwise in
Division 11. with non-hygroscopic encapsulated windings. Screens shall be provided over all frames and endshield openings.
5. Motors shall be equipped with nonreverse ratchets to prevent
damage to pumps.
6. Bearings shall be selected to have AFBMA rated minimum life of 1 year when operating continuously at rated speed of the motor and at total load consisting of the weight and hydraulic thrust load
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imposed on the motor by the pump. Angular contact ball thrust bearings, spherical roller thrust bearings, or plate thrust bearings shall be used depending on thrust requirements. Motors shall have oil lubricated thrust and guide bearings, with visual level indicators, accessible drain plugs and accessible filling plugs. Oil lubrication system shall be so designed as to provide the correct quantity of lubricant with minimum foaming or aeration. A nameplate shall be provided on all motors showing bearing numbers and oil type and required viscosity.
7. Motors shall be high thrust capable of carrying 30 percent
momentary upthrust.
8. In addition to the test report required in the preceding Subarticle, the manufacturer shall submit data indicating: guaranteed efficiencies and power factor at 100 percent, 75 percent, and 50 percent load; full load current; locked rotor current.
9. RTDs for bearing and winding overtemperature protection are required as specified below.
10. A vibration monitor for vibration protection is required as specified
below.
11. Anti-condensation heater is required for any motor to be installed outside or in an un-conditioned environment or where indicated on the Drawings. See specification below.
C. Terminal Housings (Motors Over 200 Horsepower for Operation at 600
volts or Less)
1. Stock terminal housings provided on motors over 200 horsepower by the motor manufacturer shall not be utilized if they are insufficiently sized for terminating the conductors. It should be removed after the motor is firmly mounted in its final location and all work is completed that might cause damage to the exposed motor leads.
2. The Contractor shall replace the stock terminal housing with a
stainless steel NEMA 4X enclosure with hinged door and interior subpanel. Dimensions of the enclosure shall be per the NEC, sized for the feeder conduits and number of wires entering the enclosure. The Contractor shall mount a phenolic insulated base power block on the subpanel, which utilizes set screws for bolted pressure connections. The power block shall terminate the feeder conductors on one side and the motor leads on the other. The connectors shall be tin plated copper. Acceptable manufacturers shall be Taylor Electric, Marathon, or equal.
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3. The final section of feeder conduits connecting to the NEMA 4X enclosure shall be flexible liquidtight conduit. Conduit entrance shall be so arranged that pump/motor removal shall be easily accomplished by unbolting the motor leads from the power block, unbolting the NEMA 4X box from the motor housing, and swinging the box away from the motor; out of the path of removal.
D. Thermal Protection for Motors Over 200 HP
1. For motors rated over 200HP, resistance temperature detectors
(two per phase) shall be provided in accordance with NEMA MG 1, paragraph 20.63. Detectors shall have a copper resistance element having a resistance of 10 ohms at 76 degrees F. Leads shall be terminated on terminal blocks.
2. Motor protection and management shall be provided by a digital relay, GE Multilin 269 or equal:
a. Protective functions shall include: phase overload standard
curves (51), overload by custom programmable curve (51), I2t modeling (49), stator overtemperature/bearing overtemperature with 10 independent RTD inputs (49), negative sequence unbalance/single phase (46), phase reversal (47), starts per hour and time between starts (48), short circuit (50), ground fault (50G/50N/51 G/51 N), undercurrent (37), mechanical jam/stall
b. Management functions shall include: statistical data, pre-trip
data, ability to learn, display and integrate critical parameters to maximize motor protection, communication with external devices using a RS485 port and ModBus® RTU protocol or Ethernet with Modbus TCP protocol, and a keypad and 48 character LCD display
c. A metering option shall be available as a separate unit that
communicates with the relay which may be field installed without modification to the relay. The metering option can be used with any relay where diagnosis or load measurements are required and shall also provide isolated analog outputs for average RMS amps, kW, kvar and PF. With the meter option, the relay shall be capable of displaying important metering functions, including phase voltages, kilowatt, kilovar, power factor, frequency and MWhr. In addition undervoltage (27) and low power factor alarm and trip levels shall be field programmable.
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E. Vibration Switch – Required for motors over 200 HP.
1. Provide a Robertshaw Model 366 vibration switch, or equal. Shall be NEMA 4 with 0 – 4.5G setpoint, +/-5% accuracy, relay output, and manual reset with remote reset capability.
F. Winding Heaters – Required for motors over 15 HP where located outside or in unconditioned space. 1. Heaters shall be wrapped around the winding end turns. They shall
be designated for operation on 120 volts, 1-phase, 60 Hz, alternating current and of sufficient capacity or wattage that, when energized, they will hold the temperature of the motor windings approximately 10 degrees C above the ambient temperature. They shall be designed for continuous operation and to withstand at least 10 percent overvoltage continuously. The rate of heat dissipation shall be uniform throughout the effective length of the heater. Heaters installed around the winding end turns shall consist of the required turns of heating cable wrapped around the end turns and secured in place before the winding is impregnated.
a. Heating Element: Heating element shall conform to the
requirements of ASTM B344 for an 80 percent nickel and 20 percent chromium alloy.
b. Sheath: Sheath shall be of a corrosion-resisting,
nonoxidizing metal and shall have a wall thickness not less than 0.025 inch.
c. Insulation: Insulation shall be a granular mineral refractory
material, highly resistant to heat, and shall have a minimum specific resistance of 1,000 megohms per inch cubed at 535 degrees C or 1,000 degrees F. Insulation for the heating cable (winding wraparound type) type heaters shall be suitable for a conductor temperature of 180 degrees C or 356 degrees F.
d. Terminals: The terminal box shall be readily accessible so
that winding heaters can be energized while motors are in storage.
PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. Installation of motors shall comply with motor manufacturer’s instructions as well as applicable NEMA recommendations and requirements of the driven equipment OEM (original equipment manufacturer).
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B. Motors shall be aligned to acceptable tolerances and shall not vibrate excessively.
C. Motors shall not be energized until they have been accepted by the OEM
start up personnel.
END OF SECTION
***
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SECTION 16230
STANDBY POWER GENERATOR SYSTEMS - FIXED PART 1- GENERAL 1.01 SCOPE OF WORK
A. This Specification covers the installation of a fixed emergency standby generator system and its major items of auxiliary equipment.
1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
B. Section 16496 – Automatic Transfer Switch 1.03 SUBMITTALS
A. The submittal shall include complete shop drawings and specification data on the generator systems. Submit in accordance with Section 16010 requirements.
B. The submittal shall include complete wiring schematics and
interconnection diagrams identifying by terminal number each required interconnection between the transfer switch, emergency shutoff pushbuttons, engine control panel, etc. The submittal shall also contain complete descriptive literature on every piece of equipment, battery-sizing calculations, and spare parts list.
C. The submittal shall include complete installation, startup, operation, and
maintenance instructions. D. Exceptions to this specification shall be clearly indicated in the submittal. E. The submittal shall include all factory test results for testing required
under this specification. F. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles / configurations represented on the literature. For example: Device boxes – Styles shall be listed as: For masonry walls, for electrical devices, for ceiling mounted light fixtures, etc
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1.04 QUALITY ASSURANCE
A. The engine, generator, and all equipment that make up the standby generator systems shall be bid direct to each Contractor by the manufacturer or his authorized distributor maintaining a parts and service facility within 150 miles of the project location.
B. All materials equipment and parts comprising the units specified herein
shall be new and unused, of current manufacture and of the highest grade. All equipment shall be free from all defects or imperfections.
1.05 GUARANTEE
A. Equipment furnished under this section shall be guaranteed against defective parts or workmanship for a period of 2 years from the date of field-testing and acceptance by the Owner. This warranty shall include all expenses that will normally be incurred if a service technician must visit the site to troubleshoot and/or repair a defective generator system.
1.06 REFERENCE STANDARDS
The generator covered by these specifications shall be designed, tested, rated, assembled and installed in strict accordance with current Editions of the following standards: A. NFPA 1 – Fire Code
B. NFPA70 – National Electrical Code. Equipment shall be suitable for use in
systems in compliance with Article 700, 701, and 702.
C. NFPA110 - Emergency and Standby Power Systems. (delete this requirement for smaller non-life safety systems.) The generator set shall meet all requirements for Class 24 Type 10 Level 1 systems. Level 1prototype tests required by this standard shall have been performed on a complete and functional unit; component level type tests will not substitute for this requirement.
D. UL508A. The entire control system of the generator set shall be UL508A
Listed and labeled.
E. UL2200. The generator set shall be UL2200 Listed [delete for most applications]
F. NFPA 37 “Stationary Combustion Engines and Gas Turbines”
G. NFPA 30 “Flammable and Combustible Liquids Code”
H. UL1008. The automatic transfer switch shall be UL1008 Listed.
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I. EPA – Generator engines shall be certified to the latest applicable regulations issued by the EPA regarding emissions compliance.
1.07 TESTING
A. Generator Set
The generator sets shall be completely factory tested in accordance with NFPA 110 requirements. Prior to acceptance of the installation, the equipment shall be tested to show it will perform satisfactorily, including automatic starting, subject to full load test or as much of full load as is available at the plant, shutdown, and reset as required in these Specifications. Prior to acceptance, the Contractor shall correct any defects that become evident during this test.
1.08 START-UP
A. Generator Set
On completion of the installation, the initial startup shall be performed by a factory-trained representative of the engine supplier. At the time of startup, operating instruction and maintenance procedures shall be thoroughly explained to operating personnel. Installation, operating, and maintenance instruction books shall be submitted for each electric set and all auxiliary equipment in a 3-ring binder, at the time of submittal of descriptive literature, for review. The manufacturer’s service representative shall be prepared to check phase rotation “by instrument”, prior to start-up. It will not be allowed to isolate one motor on the generator and check its rotation to determine phasing.
B. Automatic Transfer Switch
After the installation is completed, the transfer switch shall be tested by simulating a power failure and having each unit automatically start, come up to speed, and assume the available load at the site. The alarm and shutdown features of each set shall be tested to make sure they are in proper working order. Any defects that become evident at this time shall be corrected before acceptance of the complete standby generating system by the Owner. Coordination with ATS supplier is required.
1.09 PERMITTING
A. Contractor is required to obtain a fuel tank permit in accordance with State law and have the installation inspected by a certified inspector. Fees for this shall be included in the Contractor’s bid price.
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PART 2- PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Generators shall be manufactured by “Caterpillar”, “Cummins”, “Kohler”, “Generac” or equal.
B. Transfer switches shall be manufactured by “Russelectric,” “Eaton,”
“Schneider/Square D”, “Asco” or equal. 2.02 GENERATOR SET
A. Rating
1. Each standby emergency generator shall be rated as indicated on the Drawings for continuous service with normally varying loads during interruption of utility power, 0.8 power factor, 480Y/277 volts, 3 phase 4 wire, 60 Hz. and shall have a maximum operating speed of 1,800 rpm. The unit shall be rated for operation in ambient temperatures up to 104°F full sunlight and down to -20°F with zero sunlight (minimum acceptable operating range).
2. Ratings must be substantiated with manufacturer’s standard
published curves. Special ratings for a particular application are not permitted. These ratings must reflect the net power available after deducting all engine driven accessories.
B. Engine
1. The engine shall be capable of operating under full load at 1,800
rpm maximum and shall be full compression diesel type and of the 4-stroke cycle, fuel injected, water-cooled. Standby output shall not be less than as required to obtain the above power ratings at a governed speed of 1,800 rpm with fan.
2. Engines shall be capable of normal operation on commercial
grade No. 2 diesel fuel. Each unit shall be furnished with filters for fuel, oil, and intake air. A suitable lubrication oil cooler and transfer pump shall be furnished as part of the engine equipment. The engine manufacturer shall furnish lubricating oil for each unit.
3. Each engine shall have an engine-mounted radiator of sufficient
capacity to maintain safe operating temperature at an ambient temperature of 110 degrees Fahrenheit. The engine shall be equipped with thermostats and a jacket water pump of sufficient capacity to meet this requirement. The radiator shall be equipped with a core guard, fan guard, and flange for duct connection. Flexible hose connections shall be provided at the engine and radiator. Each radiator and engine cooling system shall be filled
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with a 50 percent solution of anti-freeze and water to prevent freezing. The generator set supplier shall provide antifreeze prior to start-up.
4. A critical type silencer shall be furnished for each unit with an
inlet properly sized according to the silencer manufacturer’s recommendation for the engines used. A stainless steel flexible exhaust fitting shall be provided for mounting between the engine exhaust and exhaust pipe. The silencer system shall be of a type and size to ensure against loss of engine power due to excessive backpressure. The silencer shall be equipped with a condensate drain. A bird screen shall be welded into the exterior end of the exhaust pipe. Rain-caps shall be provided where there is possibility of rain entering the pipe.
5. Safety shutoff alarms shall be provided for high water
temperature, low oil pressure, engine overspeed, engine overcrank, and high lubricating oil temperature.
6. The engine assembly shall be mounted on a structural steel
subbase and shall be provided with vibration isolators between the engine and the steel subbase or between the base and floor.
7. The engine shall be equipped with an engine mounted thermal
circulation type water heater to maintain engine jacket water at 90 degrees Fahrenheit. The heaters shall be 208V AC.
8. Each unit shall be equipped with an isochronous electronic
governor. The adjustment shall be accessible inside the panel, but not through the door. The governor shall provide frequency regulation at steady state to within +/-0.25%.
C. Generator
1. Each generator shall be of a standard generator size to provide
the specified output under jobsite conditions and shall be built to NEMA MG 1 standards.
2. Generators shall be 3 phase, 60 Hz., 0.8 power factor, single
bearing, synchronous type, NEMA Class H insulation vacuum impregnated with epoxy varnish for fungus resistance, and directly connected to the engine flywheel housing with a flex coupling. Temperature rise of the rotor and stator shall not exceed NEMA Class F 130°C (maximum) at the standby power rating in a 40 degrees Celsius ambient.
3. Generators shall have permanent magnet exciters, which shall
derive excitation current from a pilot exciter, mounted on the rotor shaft. It shall enable the alternator to sustain 300% of rated current for ten seconds during a fault condition.
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4. Generators shall have an automatic voltage regulator to provide
voltage regulation over the engine load range to within ±0.5 percent of rating for constant loads. The regulator shall include electronic voltage buildup, volts per Hertz regulation, three phase sensing, over-excitation protection, loss of sensing protection, temperature compensation, voltage limit on startup, and shall be environmentally sealed.
5. The generator shall include anti-condensation winding heaters.
D. Engine Generator Controls
1. Provide for each generator a control panel incorporating complete
controls for all functions of the electric set and associated mechanisms. The panel shall be generator mounted or freestanding, as shown on the Drawings, one enclosure of 14 gauge steel, dead front. The enclosure shall be rated NEMA 4 unless integrally mounted with the generator enclosure such that it is protected from the weather. Each panel shall contain as a minimum the following:
a. Power monitor (amperage, voltage, kva, kw, kvar, power
factor) b. Combination phase selector switch c. Engine oil pressure d. Coolant temperature e. Engine RPM f. System DC volts g. Engine Running Hours h. Generator AC volts i. Generator AC amps j. Generator frequency, digital k. Automatic starting controls as specified herein l. Automatic voltage regulator m. Field circuit breaker
2. Fully automatic engine start-stop controls shall be furnished in
each generator control panel. Provide a 4-position selector switch marked, “Auto”, “Manual”, “Off’, and “Reset”; battery charger disconnect contacts; 2 auxiliary contacts, normally open; and 2 contacts normally closed. The control panel shall be furnished with a disconnect switch for control of the engine mounted thermal circulation type water heater.
3. For generator sets with a walk-in enclosure, the generator set
shall be furnished with an emergency shutoff switch prewired and installed just inside the entrance of the enclosure.
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4. Provide the following additional indicators for protection and diagnostics according to NFPA Level 1:
a. Low Oil Pressure b. High Water Temperature c. Low Coolant Level d. Overspeed e. Overcrank (with lockout) f. Emergency Stop Depressed g. Approaching High Coolant temperature h. Approaching Low Oil Pressure i. Low Coolant temperature j. Low voltage in battery k. Control switch not in auto. Position l. Low fuel main tank m. Battery charger AC failure n. High Battery voltage o. EPS supplying load p. Spare
E. Circuit Breaker
1. Provide a generator mounted circuit breaker, molded case or insulated case construction, 3 pole, with rating as indicated on the Contract drawings.
2. Breaker shall utilize a solid-state trip unit and a shunt trip
mechanism. It shall have full short time, long time, instantaneous, and ground fault adjustments for coordination.
3. The breaker shall be UL listed with shunt trip device connected to
engine/generator safety shutdowns. 4. Provide lugs on the load side of the breaker for feeder
connections.
F. Automatic Starting System
1. The electric starting system for each unit shall be d-c with positive engagement.
2. Provide a lead-acid storage battery set with battery service safety
kit and cell covers, for each unit, of the heavy-duty diesel starting type. Battery voltage shall be compatible with the starting systems. Batteries shall be of sufficient capacity to provide full cranking power for 1-1/2 minutes cranking time without recharging at a battery and engine temperature of 32 degrees Fahrenheit (assume SAE 30 oil for calculation purposes). Supply battery racks, warming pads and all necessary cables. The battery
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warming pads shall be wired to a common cord with the jacket water heater for connection by the Contractor.
3. The battery charger to be furnished for each unit shall employ
transistor controlled magnetic amplifier circuit to provide continuous taper charging. Each charger shall maintain rated output voltage with a-c line fluctuations of +/- 10 percent. Each charger shall be equipped with full wave rectifiers, automatic surge suppressors, automatic a-c line compensation, automatic overload protection, d-c ammeter and voltmeter, fused a-c input and d-c output. Each charger shall be equipped with a timer to automatically equalize charge every 30 days for 24 hours. Input voltage shall be 120 volts, 60 Hz, a-c. The charger shall have LED annunciation for low DC volts, rectifier failure, loss of AC power, and high DC volts. Amperage output shall be no less than ten (10) amperes.
G. Weatherproof Housing
1. The enclosure shall be of the weatherproof walk-in type and
designed for a rigidity wind test of 150 miles per hour. Steel doors and panels shall be not less than 12 gauge hot roll sheet steel. The angle iron frame shall be 1-1/2" x 1/8" angle iron steel. The enclosure shall be sized by the manufacturer to meet the requirements for proper air flow and clearances as required for accessory equipment, except minimum width shall be 10'-0" (ten feet).
2. Each door shall have duty three-point latch with previsions for
padlocking and interior release. Liftoff type doors with stainless steel bolts shall permit the doors to be removed when in an open position.
3. Roofs shall be domed and provided with rain gutters where
required to prevent water from entering the enclosure. Roof loading capacity shall be a minimum of 80 lbs. per square foot.
4. Both the air intake and exhaust opening shall be louvered with
aluminum motorized 120 volt louvers equal to Arrow model AE-40 or gravity operated dampers. A duct flange with a flexible section shall be supplied to attach the louver to the radiator.
5. The enclosure shall be insulated with 1" Styrofoam insulation
material. It must be completely covered with 22 gauge galvanized sheet steel. Alternately, the enclosure may be insulated with 1” fiberglass insulation with perforated metal facing.
6. Provide one 208 volt, AC, 3-phase, space heater with thermostat
supplied and wired. Heater shall be sized to keep enclosure ambient at 50 degrees F minimum on a -20°F day.
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7. Enclosure shall be prewired such that only one 208 volt 60A
3-Phase service is required. Provide a panelboard with main breaker. Provide 2 - duplex NEMA 5-20 R receptacles. Provide internal vapor-proof LED strip fixtures of the same type being furnished by the Lighting supplier (coordinate with Contractor).
8. Provide removable lifting eyes at each corner of the enclosure. 9. The assembly shall be tested to ensure that there is no loss of
generator set performance while operating in the enclosure. 10. The housing shall be painted utilizing electrostatically applied
powder baked paint. The color shall be selected by Owner during submittal review phase. Provide a color chart with at least 10 color selections.
11. Generator exhaust system shall be insulated inside the enclosure.
H. Remote Annunciator: A remote annunciator is not required as the
generator will be monitored by the plant SCADA system. Provide dry contacts for remote monitoring of the following signals: generator running status, generator fault/alarm, generator low fuel level.
I. Sound Attenuation: Provide sound attenuation such that the noise
generated by the diesel generator set operating at 100 percent load shall not exceed the following A-weighted sound pressure level when measured in a free field at a radial distance of 22.9 feet at 45 degrees apart in all directions: 81.5dBA. This sound pressure level will be tested in the field with a sound pressure meter and the genset will be rejected if it does not pass this test.
2.04 FUEL STORAGE SYSTEM
A. Fuel System runtime capacity shall be 24 hours at full load. B. Sub-base or Integral tank
1. Provide a UL labeled double walled sub-base or integral base-
mounted tank for each emergency generator. The tank shall incorporate threaded pipe connections. The tank shall be complete with all level controls, fuel site gauge, and low level alarm detector, all prewired. The low level detector shall have a dry contact for field wiring connections. Provide a whistle valve vent such that a whistling noise is emitted when the tank is full.
2. Provide flexible connections from the tank to the engine.
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2.05 ACCESSORIES A. Provide hearing protectors, earmuff type, Willson No. 365, fibermetal No.
2011 or equal - 2 sets required. B. Provide a weatherproof Class B fire extinguisher, 10lb min, installed
inside the genset enclosure
C. Platform: Furnish OSHA approved stairs to access each door on the enclosure. The stairs shall be steel and powder-coated to the same color as the generator enclosure, and shall support a weight of 500 lbs minimum. The stairs shall be a rigidly-welded one-piece set for each door and shall have arrangements for rigidly mounting to the same concrete pad as the generator.
PART 3 - EXECUTION 3.01 GENERATOR SET INSTALLATION/APPLICATION/ERECTION
A. The design and construction of the electric generator sets shall be such that they are neat and clean in appearance, and that normal adjustments and maintenance can be effected without use of special tools. See Drawings for generator installation details.
B. An adequate supply of the proper lubricant shall be provided to perform
one oil change. In addition, spare elements shall be provided for fuel, oil, and air filters, for one complete change. The engine shall be filled with all necessary liquids required for operation. The fuel tank shall be full of fuel.
C. The Contractor shall strictly adhere to this specification and the
approved shop drawings and manufacturer’s installation instructions for the installation of the generator system and its accessories.
3.02 FUEL TANK INSTALLATION I APPLICATION I ERECTION A. Above Ground Tanks: Above ground fuel tanks shall be installed on a
concrete foundation and anchored to the foundation in accordance with manufacturer’s recommendations and Kentucky requirements. Other aspects of the installation shall be per Contract Drawings, manufacturer recommendations, and NFPA 30.
B. Initial fuel supply: The Contractor shall provide an initial tank of fuel
prior to onsite acceptance testing.
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3.03 Startup Assistance and Training A. Provide manufacturer-authorized representative services to startup and
commission the generator system. A written field report is required confirming that the generation system is installed and operating properly.
B. Provide one day of manufacturer-authorized rep training on all aspects of
the generation system.
END OF SECTION
***
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SECTION 16280
SURGE PROTECTION PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Provide surge protection devices (SPD) for distribution equipment, instrumentation, and for all other systems and equipment as indicated on the Drawings, as specified herein, and as specified in individual Division 16/17 sections.
1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements B. Section 16670 - Lightning Protection Systems C. Section 16442 - Panelboards D. Section 17100 – Instrumentation E. Section 17200 – SCADA Hardware
1.03 SUBMITTALS
A. Submit product data on all surge protective equipment. Catalog data shall
include all information necessary to prove compliance with this Specification. Proposed part numbers and options shall be flagged, and non-applicable equipment shall be crossed out. Provide a table of each suppressor location. Installation instructions and drawings shall also be included with the shop drawing submittal.
B. Clearly note all options being submitted with underlines in product
literature. Provide a list for each model number of suppressor and corresponding service used.
C. SPD specifications shall include UL 1449 surge suppression ratings.
D. Submit operation and maintenance information on all surge protective
equipment. 1.04 REFERENCES
A. ASTM A 123/A 123M (2002) Standard Specification for Zinc (Hot-Dip
Galvanized) Coatings on Iron and Steel Products B. ASTM A 153/A 153M (2005) Standard Specification for Zinc Coating (Hot-
Dip) on Iron and Steel Hardware
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C. IEEE C62.11 (latest version) Standard for Metal-Oxide Surge Arresters for
Alternating Current Power Circuits (>1kV) D. NEMA LA 1 (latest version) Standard for Surge Arresters E. NFPA 70 (latest version) - National Electrical Code
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Switchboard, MCC, and Panelboard Surge Protection Devices – Eaton, Square D, GE, Siemens, Allen-Bradley or equal.
B. Equipment and Instrumentation SPDs - “Phoenix Contact,” “Eaton,” “ABB,”
“Transtector,” “Edco” or equal. 2.02 GENERAL REQUIREMENTS
A. Surge protection equipment operating temperature shall be –20°F to 125°F, minimum range.
B. SPD equipment shall be UL 1449 listed.
2.03 DISTRIBUTION EQUIPMENT SPD
A. The SPD shall be suitable for application in category C3 environments as described in ANSI/IEEE C62.41. The SPD shall be of parallel design and provide protection, line to ground, neutral to ground, and line to neutral for wye or delta distribution systems. The SPD shall be compatible with the indicated electrical system, voltage, current and distribution configuration.
B. Non-listed manufacturers shall submit oscillographs and/or computer
generated graphs from compatible smartscopes, which demonstrate SPD clamping voltage values when tested to category C3 (per ANSI/IEE C62.45) 6kV 1.2x50 microseconds and 10kA 8x20 microseconds test waveshapes, in all specified suppression modes.
C. SPD shall comply with ANSI/IEEE C62.1, C62.41, and C62.45. The SPD
shall be capable of surviving 1,000 sequential category C3 surges without failure following IEEE test procedures established in C62.45.
D. SPD shall have 200kA short circuit current ratings. SPD shall have
thermal disconnects to protect against overvoltage conditions. E. The SPD shall use redundant LED indicators that provide indication of
suppression failure.
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F. The SPD maximum continuous operating voltage (MCOV) shall be capable
of sustaining 110 percent of the nominal RMS voltage continuously without degradation.
G. The SPD shall use only solid state clamping components to limit the
surge voltage. H. Service entrance SPD shall have surge current capacity of 80,000 amps
minimum per mode. Distribution Panelboard SPD shall have a surge current capacity of 40,000 amps minimum per mode.
I. The SPD shall have a response time no greater than 5 nanoseconds, for
any of the individual protection modes, under laboratory conditions with optimum lead lengths.
J. The SPD UL 1449 surge suppression rating for any suppression mode
shall not exceed:
Electrical System Voltage Phases
UL 1449 Surge Suppression
Ratings 120/240 1 330V 120/240 3 330V 120/208 3 330V
208 3 700V 277/480 3 700V
480 3 1500V
K. EMI/RFI filtering shall be provided for each mode with the capability to attenuate high frequency noise. Minimum attenuation shall be 20db.
L. The SPD components shall have a SPDT alarm contact rated for 250 VAC,
1 amp (minimum) used for remote indication of circuit integrity. M. SPD shall be equipped with a non-resettable digital event counter
readable on the face of the suppressor without opening any doors or covers.
2.04 CABINET/CONTROL PANEL SPD
A. The SPD shall be a Din-Rail-Mounted device and shall be installed to
protect the equipment in the cabinet from harmful surges and voltage spikes. The SPD shall have a SPDT contact rated for 250 VAC, 1 amp used for remote indication/visual indicator of circuit integrity.
B. It shall have a surge handling capacity of 10kA (8/20microsecond)
minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than
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or equal to 500V. The response time shall be less than or equal to 25 nanoseconds.
C. The device shall be a Phoenix Contact “Valvetrab” or equal.
2.05 INPUT/OUTPUT SPD
A. Analog I/O SPD
1. The Din-Rail-Mounted surge protection device shall be installed to protect the analog I/O.
2. The device shall have a surge handling capacity of 20kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 40V (Conductor to conductor) and 450V (conductor to ground). The response time shall be less than or equal to 1 nanosecond (conductor to conductor) or 100 nanoseconds (conductor to ground). The resistance of the device shall be no more than 2.2 ohms.
3. The device shall be suitable for din-rail mounting, and shall be no
more than 17.5 mm thick. 4. The device shall be suitable for use on a 4-20mA analog circuit
with 28VDC continuous operating voltage and up to 450mA continuous current.
5. The device shall be a Phoenix Contact “MCR-Plugtrab PT” surge
protection device, or equal. B. Digital 24VDC I/O SPD
1. The SPD shall be DIN-rail-mountable and shall be installed to protect the digital 24VDC I/O.
2. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 42VDC. The response time shall be less than or equal to 25 nanoseconds. The resistance of the device shall be no more than 4.7 ohms.
4. The device shall be suitable for use on 24VDC circuit with up to
300mA continuous current. 5. The device shall be a Phoenix Contact “MCR-Plugtrab PT” surge
protection device, or equal.
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C. Digital 120VAC I/O SPD
1. The SPD shall be DIN-rail-mountable and shall be installed to protect the digital 120VAC I/O.
2. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 600V. The response time shall be less than or equal to 25 nanoseconds.
4. The device shall be suitable for use on a 120VAC circuit with up to
26A continuous current. 5. The device shall be a Phoenix Contact “MCR-Plugtrab PT” surge
protection device, or equal. 2.06 NETWORKS AND TELECOMMUNICATIONS SPD
A. LAN SPD
1. The SPD shall protect Ethernet cabling systems and equipment
based on 10/100Base T standards. The SPD shall accept standard RJ-45 input and output connections, and shall incorporate 8 lines of surge protection. The SPD shall be an inline unit or a Din-rail-mountable unit as required. Furnish patch cables as necessary for a complete system.
2. The SPD maximum continuous operating voltage and current shall
be 7VDC and 1.5A minimum, respectively. The SPD shall have a surge handling capacity of 350A (line-to-line) or 2.5kA (line to ground) (8/20 microsecond) minimum. Clamping voltage shall be 22V (line-to-line) or 80V (line-to-ground), maximum. Response time shall be 500 nanoseconds (line-to-line) or 100 nanoseconds (line-to-ground), maximum. Input attenuation shall be no more than 1 dB at 100Mhz. Cutoff frequency shall be greater than 100Mhz.
3. The SPD shall have been tested and found compliant in accordance
with IEEE C62.36 standards. 4. The SPD shall be a Phoenix Contact “DataTrab” or equal.
B. Telecommunications Copper Cabling Protector Modules - Provide in accordance with UL 497 solid state type 5 pin or screw type rated for the application. Provide the number of surge protection modules equal to the number of pairs of exterior cable of the building protector assembly.
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2.09 INSTRUMENTATION SPD
A. Local Surge Protection Device for Loop-Powered 4-20mA Instruments
1. The local surge protection device shall be installed at the location of the instrument it is protecting.
2. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 40V (Conductor to conductor) and 450V (conductor to ground). The response time shall be less than or equal to 1 nanosecond (conductor to conductor) or 100 nanoseconds (conductor to ground). The resistance of the device shall be no more than 10 ohms.
3. The device shall be Class 1, Div. 2 certified under UL1604 if it is
located in a hazardous area as indicated on the Contract drawings. 4. The device shall be housed in a stainless steel pipe stub or similar
for installation on a field-mounted conduit body. Temperature range shall be –40°C to 80°C.
5. The device shall be suitable for use on a 4-20mA analog circuit
with 28VDC continuous operating voltage and up to 270mA continuous current.
6. The device shall be a Phoenix Contact “Pipetrab” surge protection
device, or equal. B. Local Surge Protection Device for Line-Powered 4-20mA Instruments
1. Provide a surge protection device that protects both the 120VAC
line supply and the 4-20mA loop output. Voltage clamp shall be no more than 325VAC on the line protection with 5 nanosecond response time. Surge current (8x20microsecond) shall be 39kA.
2. On the loop protection, voltage clamp shall be no more than 36V with 5 nanosecond response time and 10kA surge current rating.
3. Unit shall be NEMA 4X, highly corrosion resistant and suitable for
direct sunlight exposure. 4. Unit shall be an Edco SLAC surge protector, or equal.
PART 3 - EXECUTION 3.01 GENERAL INSTALLATION REQUIREMENTS
A. The conductors shall be as short and straight as practically possible and shall not exceed 6 feet in length or the manufacturer’s maximum
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recommended length (whichever is less). The input conductors are to be twisted together to reduce the SPD system inductance. An appropriately sized manual safety/disconnect switch or thermal magnetic circuit breaker shall be installed on the line side of the SPD. It shall be capable of electrically isolating the SPD from the electrical service for repair without interrupting service to the building.
B. The SPD shall be installed following the SPD manufacturer’s
recommended practices and in compliance with all applicable codes.
3.02 DISTRIBUTION EQUIPMENT SPD A. SPD shall be manufacturer-installed where indicated on the Drawing
panelboard schedules and one-line/riser diagrams. B. Provide a SPD in all control panels with 3 phase power supply.
3.03 CABINET SPD
A. Provide a Cabinet SPD on all single-phase control panels, SCADA and electronic cabinets, and all other equipment with solid-state circuitry.
3.04 INPUT/OUTPUT SPD
A. Provide SPDs on each analog and digital I/O termination in the cabinet if the circuit extends beyond the perimeter of the building underground.
3.05 INSTRUMENTATION SPD
A. Provide a local surge protection device at the instrument for all underground STIC installations that extend beyond the building wall.
B. Provide a Din-rail-mounted surge protection device at the I/O cabinet
termination on each 4-20mA loop and 24VDC instrumentation power supply circuit for underground STIC installations that extend beyond the building wall.
END OF SECTION
***
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SECTION 16430
LOW VOLTAGE SWITCHBOARD PART 1 - GENERAL 1.01 SCOPE OF WORK
A. The Contractor shall furnish and install a switchboard as specified herein and as shown on the Contract Drawings. Switchboard shall be UL listed.
B. The Contractor shall furnish a power system study as specified herein.
1.02 RELATED WORK
A. Section 16280 – Surge Protection
1.03 SUBMITTALS
A. Submit detailed Drawings of each piece of equipment that includes circuiting and construction materials.
B. Submit O&M Manuals. Service manuals shall be provided on all equipment
and accessories. The service manuals shall be bound in a 3-ring, looseleaf notebooks.
C. Shop drawings shall be furnished providing the following information:
switchboard voltage/current ratings, overall outline dimensions including available conduit space, switching and protective device amp ratings and frame size; bussing dimensions/ratings; and one line diagram. Adequate conduit space shall be provided to meet NEC requirements.
1.04 REFRENCES
A. The low voltage switchboards shall comply with the latest applicable standards of NEMA PB-2 and UL 891.
1.05 QUALIFICATIONS
A. The equipment and major components shall be suitable for and certified to meet all applicable seismic requirements of Kentucky, for the seismic zone indicated on the Contract Drawings. This shall include both vertical and lateral required response spectra as specified. Alternately, the manufacturer’s certification may be based on a detailed computer analysis of the entire assembly structure and its components. Guidelines for the installation consistent with these requirements shall be provided by the switchgear manufacturer and be based upon testing of representative equipment. The equipment manufacturer shall document the requirements necessary for proper seismic mounting of the equipment.
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B. The following minimum mounting and installation guidelines shall be met,
unless specifically modified by the above referenced standards:
1. The Contractor shall provide equipment anchorage details, coordinated with the equipment mounting provision, prepared and stamped by a licensed civil engineer in the state. Mounting recommendations shall be provided by the manufacturer based upon approved shake table tests used to verify the seismic design of the equipment.
2. The equipment manufacturer shall certify that the equipment can
withstand, that is, function following the seismic event, including both vertical and lateral required response spectra as specified in the above codes.
3. The equipment manufacturer shall document the requirements
necessary for proper seismic mounting of the equipment. Seismic qualification shall be considered achieved when the capability of the equipment, meets or exceeds the specified response spectra.
1.06 POWER SYSTEM STUDIES
A. General
1. Short Circuit Studies, Protective Device Evaluation Studies, and Protective Device Coordination Studies shall be performed by the switchboard/switchgear manufacturer. The studies shall be submitted to the Engineer prior to receiving final acceptance of the distribution equipment shop drawings and/or prior to release of equipment for manufacture. If formal completion of the studies may cause delay in equipment for manufacture, the Engineer may consider review of a preliminary submittal of sufficient study data to ensure that the selection of device ratings and characteristics will be satisfactory.
2. The studies shall include all portions of the electrical distribution
system from the normal power sources down to and including the 480 volt distribution system/motor control and 208Y/120V panelboards. Normal system connections and those which result in maximum fault conditions shall be adequately covered in the study.
3. The Short Circuit Study shall be in accordance with ANSI C37.5-
1989, IEEE st’d. 399-1990 and IEEE St’d. 141-1993.
B. Short Circuit Study
1. The short circuit study shall be performed with the aid of a digital computer program.
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2. The study input data shall include the power company’s short
circuit contribution, resistance and reactance components of the branch impedances, the X/R ratios, base quantities selected, and other source impedances. For the utility contribution, contact the Engineering Division of the serving electrical utility.
3. Short circuit momentary duty values and interrupting duty values
shall be calculated on the basis of assumed three phase bolted short circuits at each switchgear bus, medium voltage controller, switchboard, low voltage motor control center, distribution panelboard, pertinent branch circuit panel and other significant locations though the system. The short circuit tabulations shall include symmetrical fault currents, and X/R ratios. For each fault location, the total duty on the bus, as well as the individual contribution from each connected branch, shall be listed with its respective X/R ratio. If the project site is capable of being served from 2 or more substations, the calculations shall be based on the one substation with the largest contribution to a short circuit.
C. Protective Device Evaluation Study
1. A protective device evaluation study shall be performed to
determine the adequacy of circuit breakers, molded case switches, automatic transfer switches, and fuses by tabulating and comparing the short circuit ratings of these devices with the calculated fault currents. Appropriate multiplying factors based on system X/R ratios and protective device rating standards shall be applied. Any problem areas or inadequacies in the equipment due to short circuit currents shall be promptly brought to the Engineer’s attention.
D. Protective Device Coordination Study
1. A protective device coordination study shall be performed to
provide the necessary calculations and logic decisions required to select or to check the selection of power fuse ratings, protective relay characteristics and settings, ratios and characteristics of associated current transformers, and low voltage breaker trip characteristics and settings. The objective of the study is to obtain optimum protective and coordination performance from these devices.
2. The coordination study shall include all medium and low voltage
classes of equipment from the utility’s incoming line protective devices down to and including the largest rated device in the 480 volt MCC and panelboard. The phase and ground overcurrent protection shall be included as well as settings of all other adjustable protective devices.
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3. The time-current characteristics of the specified protective devices shall be drawn on Keuffel and Esser log-log paper. The plots shall include complete titles, representative one-line diagram and legends, associated power company’s relays or fuse characteristics, significant motor starting characteristics, complete parameters of transformers, complete operating bands of low voltage circuit breaker trip curves and fuses. The coordination plots shall indicate the types of protective devices selected, proposed relay taps, time dial and instantaneous trip settings, transformer magnetizing inrush and ANSI transformer withstand parameters, cable thermal overcurrent withstand limits and significant symmetrical and asymmetrical fault currents. All restrictions of the National Electrical Code shall be adhered to and proper coordination intervals and separation of characteristic curves shall be maintained. The coordination plots for phase and ground protective devices shall be provided on a system basis. A sufficient number of separate curves shall be used to clearly indicate the coordination achieved.
4. The selection and settings of the protective devices shall be
provided separately in a tabulated form listing circuit identification, IEEE device number, current transformer ratios and connection, manufacturer and type, range of adjustment and recommended settings. A tabulation of the recommended power fuse selection shall be provided for the medium voltage fuses where applied in the system. Any discrepancies, problem areas, or inadequacies shall be promptly brought to the Engineer’s attention.
E. Arc-Flash Study
1. The power system equipment shall be evaluated for arc-flash hazard level in compliance with NFPA 70E. All equipment shall be marked with hazard category and required personal protective equipment, including all 480V motor control equipment and including the 208Y/120V panelboards. Specific PPE clothing items necessary for 70E compliance are required to be listed on the labels.
F. Study Report
1. The results of the power system study shall be summarized in a
final report. Five bound copies of the final report shall be submitted for review.
2. The report shall include the following sections:
a. Description, purpose, basis and scope of the study and a
single line diagram of that portion of the power system which is included within the scope of the study.
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b. Tabulations of circuit breaker, fuse and other protective
device ratings versus calculated short circuit duties, and commentary regarding same.
c. Protective device time versus current coordination curves,
tabulations of relay and circuit breaker trip settings, fuse settings, fuse selection, and commentary regarding same.
d. Fault current calculations including a definition of terms and
guide for interpretation of computer printout. e. Arc-Flash hazard categories and required PPE.
G. Protective Device Testing, Calibration, and Adjustment
1. The equipment manufacturer shall provide the services of a
qualified field engineer and necessary tools and equipment to test, calibrate and adjust the protective relays and circuit breaker trip devices as recommended in the power system study. This service shall be performed as soon as possible after all equipment is ready for startup.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. “Square D”, “General Electric”, “Eaton” or equal. 2.02 EQUIPMENT
A. Low Voltage Switchboard
1. General Construction
a. Switchboard enclosure rating shall be NEMA 1. b. The power distribution switchboard shall be of the required
number of vertical sections bolted together to form one rigid switchboard nominally 90 inches high incorporating switching and protective devices of the number, ratings and type noted herein or as shown on the Contract Drawings with all interconnections, instrumentation, and control wiring. Switchboard construction shall be of the universal frame type using die-formed members bolted and braced through the exclusive use of self-tapping bolts. The sides, top, and rear shall be covered with removable screw-on plates having formed edges all around. Front plates shall be sectionalized and removable. All front plates shall be fabricated from code gauge steel and shall have formed
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edges all around. Ventilation openings shall be provided where required. All covers shall be secured by self-tapping screws.
c. The bus shall be tin plated aluminum of sufficient size to
limit the temperature rise to 65 degrees Celsius based on UL tests and adequately braced to withstand mechanical forces exerted during short circuit conditions when directly connected to a power source having the indicated available short circuit current. All connections shall be tightly bolted.
d. Small wiring, necessary fuse blocks and terminal blocks
within the switchboards shall be furnished when required. All groups of control wires leaving the switchboard shall be provided with terminal blocks with suitable numbering strips. All hardware used on conductors shall have a high tensile strength and an anti-corrosive zinc plating.
e. A ground bus shall be furnished firmly secured to each
vertical section structure and shall extend the entire length of the switchboard. A ground lug shall be furnished attached to the ground bus in a convenient location.
f. The switchboard shall be provided with adequate lifting
means and shall be capable of being rolled or moved into installation position and bolted directly to the floor without the use of floor sills.
g. A-B-C-N type bus arrangement, left-to-right, top-to-bottom,
and front-to-rear; as viewed from the front shall be used throughout.
h. Each switching and protective device shall be provided with
visible means of on-off identification. All terminals shall be of the anti-turn solderless type suitable for Cu or Al cable of sizes shown on the Contract Drawings.
i. All interior and exterior steel surfaces of the switchboard
shall be properly cleaned and finished with enamel over a rust-inhibiting phosphatized coating. Finish color shall be manufacturer’s standard gray.
j. Contractor shall review equipment locations on the
drawings and verify equipment will fit. Contractor is responsible for any modifications to the contract if equipment is submitted at a different size.
k. Construction shall allow maintenance of incoming line
terminations, main device connections, and all bus bolted connections to be performed without rear access. The
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feeder or branch devices shall be removable from the front and shall be panel mounted with the necessary device line and load connections front accessible.
l. The main horizontal bus bars shall be mounted on glass
polyester insulators with all 3 phases arranged in the same vertical plane. The main bus shall have a maximum ampacity as required and shall be braced for short circuits up to 100 KA min but not less than indicated on Drawings. Main bus splices shall be supplied between adjacent distribution sections.
m. Vertical sections shall be completely factory assembled,
wired, and tested before delivery. Design shall meet NEC and NEMA standards as well as OSHA requirements. Individual vertical sections shall be designed for bolting together at the job site. Thirty-six inch wide switchboard matting shall be provided on the floor to run the full length of the switchboard.
2. Circuit Breakers
a. Feeder Breakers
(1) The breakers shall be operated by a toggle type handle and shall have a quick-make, quick-break over-center switching mechanism that is mechanically trip free from the handle so that the contacts cannot be held against short circuits or abnormal currents. Tripping due to overload or short circuit shall be clearly indicated by the handle automatically assuming a position midway between the manual on and off positions. All latch surfaces shall be ground and polished. All poles shall be so constructed that they open, close, and trip simultaneously.
(2) Breakers must be completely enclosed in a molded
case. Interchangeable trip units shall be sealed to prevent tampering. Ampere ratings shall be clearly visible. Contacts shall be of non-welding silver alloy. Arc extinction must be by means of arc chutes, consisting of metal grids mounted in an insulating support.
(3) The minimum interrupting ratings of the circuit
breakers shall be at least equal to the available short circuit current at the line terminals. Circuit breaker ratings, and modifications, shall be as shown on the Contract Drawings.
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(4) The breakers shall have solid state trip elements with associated current monitors and the transfer shunt trips completely factory assembled and tested, and a push-to-trip button to mechanically check the trip mechanism or for use under emergency trip conditions.
(5) The breakers shall have adjustable rating plugs to
permit adjustment of the selected continuous current rating from 70 percent to 100 percent of the plug nameplate rating to provide the closest possible level of overload protection. An interlock in the rating plug will trip if an attempt is made to remove the plug with the breaker in the “on” position. With the plug removed, the breaker cannot be closed.
(6) The breakers shall be equipped with an adjustable
magnetic trip for all three poles which simultaneously adjusts the short delay from instantaneous at low setting to maximum of 10 cycles at high setting. Trip times and ratings shall not be affected by temperature changes.
(7) The breaker shall be equipped with integral,
adjustable ground fault protection. Full LSIG functionality is required.
3. Power Monitor – Provide a power monitor as indicated on the
Drawings. The power monitor shall be compliant with Section 16440 requirements.
PART 3 - EXECUTION 3.01 INSTALLATION / APPLICATION / ERECTION
A. Switchboards shall be firmly anchored to the concrete foundation as indicated on the Drawings.
B. Manufacturer instructions shall be followed, and gear shall be megger
tested prior to energization.
C. Switchboards shall have 36" wide rubber matting placed in front of them. 3.02 FIELD ADJUSTMENTS
A. Perform field adjustments of the protective devices in accordance with the
power system study.
END OF SECTION ***
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SECTION 16440
MOTOR CONTROL PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Contractor shall furnish and install motor control equipment as specified herein and as shown on the Drawings.
B. Provide manufacturer startup services for any motor control equipment that requires configuration or programming (soft starters, frequency drives, adjustable breakers, etc.)
1.02 RELATED WORK
A. Section 16010 – General Electrical Requirements
1.03 SUBMITTALS
A. Motor control equipment shall be new and the equipment of one manufacturer. Each component is specified by a particular trade name; however, this does not relieve the Contractor of the responsibility of submitting descriptive literature and Shop Drawings for review of all components.
B. Shop drawings, including layout drawings, complete schematic and
composite wiring diagrams, control circuit wiring diagrams and descriptive literature shall be submitted to the Engineer for review. Service manuals shall be submitted on all equipment and shall be bound in 3-ring looseleaf binders. The manuals shall also include information on accessories such as timers, etc., built in the control center.
C. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles/configurations represented on the literature.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Control Equipment
1. “Square D”, “General Electric”, “Allen-Bradley”, “Eaton” or equal.
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2.02 MOTOR CONTROL CENTERS (MCC)
A. General
1. Quality of built-in transformers, starters, lighting panelboards, timers, etc. shall be as written elsewhere in this Division unless otherwise noted.
2. Motor Control Center(s) shall consist of one or more enclosed
vertical sections joined together to form a rigid, free standing assembly. The construction of the Motor Control Center shall meet the requirements set forth by Underwriters’ Laboratories publication UL-845, NEMA publication number ICS-2-322, the National Electrical Code, and color coded.
3. The structure shall be UL listed and labeled as service equipment if
applicable. All sections shall bear UL labels.
4. Enclosures shall be NEMA 1 unless otherwise indicated, and each control center suitable for connection to an available fault current of 100,000 RMS symmetrical amperes.
B. Construction
1. Vertical Sections
a. Vertical sections shall support the horizontal and vertical
buses, combination starter units, covers and doors, and shall be designed to allow for easy rearrangement of units by the purchaser. Vertical sections shall have structural supporting members formed of a minimum of 13 gauge hot-rolled steel. All finished surfaces shall be blemish-free. Where needed, reinforcement structural parts shall be of 10-gauge steel to provide a strong rigid assembly. Each section shall be 90 inches high and shall have 7 gauge steel, 3 inch high removable lifting angle and two 1 ½ inch high base channels. Complete control center line-ups shall be divided into shipping splits no wider than approximately 60 inches. The lifting angle shall be provided on the top of each shipping split and shall extend the entire width of the shipping split. Lifting angles shall be designed to support the entire weight of the MCC section. Base channels shall be provided with holes to permit bolting the Motor Control Center(s) to the floor. The entire assembly shall be constructed and packaged to withstand all stresses induced in transit and during installation.
b. Motor Control Centers shall be designed so that matching
vertical sections of the same current rating and manufacture can be added later at either end of the line-up without use
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of transition sections and without difficulty or undue expense. Removable end closing plates shall be provided to close off openings on the end of the Motor Control Center line-up. A removable top plate shall be provided on each vertical section and shall be of one piece construction for added convenience in cutting conduit holes. The design shall allow use of the standard conduit entrance area without significant sag or deformation of the top plate.
c. Vertical sections shall be designed to accommodate plug-on
units in front-of-board or back-to-back construction as shown on Contract Drawings. Vertical sections housing plug-on units shall be 20 inches wide and shall be 20 inches deep. Wider sections will be permitted only for bolted connection type units not fitting the 20 inch wide sections. Unit mounting area shall be divided into ½ space factor divisions, each approximately 6 inches. NEMA Size 1 and 2 combination starter units shall use only 1 space factor, or 12 inches, of unit mounting space. Vertical sections shall allow for 7 space factors of unit mounting space. Removable blank plates shall cover all unused unit mounting spaces. Blank plates shall be flanged on all 4 sides and shall be mounted with captive screws. Blank space shall be equipped for future use.
d. Vertical sections shall be provided with both horizontal and
vertical wireways. Sufficient clearances shall be provided in the horizontal wireway so that no restriction is encountered in running wires from the vertical to horizontal wireway. Wireways shall be in accordance with the wireway sections contained in this document.
2. Horizontal Wireways
a. Horizontal wireways shall be provided in the top and bottom
of each vertical section as indicated in the Contract Drawings and shall be arranged to provide full length continuity throughout the entire assembly. The top horizontal wireway shall have a cross sectional area of not less than 20 square inches with openings between sections of not less than 11 ½ square inches. The bottom horizontal wireway shall extend through the length and depth of the vertical sections and shall also be provided with openings of not less than 11 ½ square inches to allow for full length continuity throughout the entire assembly. The bottom horizontal wireway height shall be not less than 9 1/4 inches. Covers for all wireways shall be equipped with captive type screws to prevent loss of hardware during installation. All wireways shall be isolated from the bus bars.
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3. Vertical Wireways
a. A vertical wire trough shall be located on the right -hand
side of each vertical section and shall extend from the top horizontal wireway to the bottom of the available unit mounting space. Each vertical wire trough shall have a cross sectional area of not less than 19 square inches and shall be isolated from the bus bars to guard against accidental contact. A separately hinged door having captive type screws shall cover the vertical wire trough to provide easy access to control wiring without disturbing control units.
b. Reusable wire ties shall be furnished in each vertical wire
trough for the purpose of grouping and securely holding wires in place for a neat and orderly installation.
4. Busbars
a. A continuous main three-conductor horizontal bus shall be
provided over the full length of the control center. A fully rated horizontal neutral bus (1200 ampere maximum) shall also be supplied over the full length of the Motor Control Center. When necessary, the bus shall be split to allow for ease in moving and handling. Splice bars will be supplied to join the bus wherever a split has been made. All splice connections shall be made with at least two bolts and shall employ the use of Belleville washers in the connection. Horizontal bus bars shall be mounted edgewise and supported by insulated bus supports.
b. For distribution of power from the main horizontal bus to
each unit compartment, a three-phase vertical bus shall be provided. The vertical bus shall be firmly bolted to the horizontal bus for permanent contact.
c. The main horizontal and vertical buses shall be made of
aluminum and the entire length shall be electrolytically tin plated to provide maximum protection to the bus bars from normal or adverse atmospheric conditions.
d. Bus supports shall be formed of high strength glass
reinforced alkyd material. Bus supports shall have generous surface clearances in the vertical plane to shed dust and maintain dielectric integrity. Bus supports and insulators shall be red to indicate proximity of energized bus parts.
e. Horizontal and vertical buses shall have continuous current
ratings adequate to handle all loads as shown on the one line diagram in the Contract Drawings. Continuous current
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ratings shall be in accordance with temperature rise specifications established by UL, ANSI, and NEMA standards.
f. A copper ground lug shall be provided in each incoming line
vertical section capable of accepting a #8 to 250 MCM cable. A horizontal copper grounding bus shall be provided in each section of the Motor Control Center. Horizontal grounding bus shall run continuously throughout the control center except where splits are necessary for ease of shipment and handling in which case splice bars shall be provided. Grounding bus shall be tin plated copper and have a cross sectional area equal to 28% of the main horizontal bus cross sectional area. Horizontal ground bus shall be located at the bottom of the Motor Control Center.
5. Bus Barriers
a. Insulated horizontal and vertical bus barriers shall be
furnished to reduce the hazard of accidental contact with the bus. Barriers shall have a red color to indicate proximity of energized buses. Vertical bus barriers shall have interlocking front and back pieces to give added protection on all sides and shall segregate the phases to reduce the possibility of accidental “flash over”. Small, separate openings in the vertical bus barriers shall permit unit plug-on contacts to pass through and engage the vertical bus bars. Bottom bus covers shall be provided below the vertical bus to protect the ends of the bus from accidental contact with fish tapes or other items entering from the bottom of the enclosure. Unused plug-on openings in the bus shall have plastic snap-in closing plates for added safety.
6. Main Incoming Lug Compartment
a. A front accessible main lug compartment shall be provided
with suitable main lugs to accommodate the number of cables per phase as indicated on the Contract Drawings. The compartment shall be located in the top most or bottom most unit space of the section to accommodate the user’s cables entering the Motor Control Center as indicated on the Contract Drawings. The main incoming lug compartment shall be covered by a hinged door for maintenance access. This door shall be held closed with captive type screws to discourage unauthorized access. (A unit door padlock attachment shall also be provided to lock the door in the closed position with one 5/16 inch diameter shackle padlock. This attachment shall also accept a meter type seal.)
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7. Units
a. Combination starter units shall consist of Size 1 minimum full voltage magnetic starters, reduced voltage solid-state starters, molded case magnetic-only circuit breakers, and auxiliary control devices, as required and/or shown on the one-line and elementary diagrams. Pilot light assemblies (push-to-test) shall be transformer type. All auxiliary equipment, except that which is specified for mounting on the door, shall be mounted within the compartment. All units shall be provided with unit doors, unit support pans, unit saddles and unit disconnect operators as outlined in this Specification. Each unit compartment shall be enclosed and isolated from adjacent units, buses and wireways except for openings for conductor entrance into units. Units shall be designed and constructed so that any fault will be localized within the compartment. All units shall be UL listed for minimum of 100,000 amperes RMS symmetrical fault withstand ability. If this is not possible then current limiting fuses must be provided in the main compartment.
b. Plug-on combination starter units of the same NEMA size
and branch feeder units of the same trip size shall be readily interchangeable with each other. It shall be possible to withdraw each plug-on unit to a de-energized position with the unit still being supported by the structure. It shall be possible to lock the unit in this position with one padlock.
c. Full voltage non-reversing combination starter units shall
have the following minimum space factor requirements, shall be provided with plug-on connections and shall be provided with ample space for customer wiring room:
Circuit Breaker Space Factor
Size 1 1 Size 2 1 Size 3 1 ½ Size 4 2
8. Unit Plug-On
a. For convenient unit connection to bus bars, unit plug-on
contacts shall be provided on the following units:
(1) For circuit breaker type units; full voltage starters, size 4 and smaller; auto-transformer reduced voltage starters, size 4 and smaller; part winding reduced
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voltage starters, size 4PW and smaller; branch circuit units, 225 ampere and smaller.
b. The plug-on connection for each phase shall be of a high
quality two point connection and shall be designed to tighten around the vertical bus bar during a heavy current surge. For trouble-free connections, the plug-on fingers shall be silver plated and coated with a compound to assure a low resistance connection. Contact fingers shall be of a floating and self-aligning design to allow solid seating onto the vertical bus bars.
c. Starters NEMA size 4 and larger shall bolt directly to the
vertical bus bars, circuit breakers rated higher than 225 amps shall also bolt directly to the bus bars.
9. Unit Doors
a. Each unit shall have a door securely mounted with rugged
concealed-type hinges which allow the door to swing open a minimum of 112 for unit maintenance and withdrawal. Doors shall be fastened to the structure so that they remain in place when a unit is withdrawn and may be closed to cover the unit space when the unit has been temporarily removed. Doors shall be held closed with captive type screws which engage self-aligning cage nuts. These screws shall provide at least two threads of engagement to hold doors closed under fault conditions. Each unit door shall be interlocked with its disconnect mechanism to prevent the door from opening when the unit is energized. A defeater mechanism shall be provided for defeating this interlock by authorized personnel. Removable door panels held with captive type screws shall be provided on starter unit doors for mounting push buttons, selector switches or pilot lights. Blank door panels capable of accepting future pilot devices shall be furnished when pilot devices are not originally specified for starter units. Each starter unit door shall house an external low-profile overload reset button for resetting the overload relay in the event of tripping.
10. Unit Support Pan
a. Each plug-on unit shall be supported and guided by a tilt
and lift-out removable pan so that unit rearrangement can be easily accomplished. For easy unit installation and rearrangement, transfer of this unit support pan from one location to another shall be accomplished with ease after the control unit and door have been removed.
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11. Unit Saddles
a. Each plug-on unit shall have a saddle of 14 gauge hot rolled steel designed and constructed to physically isolate the unit from the bus compartment and adjacent units. Saddlers shall be equipped with captive, self-aligning mounting screws which shall hold the unit securely in place during shipment. Flanged edges shall be provided on each saddle to facilitate unit removal.
12. Disconnect Operators
a. An external operator handle shall be supplied for each
switch or breaker. This mechanism shall be engaged with the switch or breaker at all times regardless of unit door position to prevent false circuit indication. The operator handle shall be color coded to display red in the “ON” position and black in the “OFF” position. The operator handle shall have a conventional up-down motion and shall be designed so that the down position will indicate the unit is “OFF”. For added safety it shall be possible to lock this handle in the “OFF” position with up to three padlocks. The operator handle shall be interlocked with the unit door to prevent switching the unit to “ON” while the unit door is open. A defeater mechanism shall be provided for the purpose of defeating this interlock by a deliberate act of an electrician should he desire to observe the operation of the operator handle assembly or the unit components. Operators shall not be higher than 6'-6" above finished floor elevation, as installed.
13. Wiring
a. The motor control center wiring shall be NEMA Class II, Type
B.
b. All wiring to the terminal strips from outside the MCC shall be made with spade type terminals of the proper size and rating for the wire used. Pull apart terminal blocks shall be provided in unit spaces of motor starters that contain field wiring energized from a remote source to comply with NEC Article 430-74.
c. Each individual control conductor must be labeled and the
labels must match the shop drawings and O&M manuals.
14. Finish
a. The finish shall be manufacturer’s standard gray enamel applied over a rust inhibiting phosphate primer.
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15. Optional Modifications and Accessories
a. Additional modifications and accessories shall be as listed
and specified on the Contract Drawings.
16. Identification
a. A control center identification nameplate describing section catalog numbers and characteristics shall be fastened on the vertical wire trough door of every section. Each control center unit shall have its own identification nameplate fastened to the unit saddle. These nameplates shall have suitable references to factory records for efficient communication with supplier. Each control center unit shall also have an engraved Bakelite nameplate fastened to the outside of each unit door inscribed as written on the Contract Drawings for ease in identification and for making changes when regrouping units. An overall structure nameplate is also required.
17. Metering
a. Provide power monitor in each MCC as specified below.
C. Starters and Overcurrent Protective Devices
1. Magnetic Starters
a. Magnetic starters shall be furnished in all combination
starter units unless otherwise indicated on Contract Drawings. Starter Sizes 1 through 4 shall employ the use of a bell-crank lever design to transform vertical action of the armature into horizontal action of the contact carriers and thus minimize contact bounce and produce extra long contact life. Thermal overload relays on starters shall be ambient temperature compensated bimetallic type with selector for either auto or manual reset. Overload heater units shall be provided in each starter unit. Overload relay heater schedules shall be provided on each starter unit.
2. Circuit Breakers
a. All breakers sized 400A frame and larger shall have
adjustable trip elements with the following adjustments: Long time pickup & delay, short time pickup & delay, Instantaneous, Ground fault pickup & delay.
b. Type FA, KA, LA, MA and PA molded case circuit breakers
shall be furnished in all starter and branch feeder units
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using circuit breakers as a disconnect means. All circuit breakers will have a push-to-trip test feature for testing and exercising the circuit breaker trip mechanism.
3. Starters shall conform to requirements listed under individually
mounted Motor Control Devices, hereinafter.
D. Lighting Panelboards
1. Lighting panelboards shall be as specified in other section of this Division. Lighting panelboard unit doors shall be held closed with captive latches that may easily be operated without the use of tools, i.e., wing nuts, handle, etc.
E. Transformers
1. 480 volt primary, 120/240 volt or 120/208 volt secondary
transformers shall be as specified in other sections of this Division.
F. Power Factor Correction Capacitors
1. UL listed power factor correction capacitors shall be provided in the Motor Control Centers where indicated on the Contract Drawings, wired into each motor starter for all 3 phase process equipment as indicated in the one-line diagram in the Drawings, so that they are switched with the motors. They shall be wired in accordance with the NEC and sized based on proper motor rpm for correction to 90-95 percent, from no load power factor. Totally enclosed capacitors mounted atop Motor Control Centers shall be utilized in those instances where their addition within unit spaces would substantially increase the length of structures from that shown on the Contract Drawings. Capacitors shall be fused, equipped with discharge resistors and pilot light assemblies visible without opening any doors to indicate blown fuses.
G. Electronic Circuit Monitors
1. Circuit Monitor Installation
a. Electronic circuit monitors shall be installed by the
equipment manufacturer for all circuits as indicated on the Contract Drawings.
b. All control power, CT, PT, and communications wire shall be
factory installed and harnessed within the lineup.
c. Where external circuit connections are required, terminal blocks shall be provided and the manufacturer’s shop drawings must clearly identify the interconnection requirements, including wire type, to be used.
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d. This equipment shall be Square D Power Logic, Allen-
Bradley, General Electric, or equal.
2. Circuit Monitor Characteristics
a. The electronic circuit monitors shall accept inputs from industry standard instrument transformers (1 20 VAC secondary PTs and 5A secondary CTs).
b. The current and voltage signals shall be digitally sampled at
a rate high enough to provide accurate rms sensing and valid data for waveform analysis beyond the 30th harmonic (fundamental of 60 Hz).
c. All setup parameters required by the circuit monitors shall
be stored in nonvolatile memory (no battery backup) and retained in the event of a control power interruption.
d. The circuit monitor shall also maintain, in nonvolatile
memory, a maximum and minimum value for each of the instantaneous values reported, as well as the time and date of the highest peak for all of the peak demand readings.
e. The circuit monitors shall be equipped with an integral LED
display to provide local access to metered quantities. f. The following instantaneous readings shall be reported by
the circuit monitor:
(1) Frequency (2) Temperature (3) Current, per phase rms (4) Current, 3-phase average rms (5) Current, apparent rms (6) Voltage, phase-to-phase & phase-to-neutral (7) Power factor, per phase (8) Power factor, 3-phase total (9) Real power, 3-phase total (10) Reactive power, 3-phase total (11) Apparent power, 3-phase total (12) Total Harmonic Distortion (current and voltage)
g. The following demand readings shall be reported by the
circuit monitor:
(1) Average demand current, per phase (2) Peak demand current, per phase (3) Average demand, real power (4) Predicted demand, real power
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(5) Peak demand, real power
h. The following energy readings shall be reported by the circuit monitor:
(1) Accumulated energy (2) Accumulated reactive energy
3. Waveform Capture Capability
a. All electronic circuit monitors shall include waveform
capture capability.
b. Upon a user-initiated command, the circuit monitor shall capture and store, in nonvolatile memory, 3-phase voltage and current samples consisting of 256 data points each.
c. These data points shall represent at least four cycles of each
current or voltage waveform.
d. These samples shall be evenly gathered from three voltage and three current phases such that the original power signals with proper magnitude and phase relationships may be reconstructed.
e. It shall be possible to recreate the original power signal
from the stored data with sufficient accuracy such that steady-state power harmonic analysis will provide valid information on harmonic content for up to the 30th harmonic of the fundamental power frequency.
4. Connecting and Networking Circuit Monitors
a. All data and calculated values stored in the circuit monitor
shall be accessible to external devices by means of an Ethernet communications port built into the circuit monitor. Either Ethernet/IP or Modbus/TCP protocol shall be utilized.
5. System Display
a. The circuit monitor shall include an LED readout which will
allow local display of the following electrical parameters:
(1) Current, per phase rms (2) Voltage, phase-to-phase & phase-to-neutral (3) Real power, 3-phase total (4) Reactive power, 3-phase total (5) Apparent power, 3-phase total (6) Power factor, 3-phase total & per phase (7) Frequency
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(8) Peak demand current, per phase (9) Peak demand, real power (10) Accumulated Energy, (MWH and MVARH) (11) Total harmonic distortion
b. Reset of the following electrical parameters shall also be
allowed from the front of the circuit monitor:
(1) Peak demand current (2) Peak demand power (3) Energy (MWH) (4) Reactive energy (MVARH)
c. Circuit monitor setup for system requirements shall be
allowed from the front of the circuit monitor. Setup provisions shall include:
(1) CT rating (xxxx:5) (2) PT rating (xxxx:120) (3) System type (3-wire and 4-wire) (4) Demand interval (5-60 min.)
d. All reset and setup functions shall be protected to prevent
unauthorized/accidental changes.
e. System display units shall be installed by the manufacturer in the equipment as indicated on the drawings.
f. The system display units shall be flush mounted on door
panels.
g. The system display unit shall utilize a 4-line by 20-character, high contrast LCD technology display with backlighting to provide high reliability and superior readability in all light conditions.
2.04 INDIVIDUALLY MOUNTED MOTOR CONTROL DEVICES (480, 240, OR 120 VOLT)
A. General
1. All motor control equipment shall be new and the product of 1 manufacturer. All individually mounted disconnects, push-button stations, latchout stations, starters, etc., indoors shall be mounted on a 1 inch galvanized unistrut, 1 inch Kindorf channel, or equal to provide an air space at rear. Outside mounted equipment shall utilize 1 inch aluminum strut as required in 16070.
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B. Starters
1. General
a. All starters shall be of the voltage rating, type, and sized for the motor size shown in these Specifications and/or on the Contract Drawings. For enclosure type see the system operation description and/or the Contract Drawings. All starters shall be of the magnetic type. Should a piece of electrically driven equipment be furnished with a larger motor than shown on the Contract Drawings, the proper size combination starter shall be provided for the equipment supplied, at no extra cost to the Owner.
b. See the Contract Drawings for the auxiliary equipment to be
furnished and/or Section 16900 - Controls of this division. Maximum control voltage shall be 120 volts, a-c. Minimum starter size shall be NEMA Size 1.
2. Overloads
a. Each starter shall have a thermal overload device in each
ungrounded leg. The overload shall be of the “Ambient compensated Bi-metallic”, thermal element type. All overloads shall be of the manual reset type and shall be reset without opening the starter enclosure. Heaters will be sized for the proper temperature rise of the motor that it is being used on. Heaters for general service shall be of the standard trip type. Adjustable Overload Relay Thermal Units are not allowed. All motors, 15 horsepower and over, require thermal elements embedded in the windings. See Motor Specifications, this division.
3. Contactors
a. All contactors for motor starters shall be of the a-c magnetic
type with “undervoltage” protection when used in conjunction with momentary contact push-button control and “undervoltage” release when used with maintained contact push-button control.
b. Contactor size shall be in accordance with NEMA Standards
for the motor controlled and shall be horsepower rated.
c. Contacts shall be of the heavy duty silver-to-silver type and shall be totally enclosed in individual arc quenching chambers. Contacts shall be easily accessible for replacement.
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d. The contactor coil shall be of the vacuum impregnated or epoxy resin type, moisture resistant and corrosion proof.
C. Control Stations
1. General
a. Control stations shall be heavy duty, maintained or
momentary contact type, as noted on the Contract Drawings. Contacts shall be silver alloy, double break type. The number and marking of controls shall be as shown on the Contract Drawings. Enclosures shall be rated as noted on the Contract Drawings. All control stations shall operate on 120 volt, a-c maximum, unless otherwise designated on the Contract Drawings.
2. Maintained Contact
a. Maintained contact control switches shall be marked “On”
and “Off”. The button pushed shall remain in and push the other button out until the other button is pushed. In general, they are to be used for hand control of motors which have to operate continuously and restart whenever power is off then resumed, without any manual operator. This is needed for motors which have to operate continuously in the absence of an operator.
3. Momentary Contact
a. Momentary contact control push-button switches shall be
marked “start” and “stop”. Pushbuttons shall spring out whenever pushed. If the circuit is dropped for any reason, operation cannot be resumed until a “start” push-button is pushed. In general, they are to be used for hand control of motors which are desired to operate intermittently in the presence of the operator and stop and start independently from more than one parallel control location.
D. Circuit Breakers
1. Circuit breakers shall be molded case type. Trip elements of multi-
pole breakers shall be effectively insulated from one another. Multi-pole breakers shall be designed so that an overload on any one pole shall open all poles simultaneously.
2. The breaker operating mechanism shall be the quick-make, quick-
break type and shall be entirely trip free to prevent the contacts being held in a closed position against a short circuit.
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3. Breakers not used with motor starters shall be of the thermal magnetic type with a thermal bimetallic element for time delayed overload protection and a magnetic element for short circuit protection.
4. The breaker shall be trip indicating with the trip position midway
between the “On” and “Off” positions. 5. Breakers for combination starters shall be 100 amp frame or
larger. All breakers for combination starters shall be MAGNETIC (MAG-GUARD) TYPE and have an adjustable magnetic trip element of the motor circuit protector type.
6. Breakers for combination starters shall be F frame or larger. All
breakers shall have adjustable magnetic trip elements. Circuit breakers K frame and larger shall have interchangeable thermal-magnetic trip elements.
E. Safety Switches
1. Safety switches shall be of the heavy-duty industrial, quick make,
quick-break type. Ratings shall correspond to that of the equipment in which circuit it is used, fuses sized as shown on the Contract Drawings. All safety switches at motor locations are of the nonfused type unless otherwise noted.
2. Safety switches shall have a mechanical door interlock to prevent
the door from being opened with the switch in the on position and facilities for locking it in the closed or open position. Enclosures for outside installation shall be NEMA 3R and inside installation, NEMA 1, unless otherwise designated in Section 16900 of this division and/or on the Contract Drawings.
3. Safety switches shall be UL listed and shall conform to NEMA
Standards. NEMA 4X enclosed safety switches where called for shall be stainless steel, or fiberglass. Fiberglass is required in corrosive areas such as chemical room and filter building.
4. NEMA 1 enclosed switches shall be phosphate coated or
equivalent, code gauge steel with baked enamel finish.
5. Safety switches shall include auxiliary contacts to disconnect any motor control circuit power indicated on the Drawings as extending to the motor terminal box (for motor space heaters, embedded winding thermostats, etc.)
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F. Selector Switches
1. Hand-off-automatic type selector switches shall be of oil-tight construction and shall have 3 positions. The switch must not have a spring loaded return. It shall be of the “quick-make”, “quick-break” type.
2. Selector switches for corrosive areas and water/wastewater plants shall be 30mm, NEMA 4X corrosion resistant, Square D Class 9001 Type SK or equal.
G. Pilot Lights and Pushbuttons
1. Pilot lights for corrosive areas and water/wastewater plants shall be
30mm, push-to-test, LED-style, NEMA 4X corrosion resistant, Square D Class 9001 Type SK or equal.
2. Pushbuttons for corrosive areas and water/wastewater plants shall be 30mm, NEMA 4X corrosion resistant, Square D Class 9001 Type SK or equal.
H. Manual Motor Starting Switches
Manual motor starting switches for the control of fractional horsepower motors shall be single pole, and shall be provided with a thermal heater of the correct size for the load controlled. Each starting switch shall be mounted where shown on the Contract Drawings. The motor starting switch shall be NEMA rated per the drawings. It shall be fiberglass in chemical or corrosive areas.
I. Limit Switches
Where limit switches are called for in these Specifications, they shall be the double pole, oil-tight type, suitable for the type mounting required.
J. Timing Relays
Time delay relays shall have an adjustable timing range as shown on the Contract Drawings. The time delay shall be after energizing timer coil. Timing relays shall be Agastat, Square D, or equal.
K. Control Relays
Control relays shall be magnetic, general purpose, "ice cube" type with 3-pole (minimum), double throw contacts rated at 5 amperes (minimum), 120 volts (minimum). Coils shall be rated to operate at the indicated control voltage. Provide proper bases, mounting track, etc. for a complete installation. All relays shall be have a retainer clip, manual operator, and pilot light. Coils connected to solid-state digital outputs shall have transient surge protection.
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PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. Motor Control Centers
1. Ends of MCC(s) shall be closed with 1/4" mesh hardware cloth and galvanized or aluminized insect screen or sill covers to prevent the entrance of rodents and large insects into the MCC housing(s).
2. Each MCC shall be provided with a 4" high concrete pad.
3. One inch air space (min.) shall be allowed between back of MCC(s)
and wall surface.
4. Lifting-eyes in tops of MCC(s) section shall be removed (and retained) and the threaded openings closed with stainless cap screws and plastic washers or plastic seals provided for that purpose by the MCC(s) manufacturer.
5. In installations where conduit runs to electrical equipment
emanate from the top of MCC(s) there shall be provided additional wiring space in the form of metal trough(s) of the same metal housing(s) dimensions and details. Trough(s) shall be provided by the manufacturer of the MCC(s).
3.02 EXTRA STOCK/SPARE PARTS
A. Provide the following spare parts:
10 fuses of each type/amperage used
3 pilot light LEDs for each unique pilot light provided
1 control transformer for each size utilized 3.03 MANUFACTURER STARTUP SERVICES
A. Provide a manufacturer representative to commission and startup the equipment. This includes the configuration and programming of the equipment, and furnishing any studies or engineering necessary to properly configure or program the equipment. Submit a field report and as-built documentation.
END OF SECTION
***
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SECTION 16442
PANELBOARDS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. This section of the Technical Specifications includes furnishing all labor, materials, equipment, and incidentals required for the installation of all lighting and distribution panelboards as hereinafter specified and as shown on the Contract Drawings.
B. All panelboards shall be by the same manufacturer.
C. Circuit breakers of size and type shown on Contract Drawings and
described herein shall be provided with the panelboards. CIRCUIT ASSIGNMENTS NOTED ON THE DRAWINGS MUST MATCH CIRCUIT ASSIGNMENTS IN ALL PANELBOARDS, AND MUST BE SHOWN IN SHOP DRAWINGS.
1.02 SUBMITTALS A. Shop Drawings, including Layout Drawings and complete over current
protection devices descriptive literature shall be submitted to the Engineer for review.
B. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Product literature with one or more styles/configurations for a single product shall have a written description of use for each of the styles/configurations represented on the literature. For example: Device boxes – Styles shall be listed as: For masonry walls, for electrical devices, for ceiling mounted light fixtures, etc
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. “Square D”, “Siemens”, “General Electric,” “Eaton.” Substitution of alternate equipment shall be submitted for review to Engineer 10 days prior to bid.
2.02 EQUIPMENT
A. Rating
1. Panelboard ratings shall be as shown on the Contract Drawings. All panelboards shall be rated for the intended voltage.
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B. Standards
1. Panelboards shall be in accordance with the Underwriter Laboratories, Inc. “Standard for Panelboards” and “Standard for Cabinets and Boxes” and shall be so labeled where procedures exist. Panelboards shall also comply with NEMA Standard for Panelboards and the National Electrical Code.
C. Panelboard Construction (NEMA 1)
1. Interiors
a. All interiors shall be completely factory assembled with
circuit breakers, wire connectors, etc. All wire connectors, except screw terminals, shall be of the anti-turn solderless type and all shall be suitable for copper or aluminum wire of the sizes indicated.
b. Interiors shall be so designed that circuit breakers can be
replaced without disturbing adjacent units and without removing the main bus connectors and shall be so designed that circuits may be changed without machining, drilling or tapping.
c. Branch circuits shall be arranged using double row
construction except when narrow column panels are indicated. Branch circuits shall be numbered by the manufacturer.
d. A nameplate shall be provided listing panel type, number of
circuit-breakers and ratings.
2. Bussing
a. Bus-bars for the mains shall be of copper. Full size neutral bars shall be included. Bus-bar taps for panels with single pole branches shall be arranged for sequence phasing of the branch circuit devices. Bussing shall be braced throughout to conform to industry standard practice governing short circuit stresses in panelboards. Phase bussing shall be full height without reduction. Cross connectors shall be copper.
b. Neutral bussing shall have a suitable lug for each outgoing
feeder requiring a neutral connection.
c. Spaces for future circuit-breakers shall be bussed for the maximum device that can be fitted into them.
d. Separate neutral and ground bus shall be provided,
insulated and isolated from each other.
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3. Boxes
a. Recessed boxes shall be made from galvanized code gauge
steel having multiple knockouts, unless otherwise noted. Surface mounted boxes shall be painted to match the trim. Boxes shall be of sufficient size to provide a minimum gutter space of 4 inches on all sides.
b. Surface mounted boxes shall have an internal and external
finish as hereinafter specified. Surface mounted boxes shall be field punched for conduit entrances.
c. At least 4 interior mounting studs shall be provided.
4. Trims
a. Hinged doors covering all circuit-breaker handles shall be
included in all panel trims.
b. Doors shall have semi flush type cylinder lock and catch, except that doors over 43 inches in height shall have a vault handle and 3-point catch, complete with lock, arranged to fasten door at top, bottom and center. Door hinges shall be concealed. Two keys shall be supplied for each lock. All locks shall be keyed alike; directory frame and card having a transparent cover shall be furnished on each door.
c. The trims shall be fabricated from code gauge sheet steel.
d. All exterior and interior steel surfaces of the panelboard
shall be properly cleaned and finished with manufacturer’s standard gray paint over a rust-inhibiting phosphatized coating. The finish paint shall be of a type to which field applied paint will adhere without cracking or peeling.
e. Trims for flush panels shall overlap the box by at least 3/4
inch all around. Surface trims shall have the same width and height as the box. Trims shall be fastened with quarter turn clamps.
D. Overcurrent Protective Devices (Circuit Breakers)
1. Panelboards shall be equipped with circuit-breakers with frame size
and trip settings as shown on the Contract Drawings.
2. Circuit-breakers shall be molded case, bolt-in, thermal-magnetic trip.
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3. Single Pole Circuit Breakers shall not be tied together to fabricate double or triple pole circuit breakers.
4. Circuit-breakers used in 120/208 volt panelboards shall have an
interrupting capacity of not less than 10,000 amperes, RMS symmetrical.
5. Circuit-breakers used in 480 volt panelboards shall have an
interrupting capacity of not less than 100,000 amperes, RMS symmetrical.
6. GFCI (ground fault circuit interrupter) shall be provided for circuits
where indicated on the Contract Drawings. GFCI units shall be 1-pole, 120 volt, molded case, bolt-on circuit-breakers, incorporating a solid state ground fault interrupter circuit insulated and isolated from the circuit-breaker mechanism. The unit shall be UL listed Class A Group I device (5 milliamp sensitivity, 25 millisecond trip time), and an interrupting capacity of 10,000 amperes RMS.
7. Trip elements of multi-pole breakers shall be effectively insulated
from one another. Multi-pole breakers shall be designed so that an overload on any pole shall open all poles simultaneously.
8. The breaker operating mechanism shall be the quick-make, quick-
break type and shall be entirely trip free to prevent the contacts being held in a closed position against a short circuit.
9. Breakers shall have a thermal bimetallic element for time delayed
overload protection and a magnetic element for short circuit protection.
10. The breaker shall be trip indicating with the trip position midway
between the “On” and “Off” positions.
11. Breakers for power distribution panels shall be F frame or larger. All breakers rated above 225 amps shall have interchangeable magnetic trip elements.
12. All breakers shall be UL listed, and conform to requirements of
NEMA Standards. PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. Boxes for surface mounted panelboards shall be mounted so there is at least ½ inch air space between the box and the mounting surface.
B. Circuit directories shall be typed giving location and nature of load
served.
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C. Each panelboard shall be nameplated with plastic engraved nameplates
stating the panel’s name, voltage, and the name of panel serving the panel. Nameplates shall be secured by use of stainless steel screws.
END OF SECTION
***
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SECTION 16444
SOLID STATE REDUCED VOLTAGE MOTOR CONTROL PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Provide all labor, materials, equipment, and services required to furnish and install solid state reduced voltage motor starters as shown on the Contract Drawings and as specified herein.
1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Divisions 0 and 1.
B. Section 16440 – Motor Control C. Section 16900 – Control Panels
1.03 SUBMITTALS
A. Submit shop drawings including descriptive literature, enclosure fabrication details, dimensions, weights, component layout drawings, front enclosure layout and nameplate engraving, enclosure paint systems and color, materials of construction, and wiring schematics, all tailored to this project.
B. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Wiring diagram must be specific to this project.
1.04 SYSTEMS DESCRIPTION
A. Motors as indicated in the Contract Drawings shall be provided with solid state starters as specified herein to limit power line disturbances and voltage drop on motor start-up.
B. The Contractor shall be responsible for coordinating the starter with
driven equipment ratings and assuring compatibility. 1.05 QUALIFICATIONS
A. The equipment shall be manufactured by Allen Bradley, Eaton, Square D, or equal.
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1.06 WARRANTY
A. This equipment shall have a warranty which shall be one (1) year, and shall run concurrently with the Contractor warranty on the entire project.
PART 2 - PRODUCTS 2.01 GENERAL DESCRIPTION
A. The soft start shall utilize a thyristor (SCR) bridge consisting of at least
two SCRs per phase to control the starting and stopping of industry standard motors (NEMA Design B).
B. The soft start shall provide torque control for linear acceleration without external feedback independent of motor load or type of application. The gating of the thyristors shall be controlled in such a manner to ensure smooth and stable acceleration ramp.
C. The soft start shall be controlled by a microprocessor that continuously monitors the current and controls the phasing of the SCRs. Analog control algorithms shall not be allowed.
D. All soft start power ratings will utilize the same control module.
E. An external shorting contactor is required. Protective features and deceleration control options integral to the soft start shall be available even when the external shorting contactor is employed.
2.02 MOTOR DATA
A. Verify actual motor nameplate values prior to manufacturing of the soft starts.
2.03 RATINGS
A. The soft start shall be designed to operate in an ambient temperature 0 degrees Celsius to 50 degrees Celsius. Manufacturer literature shall indicate any temperature derating required, and Contractor shall conform to this requirement.
B. Storage temperature range shall be -25 degrees Celsius to 70 degrees Celsius.
C. Soft starter shall be able to withstand relative humidity up to 93% at 40 degrees Celsius, non-condensing.
D. The soft start shall be designed to operate in altitudes up to 2000 feet.
E. The soft start shall be capable of operation within +/-10% of nominal voltage rating.
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F. The soft start shall be designed for 60 Hz. Frequency tolerance shall be +/- 5% when starting and +5% or -15% during steady state operation.
G. The soft start shall be capable of supplying 300% of rated full load current for 30 seconds at maximum ambient temperature.
H. The SCRs shall have a minimum P.I.V. rating of 1400 Vac. Lower rated SCRs with protection by MOVs are not acceptable.
2.04 ADJUSTMENTS AND CONFIGURATIONS
A. All dialogue functions, display units, remote functions, terminal blocks, configuration switches and adjustment potentiometers shall be accessible on the front of the control module. Exposure to control circuit boards or electrical power devices during routine adjustments shall be prohibited.
B. Digital indication shall provide, as a minimum, the following conditions:
1. Soft start status - ready, starting/stopping, run.
2. Motor status - current, torque, thermal state, power factor.
3. Fault status - Motor thermal overload, starter thermal fault, phase fault, frequency fault, supply fault, locked rotor fault, motor underload, max start time exceeded, external fault, serial link fault, phase inversion, internal failure, overcurrent.
C. The starter shall be preset to the following, however these settings shall be adjusted onsite by the Contractor for this specific project:
1. Torque acceleration ramp of 10 seconds.
2. Current limitation to 300% of the motor full load current rating.
3. Class 10 overload protection.
4. Motor current preset per NEC and UL tables for standard HP motors.
D. A digital keypad shall be utilized configure the following operating parameters as required:
1. Motor full load amps adjustable from 50 to 130% of the controller's rating.
2. Current limitation on starting adjustable from 1.5 to 7.0 times rated motor current, not to exceed 5.0 times the controller rating.
3. Torque ramp adjustable from 1 to 60 seconds.
4. Initial torque adjustable from 10 to 100% of nominal motor torque.
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5. Torque limit adjustable from 10 to 200% of nominal motor torque.
6. Maximum start time adjustable from 10 to 999 seconds.
7. Voltage boost adjustable from 50 to 100% of the nominal supply voltage.
8. Selection of freewheel, soft stop or braking.
9. Adjustable soft stop torque ramp time from 1 to 60 seconds.
10. Threshold to change to freewheel following a soft stop from 0 to 100% of the nominal motor torque.
11. Braking torque level adjustable from 0 to 100% effectiveness.
12. Selection of Class 2, 10, 10A, 15, 20, 25 or 30 motor thermal overload protection.
E. A digital keypad shall be utilized configure the following controller parameters as required:
1. Selectable automatic reset operation.
2. Cancellation of the torque control loop for multi motor installations.
3. Adjustment of the stator loss estimation for specialty motors.
4. Assignment of controller inputs and outputs.
5. Activation of phase reversal protection.
6. Reset of motor thermal state.
7. Return to factory settings.
8. Activation of test mode for use with low power motors.
9. Indication of elapsed time in hours of starting, running and stopping.
F. Output relays shall provide the following status indications:
1. One form A (N.O.) and one form B (N.C.) minimum for indication of fault or control of an isolation contactor.
2. One form A (N.O.) for indication that torque ramp is complete and current is below 130% motor FLA (End of start).
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G. Additional inputs and outputs shall be available to provide the following status indications:
1. One logic input for force to freewheel, indication of external fault, force to local control, control of cascading motors, or external motor overload reset.
2. One logic output for indication of motor thermal overload pre-alarm or presence of motor current and one logic output to indicate overcurrent alarm.
3. One analog output shall be available for 4 - 20 or 0 - 20 milliamp indication of motor current, torque, thermal state or power factor.
H. Relay and I/O functions listed above must be isolated with respect to common.
2.05 PROTECTION
A. A microprocessor controlled thermal protection system shall be included which continuously calculates the temperature-rise of the motor and soft start and provides:
1. An overload pre-alarm which indicates by relay contact that the motor has exceeded its rated temperature rise by 110%. This function shall be annunciation only.
2. A thermal fault condition which stops the motor if the temperature-rise exceeds 120% of the motor thermal capability.
3. An analog electronic circuit with a time constant adjustable to the motor's thermal cooling time constant ensuring the memorization of the thermal state even after power supply disconnection or shorting out of the power semiconductors.
B. The soft start shall provide phase loss, phase reversal, underload, stall, and jam protection.
C. The integral protective features shall be active even when the external shorting contactor is bypassing the SCRs.
2.06 CONTROLS
A. The soft start's control circuit shall be completely independent of the power circuit.
B. A special “pump control” algorithm shall be included, developed specifically to control starting/stopping of centrifugal pumps.
C. An Ethernet port shall be provided for soft starter communications and monitoring. Ethernet/IP or Modbus TCP protocol is acceptable.
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2.07 MISCELLANEOUS
A. Additional devices to be furnished and installed with the solid state motor starter shall be as specified in Sections 16440 or 16900 and as shown on the control schematic provided in the Contract Drawings.
2.08 ENCLOSURES
A. Provide in MCC as specified in 16440 with control unit mounted on external door of MCC.
B. The enclosed product shall be provided complete with one of the
following overcurrent protective devices (OCPDs) for Type 1 short circuit protection:
1. Magnetic only circuit breaker. Short circuit withstand rating shall be based on the motor horsepower as defined in UL 508.
C. Control circuitry shall be provided as indicated on the Drawings.
PART 3 - EXECUTION 3.01 EXAMINATION AND PREPARATION
A. Solid state motor starters shall be treated as specified in General and Special Conditions.
3.02 INSTALLATION/APPLICATION/ERECTION
A. Installation shall comply with applicable codes and manufacturer’s recommendations and instructions.
3.03 START-UP AND TRAINING
A. The manufacturer shall furnish the services of a factory technician to assist the Contractor in installation as required and the factory technician shall perform all adjustments and setup prior to operation. The settings shall be performed at the same time the driven equipment start-up personnel are on site to be sure all items operate well together. Furnish a written report to the Engineer on this start-up.
B. The start-up personnel from the factory shall provide Owner personnel
with training as outlined in Section 16010. 3.04 TOOLS AND SPARE PARTS
A. Any special tools needed by the Owner for the future maintenance shall be provided as part of the lump sum bid.
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B. Five (5) spare fuses shall be provided for each size/type used in this equipment.
C. One (1) spare pilot lamp/LED for each type used.
D. One (1) spare control circuit transformer of each type/size used shall be
provided.
E. One (1) complete set of spare SCR assemblies (for all 3 phases) shall be provided for each size of starter.
END OF SECTION
***
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SECTION 16455
CABLE TRAY PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Furnish and install cable tray systems complete, of straight sections, fittings, and accessories as defined in the latest NEMA standards publication VE-1. Size tray per NEC requirements.
B. The general rating of trays shall be as shown on the Contract Drawings.
C. Cable tray provided shall be UL listed as suitable as an equipment
grounding conductor. 1.02 RELATED WORK
A. Special requirements for materials and equipment are given in Division 0 and 1.
B. Special sequence or schedule requirements are found in the Summary of
Work. 1.03 QUALIFICATIONS
A. These materials shall be furnished by a single manufacturer who is experienced, reputable, and qualified in the manufacture of cable trays. It shall be manufactured by Square D, B-Line, Husky-Burndy, or equal.
1.04 SUBMITTALS
A. Shop drawings and other items needed to establish compliance with the Contract Drawings and these Specifications shall be submitted to the Engineer in accordance with Project General and/or special Conditions. As a minimum, submittals shall include descriptive literature, dimensions, weights, layout drawings, materials of construction, NEMA load class, rung spacing, depth, and shall include accessories/fittings.
B. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles / configurations represented on the literature.
1.05 WARRANTY
A. These materials shall be warranted for one year concurrent with the Contractor provided warranty.
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PART 2 - PRODUCTS 2.01 MATERIALS AND FINISHES
A. Straight section and fitting side rails and rungs shall be extruded from Aluminum Association Alloy 6063. Fabricated parts shall be made from Alloy 5052.
2.02 TRAY TYPES
A. Ladder
1. Ladder type trays shall consist of two longitudinal members (side rails) with transverse members (rungs) welded to the side rails. Rung spacing in radiused fittings shall be measured at the center of the tray’s width. Rungs shall have a minimum cable bearing surface of 7/8" with radiused edges. No portion of the rungs shall protrude below the bottom plane of the side rails.
2.03 SPLICE PLATES
A. Splice plates shall be the bolted type, using either square neck or ribbed-neck carriage bolts and serrated flange lock nuts. The resistance of fixed splice connections between an adjacent section of tray shall not exceed 0.00033 ohm. The cable tray shall be designed so that a splice plate located anywhere along the span shall not decrease the strength of the cable tray system.
B. Splice plates shall be furnished with straight sections and fittings.
2.04 ACCESSORIES
A. Covers and other special accessories shall be furnished as required to protect, support, and install the cable tray system.
2.05 LOADING CAPACITIES
A. Cable tray shall be installed to meet NEMA class descriptions for a safety factor of 1.5.
B. Cable tray shall be made to manufacturing tolerances as specified by
NEMA. PART 3 - EXECUTION 3.01 EXAMINATION AND PREPARATION
A. Cable tray and accessories shall be treated as specified in General and Special Conditions.
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3.02 INSTALLATION/APPLICATION/ERECTION
A. Installation shall comply with applicable codes and manufacturer recommendations and instructions.
B. All trapezes, hangers, and supports shall be provided as required, by the
Contractor, and materials shall be compatible and similar to the tray furnished.
C. Finish and install necessary restraints and sway bracing to comply with
KBC requirements for applicable seismic zone. 3.03 FIELD PAINTING
A. Tray shall not be painted. Natural finish is acceptable.
END OF SECTION
***
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SECTION 16460
TRANSFORMERS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Transformer locations and size shall be as shown on the Contract Drawings, as specified herein
B. All transformers shall be non-PCB type.
1.02 SUBMITTALS
A. Submit product data on all equipment. Provide a schedule describing the application of each transformer including item served, size and voltage of transformer.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Square D, General Electric, Siemens, Cutler Hammer, or equal. 2.02 FABRICATION
A. General Purpose Dry-Type Transformers
1. Single phase transformers shall be 480 or 600 volt primary and 120/240 volt secondary. Three phase transformers shall be 480 or 600 volts delta primary and 208 Y/120 or 240 volt delta secondary. Transformers 25 KVA and larger shall have a minimum of 4 (2 above, 2 below) 2-½ percent full capacity primary taps.
2. Transformers shall be 150 degrees Celsius temperature rise above
a 40 degrees Celsius ambient. All insulating materials are to be in accordance with the latest NEMA Standards for a 220 degrees Celsius UL recognized insulation system.
3. Transformer coils shall be of the continuous wire wound
construction and shall be impregnated with non-hygroscopic, thermo-setting varnish. The coils shall also have a final wrap of electrical insulating material to prevent mechanical injury to the wire as well as increasing the electrical breakdown strength.
4. All cores shall be constructed of high grade, non-aging silicon
steel with high magnetic permeability, and low hysteresis and eddy current losses. Magnetic flux densities are to be kept well below
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the saturation point. The core laminations shall be clamped together with steel angles. The completed core and coil shall then be bolted to the base of the enclosure but isolated from the base by means of rubber, vibration absorbing mounts. There shall be no metal-to-metal contact between the core and coil to the enclosure. On transformers 500 KVA and smaller, the vibration isolation system shall be designed to provide a permanent fastening of the core and coil to the enclosure. To further facilitate vibration and noise isolation, the final section of conduit to the transformer shall be flexible.
5. Transformers 25 KVA and larger shall be in heavy gauge, sheet
steel, ventilated enclosures. The ventilating openings shall be designed to prevent accidental access to live parts in accordance with UL, NEMA, and National Electrical Code Standards for ventilated enclosures. Transformers 25 KVA through 75 KVA shall be designed so they can either be floor or wall mounted. Above 75 KVA they shall be of the floor mounted design.
6. The entire transformer enclosure shall be degreased, cleaned,
phosphatized, primed, and finished in the same color as the motor control equipment. For more details see Division 9 of these Specifications.
7. The maximum temperature of the top of the enclosure shall not
exceed 50 degrees Celsius rise above a 40 degrees Celsius ambient.
8. The core of the transformer shall be visibly grounded to the
enclosure by means of a flexible grounding conductor sized in accordance with NEMA and NEC Standards.
9. The transformer shall be marked “DANGER HIGH VOLTAGE” with
labels specified in the section on marking, this Division.
10. The transformers shall be manufactured to requirements of applicable standards, especially as they apply to noise level and surface temperatures.
PART 3 - EXECUTION 3.01 INSTALLATION / APPLICATION / ERECTION
A. Transformers shall be rigidly mounted to the structure or the foundation in the case of freestanding units.
B. Transformers shall be megger tested prior to energization.
C. Transformers with taps shall be adjusted to supply the nominal service
voltage required on the secondary.
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D. Transformers shall be installed in accordance with NEC requirements and
manufacturer recommendations.
E. Ground secondary of transformer per NEC requirements.
END OF SECTION
***
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SECTION 16483
ADJUSTABLE FREQUENCY DRIVES
PART 1 GENERAL
1.01 SCOPE
A. Provide three-phase, Adjustable Frequency Drives (AFD) as specified herein and as shown on the Contract Drawings.
1.02 RELATED SECTIONS
A. Section 16010 General Electrical Requirements
B. Section 16440 Motor Control
1.03 REFERENCES
A. The adjustable frequency drives and all components shall be designed, manufactured and tested in accordance with the latest applicable standards.
1. Underwriters Laboratories (UL508C: Power Conversion Equipment)
2. IEC 61800-3
1.04 SUBMITTALS
A. The following information shall be submitted to the Engineer for approval:
1. Dimensioned outline drawing
2. Schematic diagram
3. Power and control connection diagram(s)
4. Descriptive bulletins
5. Product sheets
B. O&M manuals are required in accordance with Section 16010 requirements. As-built wiring diagrams and as-built parameter settings list are required.
1.05 QUALIFICATIONS
A. The supplier of the assembly shall be the manufacturer of the electromechanical power components used within the assembly, such as bypass contactors when specified.
B. For the equipment specified herein, the manufacturer shall be ISO 9001 certified.
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1.06 DELIVERY, STORAGE, AND HANDLING
A. Equipment shall be handled and stored in accordance with manufacturer's instructions. A copy of these instructions shall be included with the equipment at time of shipment.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Allen Bradley
B. Eaton
C. Square D
D. Or equal.
2.02 ADJUSTABLE FREQUENCY DRIVES (AFD)
A. Adjustable frequency drives shall have the following features:
1. The AFD shall be rated for the voltage indicated on the Drawings. The AFD shall provide microprocessor-based control for three-phase induction motors. The AFD shall be variable torque or constant torque as indicated on the Contract drawings. If not indicated, the AFD shall be rated for constant torque.
2. The AFD shall be of the Pulse Width Modulated (PWM) design converting the utility input voltage and frequency to a variable voltage and frequency output via a two-step operation. Adjustable Current Source AFDs are not acceptable. Insulated Gate Bipolar Transistors (IGBT’s) shall be used in the inverter section. Bipolar Junction Transistors, GTO’s or SCR’s are not acceptable.
3. The AFD shall have efficiency at full load and speed that exceeds 95% for AFD below 15-HP and 97% for drives 15-HP and above. The efficiency shall exceed 90% at 50% speed and load.
4. The AFD shall maintain the line side displacement power factor at no less than 0.96, regardless of speed and load.
5. The AFD shall have a one (1) minute overload current rating of 150% and a three (3) second overload current rating of 180% for constant torque drives. The AFD shall have a one (1) minute overload current rating of 110% for variable torque drives.
6. The AFD shall be capable of operating of operating any NEMA design B squirrel cage induction motor, regardless of manufacturer, with a horsepower and current rating within the capacity of the AFD.
7. The AFD shall have an integral EMI/RFI filter as standard.
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8. AFDs rated 5HP and below are not required to have line reactors. AFDs rated 6HP to 20HP shall have a standard 3% nominal impedance AC three-phase line reactor. AFDs above 20HP shall have a standard 5% nominal impedance AC three-phase line reactor. The line reactors may be integral to or separate from the drive.
9. The AFD shall be able to start into a spinning motor. The AFD shall be able to determine the motor speed in any direction and resume operation without tripping. If the motor is spinning in the reverse direction, the AFD shall start into the motor in the reverse direction, bring the motor to a controlled stop, and then accelerate the motor to the preset speed.
10. Standard operating conditions shall be:
a. Incoming Power: As indicated voltage (+10% to -15%) and 50/60 Hz (+/-5 Hz)
b. Frequency stability of +/-0.05% for 24 hours with voltage regulation of +/-1% of maximum rated output voltage.
c. Speed regulation of +/- 0.5% of base speed.
d. Load inertia dependant carryover (ride-through) during utility loss.
e. Insensitive to input line rotation.
f. Humidity: 0 to 95% (non-condensing and non-corrosive).
g. Altitude: 0 to 3,300 feet (1000 meters) above sea level.
h. Ambient Temperature: -10 to 50 °C (CT), -10 to 40 °C (VT).
i. Storage Temperature: -40 to 60 °C.
11. Control Functions
a. AFD programmable parameters shall be adjustable from a digital operator keypad. The AFD shall have an alphanumeric programmable display with status indicators. Keypads must use plain English words for parameters, status, and diagnostic messages. Keypads that are difficult to read or understand are not acceptable, and particularly those that use alphanumeric code and tables. Keypads shall have backlighting.
b. The keypad shall include a Local/Remote pushbutton selection. Both start/stop source and speed reference shall be independently programmable for Keypad, Remote I/O, or Field Bus.
c. The frequency drive shall include an Ethernet port for programming, monitoring, and control. Ethernet/IP is the required protocol.
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d. The operator shall be able to scroll through the keypad menu to choose between the following:
1. Monitor
2. Operate
3. Parameter setup
4. Actual parameter values
5. Active faults
6. Fault history
7. Information to indicate the standard software and optional features software loaded.
e. The following setups and adjustments, at a minimum, are to be available:
1. Start command from keypad, remote or communications port
2. Speed command from keypad, remote or communications port
3. Motor direction selection
4. Maximum and minimum speed limits
5. Acceleration and deceleration times, two settable ranges
6. Critical (skip) frequency avoidance
7. Torque limit
8. Multiple attempt restart function
9. Multiple preset speeds adjustment
10. Catch a spinning motor start or normal start selection
11. Programmable analog output
12. DC brake current magnitude and time
13. PID process controller
12. The AFD shall have the following system interfaces:
a. Inputs – A minimum of four (4) programmable digital inputs, two (2) analog inputs and Ethernet communications interface shall be provided with the following available as a minimum:
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1. Remote manual/auto
2. Remote start/stop
3. Remote forward/reverse
4. Remote preset speeds
5. Remote external trip
6. Remote fault reset
7. Process control speed reference interface, 4-20mA DC
8. Potentiometer and 1-10VDC speed reference interface
9. Ethernet programming and operation interface port
B. Outputs – A minimum of two (3) discrete programmable digital outputs and two (2) programmable analog outputs shall be provided, with the following available at minimum.
1. Programmable relay outputs with one (1) set of Form C contacts for each, selectable with the following available at minimum:
a. Fault
b. Run
c. Ready
d. Reversed
e. Jogging
f. At speed
g. Torque Limit Supervision
h. Motor rotation direction opposite of commanded
i. Over-temperature
2. Programmable analog output signal, selectable with the following available at minimum:
a. Motor current
b. Output frequency
c. Frequency reference
d. Motor speed
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e. Motor torque
f. Motor power
g. Motor voltage
h. DC-bus voltage
i. AI1 (Analog Input 1)
j. AI2 (Analog Input 2)
k. PT100 temperature
3. Monitoring and Displays
a. The AFD display shall be a LCD type capable of displaying the following thirteen (13) status indicators:
1. Run
2. Forward
3. Reverse
4. Stop
5. Ready
6. Alarm
7. Fault
8. Input/Output (I/O) terminal
9. Keypad
10. Bus/Communication
11. Local (LED)
12. Remote (LED)
13. Fault (LED)
4. The AFD keypad shall be capable of displaying the following monitoring functions at a minimum:
a. Output frequency
b. Frequency reference
c. Motor speed
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d. Motor current
e. Motor torque
f. Motor power
g. Motor voltage
h. DC-bus voltage
i. Unit temperature
j. Calculated motor temperature
k. Voltage level of analog input
l. Current level of analog input
m. Digital inputs status
n. Digital and relay outputs status
o. Analog Input
5. Protective Functions
a. The AFD shall include the following protective features at minimum:
1. Over-current
2. Over-voltage
3. Inverter fault
4. Under-voltage
5. Input phase loss
6. Output phase loss
7. Under-temperature
8. Over-temperature
9. Motor stalled
10. Motor over-temperature
11. Motor under-load
12. Logic voltage failure
13. Microprocessor failure
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b. The AFD shall provide ground fault protection during power-up, starting, and running. AFD with no ground fault protection during running are not acceptable.
6. Diagnostic Features
a. Fault History
1. Record and log faults
2. Indicate the most recent first, and store up to 30 faults
7. The AFD manufacturer shall maintain, as part of a national network, engineering service facilities within 150 miles of project to provide start-up service, emergency service calls, repair work, service contracts, maintenance and training of customer personnel.
2.03 SPARE PARTS:
1. Spare Parts
a. The main logic board, keypad and power supply board shall be supplied as spares, one for each different part number supplied.
PART 3 EXECUTION
3.01 FACTORY TESTING
A. The following standard factory tests shall be performed on the equipment provided under this section. All tests shall be in accordance with the latest version of UL and NEMA standards.
1. All printed circuit boards shall be functionally tested via automatic test equipment prior to unit installation.
2. After all tests have been performed, each AFD shall undergo a burn-in test. The drive shall be burned in at 100% inductive or motor load without an unscheduled shutdown.
3. After the burn-in cycle is complete, each AFD shall be put through a motor load test before inspection and shipping.
B. The manufacturer shall provide three (3) certified copies of factory test reports.
3.02 INSTALLATION
A. Install per manufacturer’s instructions.
B. Configure parameters according to actual driven motor nameplate data.
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C. Set the minimum and maximum speeds as directed by the motor manufacturer.
3.03 FIELD QUALITY CONTROL
A. Provide the services of a qualified manufacturer's employed Field Service Engineer to assist the Contractor in installation and start-up of the equipment specified under this section. Field Service personnel shall be factory trained with periodic updates and have experience with the same model of AFD on the job site. Sales representatives will not be acceptable to perform this work. The manufacturer's service representative shall provide technical direction and assistance to the Contractor in general assembly of the equipment, installation as specified in manufacturer’s installation instructions, wiring, application dependant adjustments, and verification of proper AFD operation.
B. The Contractor under the technical direction of the manufacturer’s service representative shall perform the following minimum work.
1. Inspection and final adjustments.
2. Operational and functional checks of AFD and spare parts.
3. The Contractor shall certify that he has read the drive manufacturer’s installation instructions and has installed the AFD in accordance with those instructions.
C. The Contractor shall provide three (3) copies of the manufacturer's field start-up report.
3.04 MAINTENANCE/WARRANTY SERVICE
A. Warranty shall be a minimum of two years from the date of start-up and include all parts, labor, and travel time.
3.05 TRAINING
A. The Contractor shall provide a training session for up to 5 owner's representatives for one normal workday. Training and instruction time shall be in addition to that required for start-up service.
B. The manufacturer’s qualified representative shall conduct the training.
C. The training program shall consist of the following:
1. Instructions on the proper operation of the equipment.
2. Instructions on the proper maintenance of the equipment.
END OF SECTION
***
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SECTION 16495
SWITCHBOARD MATTING PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Switchboard matting shall be furnished by the Contractor and placed in front of all 480V power distribution and control equipment as indicated on the Contract Drawings.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Switchboard matting shall be W.H. Salisbury & Company, Safety Line, Inc., Tepromark, Wearwell, Erico, or equal.
2.02 MATERIALS
A. Switchboard matting shall be nonconductive with a minimum of 40,000 volts dielectric strength. The mat shall have a corrugated, non-slip surface and shall be a minimum of 1/4 inch thick. Width shall be 36 inches and length shall be as required at each location. The mat shall be black in color, ozone and oil resistant, and manufactured to meet all applicable ANSI/ASTM standards.
PART 3 - EXECUTION Not Applicable.
END OF SECTION
***
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SECTION 16496
AUTOMATIC TRANSFER SWITCH
PART 1 GENERAL
1.01 SCOPE
A. Furnish and install the low voltage automatic transfer switches having the ratings, features/accessories and enclosures as specified herein and as shown on the Contract Drawings.
B. ATS must have drawout construction that allows removal, maintenance, and repair of switching components while the plant remains online on the other switch. A bypass-isolation type switch that accomplishes this same goal may be allowed in lieu of drawout construction.
1.02 RELATED SECTIONS
A. SECTION 16230 - GENERATOR
1.03 REFERENCES
A. The automatic transfer switches and all components shall be designed, manufactured and tested in accordance with the latest applicable standards of UL and NEMA as follows:
1. UL 1008 – Transfer Switches
2. UL 991 - Tests for Safety-Related Controls Employing Solid-State Devices
3. NFPA 70 – National Electrical Code
4. NFPA 99 – Essential Electrical Systems of Health Care Facilities
5. NFPA 110 – Emergency and Standby Power Systems
6. NEMA ICS 10 – AC Transfer Switch Equipment
7. IEEE 446 – Recommended Practice for Emergency and Standby Power Systems
1.04 SUBMITTALS – FOR REVIEW/APPROVAL
A. The following information shall be submitted to the Engineer:
1. Front view and plan view of the assembly
2. Schematic diagram
3. Conduit space locations within the assembly.
4. Assembly ratings including:
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a. Withstand and Closing rating
b. Voltage
c. Continuous current rating
d. Short-Time rating if applicable
e. Short-circuit rating if ordered with integral protection
5. Cable terminal sizes
6. Product Data Sheets.
B. Where applicable, the following additional information shall be submitted to the Engineer:
1. Busway connection
2. Connection details between close-coupled assemblies
3. Composite front view and plan view of close-coupled assemblies
1.05 SUBMITTALS – FOR CONSTRUCTION
A. The following information shall be submitted for record purposes:
1. Final as-built drawings and information for items listed in section 1.04
2. Wiring diagrams
3. Certified production test reports
4. Installation information
5. Seismic certification as specified
B. The final (as-built) drawings shall include the same drawings as the construction drawings and shall incorporate all changes made during the manufacturing process.
1.06 QUALIFICATIONS
A. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly.
B. For the equipment specified herein, the manufacturer shall be ISO 9001 or 9002 certified.
C. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.
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D. The equipment and major components shall be suitable for and certified by actual seismic testing to meet all applicable seismic requirements of the Kentucky Building Code.
E. Provide a certificate of compliance with UL 1008 for the transfer switches furnished under this section.
1.07 DELIVERY, STORAGE AND HANDLING
A. Equipment shall be handled and stored in accordance with manufacturer’s instructions. A copy of these instructions shall be included with the equipment at time of shipment.
1.08 OPERATION AND MAINTENANCE MANUALS
A. Equipment operation and maintenance manuals shall be provided with each assembly shipped, and shall include instruction leaflets and instruction bulletins for the complete assembly and each major component.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Eaton
B. Square D/Schneider
C. Asco
2.02 CONSTRUCTION
A. Switches shall be free standing construction utilizing draw-out mounted power case switches or circuit breakers, Eaton type MAGNUM DS or approved equal.
B. Ratings shall be per the drawing. All breakers shall be UL listed for application in their intended enclosures for 100% of their continuous ampere rating. Breakers shall be electrically operated.
C. All breakers shall be provided with a true, two-step stored energy mechanism providing a maximum of three-cycle closing. All the energy required for closing the breakers shall be completely stored and held in readiness pending a release to close action. The power case switch or breaker shall have high-endurance characteristics being capable of no-load and full-load interruptions at rated current equal to or exceeding the UL endurance ratings for power circuit breakers without maintenance.
D. Transfer switches shall be open delayed transition and operate with a time delay in the neutral position, adjustable from 0 to 120 seconds.
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E. Transfer switch shall be service entrance rated and shall have power circuit breakers with programmable trip units. Full LSIG programmability is required for selective coordination with rest of switchgear.
F. The switching panel shall consist of completely enclosed contact assemblies and a separate control or transformer panel. Control power for all transfer operations shall be derived from the line side of the source to which the load is being transferred.
G. Each transfer switch shall be positively interlocked both mechanically and electrically to prevent simultaneous closing of both sources under either automatic or manual operation. Main contacts shall be mechanically locked in position in both normal and emergency positions. A neutral position shall not be possible under normal electrical operation unless a delayed transition accessory is required for switching highly inductive loads.
H. Transfer switches shall be capable of being operated manually under full rated load conditions. Manual operation shall be accomplished by a permanently attached manual operator, or by integrally mounted pushbuttons.
I. A fourth pole for switching the neutral is required, and the neutral shall be fully rated with equal withstand, closing and interrupting ratings to the power poles. Switched neutral poles which are add-on or overlap, or that are not capable of breaking full rated load current are not acceptable.
J. The transfer switch shall have a multi-tap voltage selection plug for ease of voltage adjustment in the field.
K. Transfer switches shall be provided with over-current trip units and a service entrance label . A key-operated selector switch shall be provided to disconnect the power supplies. Indicators shall be provided to show the availability of each source as well as breakers in a disconnected position. Provide a neutral-to-ground main bonding jumper for all switches to meet UL service entrance requirements. Ground fault protection shall be provided in accordance with NEC.
L. The transfer switch shall be provided with a draw-out mechanism to allow easy access for preventive maintenance, testing or inspection. The draw-out mechanism shall provide visual indicators as to the position of the switch/breaker during the draw-out operation.
M. Shuttered cassettes shall be provided for safety purposes
N. A roof mounted breaker lifting device shall be included.
2.03 MICROPROCESSOR LOGIC
A. The transfer switch shall be equal to an Eaton ATC-900 (or equal) type microprocessor-based controller. The controller shall be hardened against
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potential problems from transients and surges. Operation of the transfer switch and monitoring of both sources shall be managed by the controller.
B. The automatic transfer switch controllers shall meet or exceed the following standards in addition to the basic switch standards:
1. IEC 61000-4-2 - EMC Testing and Measurement Techniques - Electrostatic Discharge Immunity Test
2. IEC 61000-4-3 - EMC Testing and Measurement Techniques - Radio-frequency, Electromagnetic Field Immunity Test
3. IEC 61000-4-4 - EMC Testing and Measurement Techniques - Electrical Fast Transient/Burst Immunity Test
4. IEC 61000-4-5 - EMC Testing and Measurement Techniques - Surge Immunity Test
5. IEC 61000-4-6 - EMC Testing and Measurement Techniques - Immunity to Conducted Disturbances, Induced by Radio-frequency Fields
6. IEC 61000-4-11 - EMC Testing and Measurement Techniques - Voltage Dips, Short Interrupts and Voltage Variations Immunity Tests
7. CISPR11, Class B - Industrial, Scientific and Medical Radio-frequency Equipment - Electromagnetic Disturbance Characteristics - Limits and Methods of Measurement
8. FCC Part 15, Subpart B, Class B
2.04 ENCLOSURE
A. The transfer switch shall be provided in a NEMA 1 enclosure suitable for use in environments indicated in the Drawings.
B. Enclosure shall be painted with the manufacturer’s standard light gray ANSI 61paint.
2.05 CONTROLLER DISPLAY AND KEYPAD
A. The microprocessor-based controller display shall be UV resistant and include a 4.3 inch Color TFT (480x272), backlit display. The controller shall be capable of displaying transfer switch status, parameters, and diagnostic data. All set point parameters shall be password protected and programmable using the controller keypad, USB port, or remotely using serial port access. Limited abbreviations or codes shall be used for transfer switch functions.
B. The microprocessor-based controller shall include a mimic bus display consisting of six (6) individual LED’s (3mm) for indicating the following:
1. Availability status of source 1
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2. Availability status of source 2
3. Connection status of source 1
4. Connection status of source 2
5. Source 1 Preferred
6. Source 2 Preferred
2.06 VOLTAGE AND FREQUENCY SENSING
A. The controller shall have a voltage range of 0-790 volts (50/60 Hz) and an accuracy of +/- 1% of the reading and a frequency range of 40-70 Hz and an accuracy of +/- .3 Hz.
B. Voltage and frequency dropout and pickup parameters are set as a percentage of the nominal voltage as indicated in the table below.
Setpoint Sources Dropout Pickup
Undervoltage Source1 and 2 70 – 97% (DO + 2%) - 99%
Overvoltage Source 1 and 2
105 – 110%
103% - (DO – 2%)
Underfrequency Source 1 and 2
90 – 97% (DO + 1Hz) – 99%
Overfrequency Source 1 and 2
103 – 105%
101% - (DO – 1Hz)
Voltage Unbalance
Source 1 and 2
5 – 20% (UNBAL DO% - 2) – 3%
C. The normal and emergency sources shall include phase reversal protection. The preferred rotation is programmable as ABC or CBA.
2.07 TIME DELAYS
A. A time delay shall be provided on transfer to source 2, adjustable from 0 to 166 minutes. Also include time-delay in neutral position from 0 to 120 seconds.
B. A time delay shall be provided to override a momentary power outage or voltage fluctuation, adjustable from 0 to 120 seconds.
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C. A time delay shall be provided on retransfer from source 2 to source 1, adjustable from 0 to 166 minutes.
D. A time delay shall be provided after retransfer that allows the generator to run unloaded prior to shutdown, adjustable form 0 to 166 minutes.
E. A time delay shall be provided for engine failure to start, adjustable 0- 60 seconds.
F. A pre and or post transfer time delay output adjustable from 0-120 seconds. The contact shall be a form-c contact rated for 10-Amp at 250-Vac and 10-Amp at 30-Vdc.
G. All delays shall be field adjustable from the microprocessor-based controller without the use of special tools.
2.08 ADDITIONAL FEATURES
A. The controller shall include two independently programmable Engine Exercisers, selectable as disabled, 7, 14, or 28 day interval, or by calendar date. Run time shall be adjustable for 0-600 minutes, with or without load. Upon loss of source 2 power, the ATS shall automatically return to source 1. Transfer time delays shall also be independently programmable for test events.
B. The controller shall include a keypad pushbutton to initiate a system test.
C. The controller shall include 4 user configurable inputs. Each input provides 50 volts at 10ma and can be user configured to one of the following features:
1. Input to accept a remote contact which closes to initiate a transfer to source 2. This feature shall be failsafe and an automatic retransfer shall occur in the event that source 2 power is lost.
2. Input to accept a remote contact which closes to initiate a transfer to source 2. This feature shall be failsafe and an automatic retransfer shall occur in the event that source 2 power is lost.
3. Input to accept a remote contact which opens to inhibit transfer to source 2.
4. Input to enable monitor mode to disable automatic operation of the transfer switch while continuing to display status. Monitor mode allows set point programming at the controller display.
5. Input to enable lockout feature to disable automatic operations of the transfer switch following an overcurrent trip of an integral circuit breaker.
6. Input to enable or disable manual retransfer to source 1.
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7. Input to initiate manual retransfer to source 1.
8. Input to initiate a remote engine test. The test will run using the programmed engine test set points.
9. Input to select source 1 or source 2 as the preferred source.
10. Input to initiate a remote load test.
11. Input to indicate the bypass transfer switch is closed on a source.
12. Input to bypass time delays
13. Input to receive engine start signal from a master controller in a three source application.
D. The controller shall include 4 user configurable outputs rated for 10-Amp at 250-Vac and 10-Amp at 30-Vdc. Each input can be user configured to one of the following features:
a. Source 1 connected
b. Source 2 connected
c. ATS in test
d. ATS not in automatic mode (Monitor Mode)
e. General Alarm indication for failure to transfer, mechanical fault, or electrical fault.
f. Engine Test Aborted
g. Engine cool down in process
h. Engine start contact status
i. Emergency inhibit on
j. Load sequence – Output used to signal select loads to disconnect prior to transfer and reconnect 0-120 seconds after. Loads are reconnected sequentially.
k. Selective load shed – Output used to shed low priority loads when the load reaches a programmed threshold value. A load shed and load restore set point (measured in kW) are associated with this feature.
l. Load bank control – Output to disconnect a load bank during an engine run test if a transfer to a source 2 generator is required.
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m. Pre and/or post transfer signal - A pre and or post transfer time delay output adjustable from 0-120 seconds.
E. One Form C auxiliary contact to indicate Source 1 position and one Form C contact to indicate source 2 position. The contacts shall be rated for 10-Amp, 1/3-Horsepower at 250-Vac and 10-Amp at 30-Vdc.
F. One Form C contact for Source 1 Available. The contacts shall be rated for 10-Amp, 1/3-Horsepower at 250-Vac and 10-Amp at 30-Vdc.
G. One Form C contact for Source 2 Available. The contacts shall be rated for 10-Amp, 1/3-Horsepower at 250-Vac and 10-Amp at 30-Vdc.
H. Data Logging
1. Historical Data Storage to include:
a. Engine Run Time
b. Source 1 Available time
c. Source 2 Available time
d. Source 1 Connected time
e. Source 2 Connected time
f. Source 1 Engine Run Time
g. Source 2 Engine Run Time
h. Load Energized Time
i. Number of Transfers
2. Event Summary shall include up to 100 date and time stamped events. All metered values are logged for each event. Event summaries include:
a. Transfer events
b. Alarms
c. Changes to the set points
d. Changes to the time/date
e. Resetting a historical counter
f. Engine Run test
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3. Event Details shall include up to 350 date and time stamped events. All metered values are logged for each event. Event details include detailed sequence of operations of a transfer event.
4. Event recording shall capture 4 seconds of metered data, stored every 20 msec for certain events. The data is captured 2 seconds before and 2 seconds after the event. Oscillographic data for 10 events is stored and may be downloaded over USB. Events Include:
a. Source unavailability actions that initiate a transfer sequence (Undervoltage, Overvoltage, etc.)
b. Successful transfers (at the point of breaker/contactor closure)
c. Unsuccessful transfers (at the point of breaker/contactor failure to close or open)
2.09 REQUIRED ACCESSORIES
A. Non-Automatic Control: Provide a 3-Position Selector Switch, maintained contact, marked: “Automatic” and “Non-Automatic”. The transfer switch shall be transferred by actuating a three position maintained selector switch labeled “Source 1”, “Off” and “Source 2”. A 30mm pilot light shall be provided labeled “Not in Automatic”.
B. Manual Retransfer Control: The ATS shall remain connected to the emergency source after the normal source becomes available until a momentary pushbutton contact closure signal is received to initiate the retransfer. Should a failure of the emergency source occur while waiting for the manual return, the re-transfer proceeds automatically.
C. Communications Interface to be Ethernet TCP/IP.
D. Provide a 200KA surge protection device on source 1.
E. Space heater with thermostat rated for 100 watts.
2.10 WITHSTAND AND CLOSING Ratings
A. The transfer switch shall have a 30 cycle short time withstand and closing rating of 100KA at 480 volts.
PART 3 EXECUTION
3.01 FACTORY TESTING
A. The following standard factory tests shall be performed on the equipment provided under this section. All tests shall be in accordance with the latest version of UL and NEMA standards.
1. Insulation check to ensure the integrity of insulation and continuity of the entire system
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2. Visual inspection to ensure that the switch matches the specification requirements and to verify that the fit and finish meet quality standards
3. Mechanical tests to verify that the switch's power sections are free of mechanical hindrances
4. Electrical tests to verify the complete electrical operation of the switch and to set up time delays and voltage sensing settings of the logic
A. The manufacturer shall provide a certified copy of factory test reports.
B. Transfer switch shall include a label indicating order number, catalog number and date
3.02 INSTALLATION A. The Contractors shall install all equipment per the manufacturer’s
recommendations and the contract drawings
B. All necessary hardware to secure the assembly in place shall be provided by the contractor
3.03 FIELD QUALITY CONTROL A. Provide the services of a qualified factory-trained manufacturer’s
representative to assist the contractor in installation and start-up of the equipment specified under this section. The manufacturer’s representative shall provide technical direction and assistance to the contractor in general assembly of the equipment, connections and adjustments, and testing of the assembly and components contained therein.
3.04 MANUFACTURER’S CERTIFICATION A. A qualified factory-trained manufacturer’s representative shall certify in
writing that the equipment has been installed, adjusted and tested in accordance with the manufacturer’s recommendations.
B. The Contractor shall provide a copy of the manufacturer’s representative’s certification.
3.05 TRAINING A. The Manufacturer’s qualified representative shall conduct a training session
for up to five (5) owner’s representatives for one normal workday at the jobsite location. The training program shall consist of the instruction on the operation of the transfer switch and the major components within the assembly.
3.06 FIELD SERVICE ORGANIZATION A. The manufacturer of the ATS shall also have a national service organization
that is available throughout the contiguous United States and is available on call 24 hours a day, 365 days a year.
END OF SECTION ***
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SECTION 16500
LIGHTING PART 1 - GENERAL 1.01 SCOPE OF WORK
A. The specific characteristics of the light fixtures to be furnished and installed shall be as detailed in the light fixture schedule on the Contract Drawings.
B. All Luminaires shall be quiet. If a Luminaire develops a noticeable hum
within the warranty period, the Luminaire shall be replaced without cost to the Owner.
1.02 RELATED WORK SPECIFIED ELESEWHERE
A. Related Sections: The following sections contain requirements that related to this section. 1. Division 1 – General Requirements
2. Section16010 – General Electrical Requirements
1.03 SUBMITTALS
A. General: Submit the following in accordance with Section 16010 General Electrical Requirements and the General and Special Conditions:
1. The lighting submittal shall be complete with all fixtures listed
utilizing the same tagging convention as listed in the Light Fixture Schedule on the Drawing.
2. The submittal shall be bound in a three ring binder. 3. The minimum data for each light fixture shall include complete
photometrics, electrical characteristics, construction characteristics, and options clearly listed.
4. If requested by the Architect/Engineer, the Contractor shall be prepared to submit sample equipment for appraisal when requested, and shall assume all transportation costs involved in the shipment and return of samples. All sample fixtures submitted shall be provided with lamps and shall be wired with cord and plug, connectable at 120 volts, single phase.
B. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles / configurations represented on the literature.
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PART 2 - PRODUCTS 2.01 MANUFACTURERS
A. Holophane, Lithonia, Cooper, Hubbell or equal
2.02 HARMONIC DISTORTION
A. Fixtures are required to have less than 10% harmonic distortion. 2.03 LUMINAIRES
A. All fixtures shall be delivered complete with suspension and mounting accessories, drivers, diffusers, reflectors, etc., all wired and assembled. All accessory wiring shall be furnished and installed as shown on the Contract Drawings.
B. All supports required for luminaires in addition to that furnished under
the general building construction shall be furnished and installed by the Contractor.
C. When fixtures are noted to be installed flush, they shall be complete with
the proper accessories for installing in the particular ceiling involved. All flush mounted fixtures shall be supported from the structure and shall not be dependent on the hung ceilings for their support.
D. Luminaire wire shall be of non-asbestos construction.
2.04 LIGHTING CONTACTORS
A. Contactor shall be NEMA ICS 2, electrically held contactor. Contacts shall
be rated 600 volts, 30 amperes, and shall include the number of poles indicated on the Drawings. Coils shall be rated for the voltage indicated on the Drawings. Provide in NEMA 1 enclosure conforming to NEMA ICS 6 unless otherwise indicated. Contactor shall have silver alloy double-break contacts. Provide contactor with hand-off-automatic selector switch. Contactor shall be Square D, or equal.
PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. General:
1. The Contractor shall furnish all light fixtures, lighting equipment, components, hangers, etc., as shown on the Contract Drawings and shall install them at the locations shown on the Contract Drawings.
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2. Deliver lighting fixture in individually wrapped in factory containers. Stack and store in accordance with manufacturer’s instructions.
3. All fixture wiring shall be in conformance with the latest revision of
the NEC and UL standards. All fixtures must be UL labeled and listed.
4. Lamps of the proper type, wattage and voltage rating shall be
delivered to the project in the original cartons and installed in the fixtures just prior to the completion of the project.
5. Locations of fixtures shall be coordinated with reflected ceiling
plans where they exist. Any conflicts between electrical plans and Engineer’s reflected ceiling plans, the reflected plans shall override.
B. Luminaires:
1. All recessed fixtures shall be securely fastened per detail on the
drawings. 2. Mounting heights specified as indicated shall be to bottom of
fixture. Coordinate exact mounting of lighting fixture with type, style and pattern of ceiling being installed.
3. Clean interior lighting fixtures of dirt and debris upon completion
of installation. Protect installed fixtures from damage during remainder of construction period.
4. At date of substantial completion, replace lamps in lighting fixture
which are observed to be inoperable or noticeably dimmed after Contractors use and testing, as judged by Architect/Engineer.
5. Flexible fixture hangers shall be used for all pendant-mounted
fixtures.
6. Conduit run in areas with hung ceilings shall be installed in the space above the hung ceiling as close to the structure as possible. Junction boxes shall be supported from the structure. Conduit shall be supported from structure on 4’ 6” centers. No conduit shall be lying on ceiling tile.
7. No light fixtures shall be hung or installed until after painting is
completed, however, the Contractor shall provide temporary lighting. Fixtures in suspended ceilings shall be fastened to the main tees of the ceiling grid.
8. All fixtures shall be left in a clean condition, free of dirt and
defects, before acceptance by the Engineer.
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C. Light Poles:
1. A concrete foundation shall be provided for each pole as detailed on the Contract Drawing. The poles shall be mounted utilizing anchor bolts set in the concrete. The anchor bolts shall have galvanized or plated threads and shall be furnished with the pole by the manufacturer.
2. When anchor bolts are positioned prior to pouring concrete,
spacing and projection must be verified with pole manufacturer’s recommendations. A plastic or plywood template should be fabricated from the manufacturer’s instructions to use when setting the anchor bolts. Anchor bolts that are not installed plumb and in the correct locations shall be removed and replaced. The Contractor shall not be allowed to bend the anchor bolts back to plumb after concrete is set.
3. Leveling nuts shall be utilized for the mounting of poles to
foundations. A nut should be screwed down on each bolt until it meets the concrete, then the nuts must be adjusted until they are level.
4. The pole shall be carefully lowered onto the anchor bolts and
allowed to rest on the leveling nuts. Flat washers followed by lockwashers should be placed on the anchor bolts and the top nut installed. Minor adjustments on the leveling nuts may be necessary to plumb the pole before the top nuts are tightened down. Special care shall be taken to tighten the top nuts to the torque level recommended by the pole manufacturer. All nuts and washers shall be galvanized or plated.
5. Concrete grout of the nonshrink type must be installed between
the base of the pole and the concrete foundation. The grout should be puddled around the edge of the pole base and firmly packed in the space between the pole and foundation. A short piece of small diameter pipe must be installed to make a drain hole through the grout to the pole interior.
6. Aluminum poles must have the bottom of the base painted with
Koppers bitumastic No. 50 or equal substitute product before grouting so that the aluminum does not come in contact with the concrete.
7. Poles shall not be modified or drilled on the job site.
8. Under no circumstances should a ground wire be wrapped around
an anchor bolt underneath an anchor bolt nut.
9. Do not set poles without light fixtures installed, as poles are more likely to vibrate and become damaged.
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10. Manufacturer’s installation instructions should be followed as well
as those instructions contained herein. Should a discrepancy exist, promptly contact the Engineer for clarification.
11. Bases shall have 1" chamfer all around and rubbed and buffed
smooth to below grade.
12. Anchor bolt covers shall also be provided and installed.
END OF SECTION
***
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SECTION 16580
OCCUPANCY SENSORS
PART 1 – GENERAL
1.01 SUMMARY
A. The Occupancy Sensor system shall sense the presence of human activity within the desired space and fully control the “On” / “Off” function of the loads automatically. Sensors shall turn “On” the load within 2 feet of entrance and shall not initiate “On” outside of entrance.
B. The Contractor shall be responsible for a complete and functional system in accordance with all applicable local and national codes.
C. Product shall be warranted for 5 years.
D. The Occupancy Sensor shall be designed to override to the “Off” position when wired in conjunction with a standard wall type light switch.
2.01 MANUFACTURERS AND SUBSTITUTIONS
A. Manufacturers shall be Sensor Switch, GE, Leviton, Novitas, or equal.
B. All substitutions must provide technical literature. All substitutions must clearly identify any and all exceptions to the specifications with a detailed explanation as to the exception.
C. Shop Drawings shall be clearly marked and or highlighted as to which product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles / configurations represented on the literature. For example: Device boxes – Styles shall be listed as: For masonry walls, for electrical devices, for ceiling mounted light fixtures, etc.
D. Active Ultrasonic sensing technology shall not be accepted.
E. Sensing technologies shall be completely passive in nature. The occupancy sensor system shall not emit or interfere with any electronic device, or human characteristic. Acceptable technology is PIR/Microphonic Passive Dual Technology.
F. Time Delay settings shall be factory set at 10 minutes, and shall not be adjusted unless specifically instructed. Maximum adjustment shall be 20 minutes. Automatic adjustments to this delay period by the sensor shall not be permitted.
G. All line voltage devices shall be UL Listed under Energy Management Equipment, or Industrial Control Equipment. UL Listing under Appliance Control shall not be accepted.
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2.02 WALL SWITCH SENSORS – SMALL AREAS
A. Sensor shall recess into single gang switch box and fit a standard GFI opening.
B. Sensor must meet NEC grounding requirements by providing a dedicated ground connection and grounding to mounting strap. Line and load wire connections shall be interchangeable.
C. Sensor shall use PIR sensing incorporating a nominal one half inch focal length lens viewing 9 inches above and below horizontal view pattern measured at 10 feet.
D. Sensor shall have optional features for photocell/daylight override, vandal resistant lens, and no switch as specified.
E. In areas with inboard/outboard switching, sensor shall provide two dedicated relays and override switches.
F. In areas with obstructions to the occupant’s workspace, sensor shall utilize dual technology PIR/Microphonic sensing.
G. Sensor shall be the following Sensor Switch model numbers. Device color and optional features as specified.
1. WSD-PDT (PIR/Microphonic), or equal.
2.03 WALL SWITCH SENSORS – LARGE AREAS
A. Sensor shall surface mount to single gang switch box.
B. Sensor shall use PIR sensing incorporating a nominal one-inch focal length lens viewing 9 inches above and below horizontal view pattern measured at 20 feet.
C. Sensor shall have optional feature for photocell/daylight override.
D. In areas with inboard/outboard switching or two circuits, sensor shall provide two dedicated relays and override switches.
E. In areas with obstructions to the occupant’s workspace, sensor shall utilize dual technology PIR/Microphonic sensing.
F. Sensor shall be the following Sensor Switch model numbers. Device color and optional features as specified.
1. LWS-PDT (PIR/Microphonic) , or equal.
2. LWS-PDT-2P (PIR/Microphonic inboard/outboard or two circuits), or equal.
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PART 3 - EXECUTION
3.01 INSTALLATION/APPLICATION/ERECTION
A. General:
1. The Contractor shall furnish all equipment, components, interconnecting wiring, hangers, etc., as shown on the Contract Drawings and shall install sensors at the locations shown on the Contract Drawings.
2. All occupancy sensor wiring shall be in conformance with the latest revision of the NEC and UL standards. All units shall be UL labeled and listed.
3. All conductors and wiring shall be provided per Manufacturer’s recommendations in ¾” conduit.
4. Contractor, in accordance with manufacturer’s recommendation, shall determine final sensor location. All sensors shall have non-adjustable factory calibrated sensitivity for maximum performance. Time Delay and Photocell field adjustments shall be provided as needed.
END OF SECTION
***
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SECTION 16670
LIGHTNING PROTECTION SYSTEMS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. New lightning protection systems are required on the Filter building, High Service building, and Chemical Building. An extension of the existing lightning protection system is required on the Administration building.
B. The lightning protection system shall be furnished, installed, and
connected as detailed on the Contract Drawings to provide a complete and functional system. Installation and equipment construction shall comply with Lightning Protection Institute Installation Code LPI-175, UL Master Label Code 96A, and NFPA 780.
B. The Contractor shall provide shop drawings indicating location and
installation of equipment for review of the Engineer before beginning installation.
C. All equipment shall be of the same manufacturer, insofar as possible.
D. Equipment specified herein supplements actual suppression devices
specified in Section 16280. PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. “Thompson Lightning Protection, Inc.,” “Independent Protection Co., Inc.,” “National Lightning Protection, Inc.” or equal.
2.02 EQUIPMENT
A. All equipment used in this installation shall be UL approved and labeled in accordance with UL procedures, with each air terminal bearing an “A” label and all main conductors bearing a “B” label at 10'-0" intervals.
B. All equipment shall be new, and of design and construction to suit the
application where it is used in accordance with accepted industry standards and LPI and UL code requirements and as per manufacturers recommendations.
C. Downlead conductors from roof to ground shall be copper, of 28 strands,
17 gauge minimum. All main roof conductors shall be aluminum, of 24 strands, 14 gauge minimum.
D. Air terminals shall be solid, round aluminum bar of ½” minimum
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diameter, and shall project 10" minimum above the object to be protected.
E. Air terminal bases shall be of cast aluminum with bolted pressure cable
connections and shall be securely mounted with stainless steel screws or bolts. Bases on built-up tar and gravel roofs shall be secured with a proper adhesive and shall have a minimum surface contact area of 18.5 square inches.
F. Ground rods shall be a minimum of 3/4" in diameter and 10'-0" long.
They shall be connected to the system using exothermic welds, Cadweld, or equal.
G. Cable fasteners shall be substantial in construction, electrolytically
compatible with the conductor and mounting surface and shall be spaced according to LPI and UL code requirements.
H. Bonding devices, cable splicers and miscellaneous connectors shall be of
cast aluminum with bolted pressure connections to cable. Cast or stamped crip fittings are not acceptable.
I. Equipment on stacks and chimneys shall be protected from corrosion and
sized in accordance with LPI and UL requirements.
J. All miscellaneous bolts, nuts, and screws shall be stainless steel.
K. An approved bimetal transition fitting shall be used at the roof level to change from aluminum roof conductor to copper downlead cable.
PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. The installation shall be accomplished by an experienced installer listed with Underwriters’ Laboratories as qualified and who is also a Certified Master Installer of the LPI or working under the direct supervision of an LPI manufacturer as listed above or his authorized LPI Certified Master Installer representative.
B. All equipment shall be installed in a neat workmanlike manner in the
most inconspicuous manner possible. The system shall consist of a complete cable network on the roof including all air terminals, splices, and bonds with cable downleads routed concealed in the building construction.
C. The copper downlead cables shall not be brought directly through the
roof. Through roof connectors with solid rods or conduits though pitch pockets shall be utilized for this purpose. System must be approved by the roof supplier.
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D. The limitations on areas of usage for aluminum cables and for copper and aluminum materials together as outlined in UL 96A and LPI 175 shall be observed. The lightning protection installer will work with other trades to ensure a correct, neat, and unobtrusive installation.
E. It shall be the responsibility of the lightning protection installer to assure
a sound bond to the metallic main water service and to assure interconnection with other building ground systems, including both telephone and electrical and also to ensure that proper arresters have been installed on the power service.
F. Downlead conductors from roof to ground shall be protected from
mechanical damage from a point 8 feet above to 1 foot below grade by conduit or other means. Downlead conductors must be installed CONCEALED on all new construction.
G. The lightning protection installer shall secure and deliver a UL Master
Label and LPI System Certification to the Engineer for the Owner upon completion of the installation.
H. The Contractor shall also submit 2 copies of as built shop drawings, 1
with the UL Master Label Application Form and another with LPI forms 175A and B.
I. A permanent plate shall be affixed to the protected structure in a
prominent location, indicating its UL approval.
END OF SECTION
***
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SECTION 16710
BUILDING TELECOMMUNICATIONS CABLING SYSTEM
PART 1 - GENERAL
1.01 SCOPE OF WORK
A. Provide a building telecommunications cabling and pathway system which shall include permanently installed backbone and horizontal cabling, horizontal and backbone pathways, work area pathways, telecommunications outlet assemblies, conduit, raceway, and hardware for splicing, terminating, and interconnecting cabling necessary to transport telephone and data (including LAN) between equipment items in a building. The backbone cabling and pathway system includes intrabuilding and interbuilding interconnecting cabling, pathway, and terminal hardware.
B. Provide telephone backboards in each building except for Admin Building as indicated on the Drawings. Coordinate with Section 16821. In the Admin building, the phone cabling shall be cross-connected in the IDF-Admin cabinet via patch panels and routed to the MDF where the phone system controller resides.
C. Provide IDF data cabinets in each of (4) new buildings.
D. Provide telecommunications outlet assemblies where indicated on the Contract Drawings.
E. Provide grounding as specified herein and as indicated.
F. All work shall be in accordance with BICSI cabling standards.
G. Install the network switching/routing hardware furnished under Section 16711 and coordinate with networking vendor.
1.02 RELATED WORK
A. Drawings and General Provisions of this Contract including General and Supplementary Conditions and Division 1 Specifications Sections, apply to work of this Section.
B. Section 16010 – General Electrical Requirements
C. Section 16130 - Raceways
D. Section 16131 – Boxes
E. Section 16711 – Network Switching/Routing
F. Section 16821 – Telephone System
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1.03 REFERENCES
A. The publications of the standards organizations listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the organization abbreviation with applicable publication number.
1. ASTM INTERNATIONAL (ASTM)
2. ELECTRONIC INDUSTRIES ALLIANCE (EIA)
3. INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
4. INSULATED CABLE ENGINEERS ASSOCIATION (ICEA)
5. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
6. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
7. U.S. FEDERAL COMMUNICATIONS COMMISSION (FCC)
8. UNDERWRITERS LABORATORIES (UL)
9. U.S. Dept. of Agriculture (USDA) – (RUS)
10. Building Industry Consulting Service International (BICSI)
1.04 DEFINITIONS
A. Unless otherwise specified or indicated, electrical and electronics terms used in this specification shall be as defined in EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2, EIA TIA/EIA-568-C.3, EIA TIA/EIA-569-A, EIA TIA/EIA-606-A and IEEE Std 100 and herein.
B. Main Distribution Frame (MDF) - A distributor from which the campus backbone cabling emanates. Also known as a main cross-connect or campus distributor.
C. Intermediate Distribution Frame (IDF) - A distributor used to connect horizontal cable and cabling subsystems or equipment in each building.
D. Telecommunications Room (TR) - An enclosed space for housing telecommunications equipment, cable, terminations, and cross-connects. The room is the recognized cross-connect between the backbone cable and the horizontal cabling.
E. Entrance Facility (EF) (Telecommunications) - An entrance to the building for both private and public network service cables (including antennae) including the entrance point at the building wall and continuing to the entrance room or space.
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F. Entrance Room (ER) (Telecommunications) - A centralized space for telecommunications equipment that serves the occupants of a building. Equipment housed therein is considered distinct from a telecommunications room because of the nature of its complexity.
G. Open Cable - Cabling that is not run in a raceway as defined by NFPA 70. This refers to cabling that is "open" to the space in which the cable has been installed and is therefore exposed to the environmental conditions associated with that space.
H. Open Office - A floor space division provided by furniture, moveable partitions, or other means instead of by building walls.
I. Pathway - A physical infrastructure utilized for the placement and routing of telecommunications cable.
1.05 SUBMITTALS
A. The submittals listed below are required and shall be submitted in accordance with Section 16010. Submittals shall include the manufacturer's name, trade name, place of manufacture, and catalog model or number. Include performance and characteristic curves. Submittals shall also include applicable federal, industry, and technical society publication references.
B. Shop Drawings/Product Data (submit prior to procurement/installation)
1. Telecommunications block (one-line) diagram - Shall show all equipment, cabling, and outlets with unique identifiers (tags) for all equipment and cables.
2. Telecommunications plans – Provide drawings in accordance with EIA TIA/EIA-606-A. The identifier for each termination and cable shall appear on the drawings. The plans shall include a layout of complete building per floor, including Building Area Boundaries, Backbone Systems, Horizontal Pathways, Drop Locations and Cable Identification (ID’S). The plans shall include details that identify circuit terminals and indicate the internal wiring for each item of equipment and the interconnection between each item of equipment. Include typical details for terminations. Floor plans in AutoCAD™ format are available from the Architect/Engineer for a fee of $75 per sheet.
3. Product data – Shall include telecommunications cabling, patch panels, telecommunications outlet/connector assemblies, connector blocks, equipment support frames, and all other equipment to be installed.
4. Manufacturer Test Reports – Shall include manufacturer’s factory reel test.
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5. Certificates – Shall include Telecommunications Contractor qualifications, Key Personnel qualifications, and Manufacturer qualifications
6. Test plan - Provide a complete and detailed test plan for the telecommunications cabling system including a complete list of test equipment for the UTP and optical fiber components and accessories. Include procedures for certification, validation, and testing.
C. Operation and Maintenance Manuals (submit when installation is substantially complete)
1. Include operation and maintenance information, including user manuals for all equipment.
2. Include all information in the shop drawing/product data submittal with updated as-built information and drawings.
3. Submit any required telecommunications management software on Compact Disk, along with a backup copy of any electronic databases or files developed during the course of the project.
D. Test Reports – Submit a binder with report of all testing required by Part 3 of this Section. Each cable shall have an individual test report signed and certified by the tester.
1.06 QUALITY ASSURANCE
A. Work under this section shall be performed by and the equipment shall be provided by an approved telecommunications contractor and key personnel. Qualifications shall be provided for the telecommunications system contractor, the telecommunications system installer, and the supervisor (if different from the installer). A minimum of 30 days prior to installation, submit documentation of the experience of the telecommunications contractor and of the key personnel.
B. Telecommunications Contractor - The Contractor shall be a firm which is regularly and professionally engaged in the business of the applications, installation, and testing of the specified telecommunications systems and equipment.
C. Key Personnel - Supervisors and installers assigned to the installation of this system or any of its components shall be Building Industry Consulting Services International (BICSI) Registered Cabling Installers, Level 2 minimum. Submit documentation of current BICSI certification for each of the key personnel. They shall have factory or factory-approved certification from each equipment manufacturer indicating that they are qualified to install and test the provided products. Submit documentation for a minimum of three and a maximum of five successful telecommunication system installations for each of the key personnel.
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1.07 ENVIRONMENTAL REQUIREMENTS
A. Connecting hardware shall be rated for operation under ambient conditions of 0 to 60 degrees C (32 to 140 degrees F) and in the range of 0 to 95 percent relative humidity, noncondensing.
1.08 WARRANTY
A. The warranty shall comply with the General Conditions of this Contract.
1.09 SPARE PARTS
A. Furnish one spare set of batteries for each unique UPS supplied.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS
A. Cabling and Accessories
1. Copper – “Belden,” “Alpha Wire,” “General Cable,” or equal.
2. Fiber – “Corning,” “Belden,” “Alpha Wire,” “General Cable,” or equal.
B. Cable Runway and Accessories
1. “B-Line,” “Homaco,” “Chalfant,” or equal.
2.02 COMPONENTS
A. All components shall be UL or third party certified. Where equipment or materials are specified to conform to industry and technical society reference standards of the organizations, submit proof of such compliance. The label or listing by the specified organization will be acceptable evidence of compliance. Provide a complete system of telecommunications cabling and pathway components using star topology. Provide support structures and pathways, complete with outlets, cables, connecting hardware and telecommunications cabinets/racks. Cabling and interconnecting hardware and components for telecommunications systems shall be UL listed or third party independent testing laboratory certified, and shall comply with NFPA 70 and conform to the requirements specified herein.
2.03 TELECOMMUNICATIONS PATHWAY
A. Provide telecommunications pathways in accordance with EIA TIA/EIA-569-A and as specified herein.
B. Conduit – See Section 16130 for requirements. Conduit is required in all areas except for the Administration building above ceiling, or inside electrical rooms wherein cable trays and open cable supports may be used.
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C. Cable Trays – Shall be NEMA VE 1 compliant. Cable trays shall form a wireway system, and shall be constructed of steel that has been zinc-coated after fabrication. Trays shall include splice and end plates, dropouts, and miscellaneous hardware. Edges, fittings, and hardware shall be finished free from burrs and sharp edges. Fittings shall have not less than load-carrying ability of straight tray sections and shall have manufacturer's minimum standard radius. Radius of bends shall be 12 inches minimum.
D. Open Telecommunications Cable Support
1. Open Top Cable Supports - Provide open top cable supports in accordance with UL 2043. Open top cable supports shall be galvanized steel.
2. Closed Ring Cable Supports - Provide closed ring cable supports in accordance with UL 2043. Closed ring cable supports shall be galvanized steel.
2.04 TELECOMMUNICATIONS CABLING
A. Cabling shall be UL listed for the application and shall comply with EIA TIA/EIA-568 and NFPA 70. Provide a labeling system for cabling as required by EIA TIA/EIA-606-A and UL 969. Cabling manufactured more than 12 months prior to date of installation shall not be used.
B. Backbone Cabling
1. Backbone Copper (Outside Plant) – Shall be RDUP/RUS PE-89 filled foam insulated telephone cable, 22 AWG, water blocked and designed for installation in underground ducts with 0.006” steel tape armor. Provide 25 pair minimum unless specified otherwise on the Drawings. General Cable Type 2007 or equal.
2. Backbone Optical Fiber
a. Provide in accordance with ICEA S-83-596, EIA TIA/EIA-568-C.3, UL 1666 and NFPA 70. Cable shall be imprinted with fiber count, fiber type and aggregate length at regular intervals not to exceed 40 inches.
b. Backbone fiber shall be EIA TIA/EIA-492AAAB, multimode, 50/125-um diameter, 0.275 numerical aperture and tight buffered fiber optic cable. Each fiber cable shall have a minimum of (6) fibers. Fiber cable shall be listed for outdoor wet location use in conduits/ducts. The cable cordage jacket, fiber, unit, and group color shall be in accordance with EIA TIA/EIA-598-B.
C. Horizontal Cabling - Provide horizontal cable in compliance with NFPA 70 and performance characteristics in accordance with EIA TIA/EIA-568-C.1.
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1. Horizontal Copper - Provide horizontal copper cable in accordance with EIA TIA/EIA-568-C.2, UL 444, ICEA S-90-661 UTP (unshielded twisted pair), 100 ohm, tested to 500Mhz minimum. Provide four each individually twisted pair, 24 AWG conductors, Category 6, with a blue (data) or white (telephone) thermoplastic jacket. Cable shall be imprinted with manufacturers name or identifier, flammability rating, gauge of conductor, transmission performance rating (category designation) at regular intervals not to exceed 3 feet. The word "FEET" or the abbreviation "FT" shall appear after each length marking. Provide communications general purpose (CM or CMG), communications plenum (CMP) or communications riser (CMR) rated cabling in accordance with NFPA 70. Type CMP and CMR may be substituted for type CM or CMG and type CMP may be substituted for type CMR in accordance with NFPA 70.
2. Work Area Cabling & Patch Cables
1. Work Area Copper - Provide pre-connectorized work area copper cable and patch cables in accordance with EIA TIA/EIA-568-C.2, with a blue thermoplastic jacket, compliant with same specifications as Horizontal Copper cabling above.
2. Work Area Optical Fiber - Provide pre-connectorized optical work area cable and patch cables in accordance with EIA TIA/EIA-568-C.3. Fibers shall be 50/125 um. Connectors shall be ST or SC, or type LC where required for ethernet switches.
2.05 TELECOMMUNICATIONS SPACES
A. Provide connecting hardware and termination equipment in the telecommunications entrance facility and telecommunication equipment room to facilitate installation as shown on design drawings for terminating and cross-connecting permanent cabling. Provide telecommunications interconnecting hardware color coding in accordance with EIA TIA/EIA-606-A.
B. Building Protector Assemblies - Provide self-contained 5 pin or screw type unit supplied with a field cable stub factory connected to protector socket blocks to terminate and accept protector modules for outside cable. Building protector assembly shall have interconnecting hardware for connection to interior cabling at full capacity. Provide manufacturer’s instructions for building protector assembly installation.
C. Protector Modules - Provide in accordance with UL 497 solid state type 5 pin or screw type rated for the application. Provide the number of surge protection modules equal to the number of pairs of exterior cable of the building protector assembly.
D. Backboards - Provide plywood 3/4-inch thick.
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E. Equipment Support Frame - Provide in accordance with EIA-310-D and UL 50.
a. Administration Building: Provide a free-standing cabinet suitable depth to house the servers, 16 gauge steel or 11gauge aluminum construction , minimum, treated to resist corrosion. Cabinet shall have removable and lockable side panels, front and rear doors, and have adjustable feet for leveling. Cabinet shall be vented in the roof and rear door. Cabinet shall have cable access in the roof and base and be compatible with 19 inch panel mounting. Provide cabinet with grounding bar, roof-mounted 550 CFM fan with filter and a surge protected power strip with 6 duplex 20 amp receptacles. All cabinets shall be keyed alike.
b. Filter, Chemical, & High Service Buildings; Provide double-hinged wall-mount cabinets, 16 gauge steel or 11 gauge aluminum construction , minimum, treated to resist corrosion. Cabinet shall have lockable front and rear door[s], louvered side panels, 250 CFM roof mounted fan, ground lug, and top and bottom cable access. Cabinet shall be compatible with 19 inch panel mounting. All cabinets shall be keyed alike. A surge protected power strip with 6 duplex 20 amp receptacles shall be provided within the cabinet.
F. Connector Blocks - Provide insulation displacement connector (IDC) Type 110. Provide blocks for the number of horizontal and backbone cables terminated on the block plus 25 percent spare.
G. Cable Guides - Provide cable guides, ring or bracket type, specifically manufactured for the purpose of routing cables, wires and patch cords horizontally and vertically on 19 inch equipment racks, cabinets, and telecommunications backboards.
H. Patch Panels - Provide ports for the number of horizontal and backbone cables terminated on the panel plus 25 percent spare. Provide pre-connectorized patch cords for patch panels – one for each switch port including spare ports. Provide patch cords, as complete assemblies, with matching connectors as specified. Provide fiber optic patch cables with crossover orientation in accordance with EIA TIA/EIA-568-C.3. Patch cords shall meet minimum performance requirements specified in EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2 and EIA TIA/EIA-568-C.3 for cables, cable length and hardware specified.
1. Modular to 110 Block Patch Panel - Provide in accordance with EIA TIA/EIA-568-C.1 and EIA TIA/EIA-568-C.2. Panels shall be third party verified and shall comply with EIA/TIA Category 6 requirements. Panel shall be constructed of 0.09 inch minimum aluminum and shall be 19” rack mounted. Panel shall provide 24 non-keyed, 8-pin modular ports, wired to T568B. Patch panels shall terminate the building cabling on Type 110 IDCs and shall utilize a
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printed circuit board interface. The rear of each panel shall have incoming cable strain-relief and routing guides. Panels shall have each port factory numbered and be equipped with Cable ID labels above each port.
2. Fiber Optic Patch Panel - Provide panel for maintenance and cross-connecting of optical fiber cables. Panel shall be constructed of 16 gauge steel or 11 gauge aluminum minimum and shall be rack mounted and compatible with a EIA-310-D 19 inch equipment rack. Provide dust cover for unused adapters. The rear of each panel shall have a cable management tray a minimum of 8 inches deep with removable cover, incoming cable strain-relief and routing guides. Panels shall have each adapter factory numbered and be equipped with laminated plastic nameplates above each adapter. Each fiber shall be terminated including spares.
2.06 TELECOMMUNICATIONS OUTLET/CONNECTOR ASSEMBLIES
A. Outlet/Connector Copper - Outlet/connectors shall comply with FCC Part 68EIA TIA/EIA-568-C.1, and EIA TIA/EIA-568-C.2. UTP outlet/connectors shall be UL 1863 listed, non-keyed, 8-pin modular, constructed of high impact rated thermoplastic housing, third party verified, and shall comply with EIA TIA/EIA-568-C.2 Category 6 requirements. Outlet/connectors provided for UTP cabling shall meet or exceed the requirements for the cable provided. Outlet/connectors shall be terminated using a Type 110 IDC PC board connector, color-coded for both T568A and T568B wiring. Each outlet/connector shall be wired T568B. UTP outlet/connectors shall comply with EIA TIA/EIA-568-C.2 for 200 mating cycles. UTP outlet/connectors installed in outdoor or corrosive environments shall be jell-filled type containing an anti-corrosive, memory retaining compound.
B. Cover Plates - Telecommunications cover plates shall comply with UL 514C, and EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2, EIA TIA/EIA-568-C.3; flush design constructed of stainless material to match color of receptacle/switch cover plates specified in Section 16140. Provide labeling in accordance with the paragraph LABELING in this section.
2.07 GROUNDING AND BONDING PRODUCTS
A. Provide in accordance with UL 467, TIA J-STD-607-A, and NFPA 70. Components shall be identified as required by EIA TIA/EIA-606-A
2.08 FIELD FABRICATED NAMEPLATES
A. Provide laminated plastic nameplates for each equipment enclosure, relay, switch, and device. Each nameplate inscription shall identify the function and, when applicable, the position. Nameplates shall be melamine plastic, 0.125 inch thick, white with black center core. Surface shall be matte finish. Corners shall be square. Accurately align lettering and engrave into the core. Minimum size of nameplates shall be 1 by 2.5
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inches. Lettering shall be a minimum of 0.25 inch high normal block style.
2.09 TESTS, INSPECTIONS, AND VERIFICATIONS
A. Factory Reel Tests - Provide documentation of the testing and verification actions taken by manufacturer to confirm compliance with EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.3, and EIA TIA/EIA-526-14A for multimode optical fiber cables.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Install telecommunications cabling and pathway systems, including the horizontal and backbone cable, pathway systems, telecommunications outlet/connector assemblies, and associated hardware in accordance with EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2, EIA TIA/EIA-568-C.3, EIA TIA/EIA-569-A, NFPA 70, and UL standards as applicable. Provide cabling in a star topology network. Pathways and outlet boxes shall be installed as specified in Sections 16130 and 16131. Install telecommunications cabling with copper media in accordance with the following criteria to avoid potential electromagnetic interference between power and telecommunications equipment. The interference ceiling shall not exceed 3.0 volts per meter measured over the usable bandwidth of the telecommunications cabling. Cabling shall be run with horizontal and vertical cable guides in telecommunications spaces with terminating hardware and interconnection equipment. All cable should be installed in a neat and workmanlike manner.
B. Cabling – Install UTP and optical fiber telecommunications cabling system as detailed in EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2, EIA TIA/EIA-568-C.3. Screw terminals shall not be used except where specifically indicated on plans. Use an approved insulation displacement connection (IDC) tool kit for copper cable terminations. Do not untwist UTP cables more than 1/2 inch from the point of termination to maintain cable geometry. Provide service loop on each end of the cable, 10 feet in the telecommunications room, and 12 inches in the work area outlet. Do not exceed manufacturers' cable pull tensions for copper and optical fiber cables. Provide a device to monitor cable pull tensions. Do not exceed 25 pounds pull tension for four pair copper cables. Do not chafe or damage outer jacket materials. Use only lubricants approved by cable manufacturer. Do not over cinch cables, or crush cables with staples. For UTP cable, bend radii shall not be less than four times the cable diameter. Cables shall be terminated; no cable shall contain unterminated elements. Cables shall not be spliced. Label cabling in accordance with paragraph LABELING in this section.
1. Open Cable - Use only above ceiling in the administration building or in electrical rooms. Install in accordance with EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2 and EIA TIA/EIA-568-C.3. Do not exceed
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cable pull tensions recommended by the manufacturer. Copper cable not in a wireway or pathway shall be suspended a minimum of 8 inches above ceilings by cable supports no greater than 60 inches apart. Cable shall not be run through structural members or in contact with pipes, ducts, or other potentially damaging items. Placement of cable parallel to power conductors shall be avoided, if possible; a minimum separation of 12 inches shall be maintained when such placement cannot be avoided.
C. Pathway Installations - Provide in accordance with EIA TIA/EIA-569-A and NFPA 70. Provide building pathways as specified herein and in Section 16130.
D. Cable Tray Installation - Install cable tray per manufacturer's instructions and NFPA 70. Only CMP and OFNP type cable shall be installed in a plenum.
E. Work Area Outlets
1. Terminations - Terminate UTP cable in accordance with EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2 and wiring configuration as specified.
2. Cover Plates - As a minimum, each outlet/connector shall be labeled as to its function and a unique number to identify cable link in accordance with the paragraph LABELING in this section.
3. Cables - Unshielded twisted pair cables shall have a minimum of 12 inches of slack cable loosely coiled into the telecommunications outlet boxes. Minimum manufacturer's bend radius for each type of cable shall not be exceeded.
4. Pull Cords - Pull cords shall be installed in conduit serving telecommunications outlets that do not have cable installed.
F. Telecommunications Space Termination - Install termination hardware required for Category 6 and optical fiber system. An insulation displacement tool shall be used for terminating copper cable to insulation displacement connectors.
1. Connector Blocks - Connector blocks shall be rack mounted in orderly rows and columns. Adequate vertical and horizontal wire routing areas shall be provided between groups of blocks. Install in accordance with industry standard wire routing guides in accordance with EIA TIA/EIA-569-A.
2. Patch Panels - Patch panels shall be mounted with sufficient ports to accommodate the installed cable plant plus 25 percent spares.
a. Copper Patch Panel - Copper cable entering a patch panel shall be secured to the panel with cable ties or as
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recommended by the manufacturer to prevent movement of the cable.
b. Fiber Optic Patch Panel - Fiber optic cable loop shall be 3 feet in length. The outer jacket of each cable entering a patch panel shall be secured to the panel to prevent movement of the fibers within the panel, using clamps or brackets specifically manufactured for that purpose.
3. Equipment Support Frames - Install in accordance with EIA TIA/EIA-569-A. Provide a quad-plex receptacle at each backboard.
G. Electrical Penetrations - Seal openings around electrical penetrations through fire resistance-rated wall, partitions, floors, or ceilings as specified in Section 16010.
H. Grounding and Bonding - Provide in accordance with TIA J-STD-607-A and NFPA 70. Provide a #2 AWG insulated isolated ground conductor from the service entrance ground point to the backboard or cabinet/rack where terminal equipment is to be located. The Contractor shall be responsible for this installation, and the conductor shall terminate on an isolated ground bus, 12 inches in length, equal in capacity to the #2 conductor.
I. Surge Protection - All cables and conductors, except fiber optic cable, which serve as communication lines through off-premise lines, shall have surge protection installed at each end which meet the requirements of RUS Bul 1751F-815.
3.02 LABELING
A. Labels - Provide labeling in accordance with EIA TIA/EIA-606-A. Handwritten labeling is unacceptable. Stenciled lettering for voice and data circuits shall be provided using thermal ink transfer process (such as a Brady labeler) or a laser printer.
B. Cables shall be labeled using color labels on both ends with identifiers in accordance with EIA TIA/EIA-606-A.
C. Termination Hardware - Workstation outlets and patch panel connections shall be labeled using color coded labels with identifiers in accordance with EIA TIA/EIA-606-A.
3.03 FIELD APPLIED PAINTING
A. PVC conduit is required to be painted. Painting shall be as specified in Division 9.
3.04 FIELD FABRICATED NAMEPLATE MOUNTING
A. Fasten nameplates to the device with a minimum of two stainless steel machine screws or rivets.
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3.05 TESTING
A. Telecommunications Cabling Testing - Perform telecommunications cabling inspection, verification, and performance tests in accordance with EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2, and EIA TIA/EIA-568-C.3 where applicable. Perform optical fiber field inspection tests via attenuation measurements on factory reels and provide results along with manufacturer certification for factory reel tests. Remove failed cable reels from project site upon attenuation test failure.
1. Inspection - Visually inspect UTP and optical fiber jacket materials for UL or third party certification markings. Inspect cabling terminations in telecommunications rooms and at workstations to confirm color code for T568B pin assignments, and inspect cabling connections to confirm compliance with EIA TIA/EIA-568-C.1, EIA TIA/EIA-568-C.2, and EIA TIA/EIA-568-C.3. Visually confirm Category 6 marking of outlets, cover plates, outlet/connectors, and patch panels.
2. Verification Tests - UTP backbone copper cabling shall be tested for DC loop resistance, shorts, opens, intermittent faults, and polarity between conductors, and between conductors and shield, if cable has overall shield. Test operation of shorting bars in connection blocks. Test cables after termination but not cross-connected. For multimode optical fiber, perform optical fiber end-to-end attenuation tests in accordance with EIA TIA/EIA-568-C.3 and EIA TIA/EIA-526-14A using Method A, Optical Power Meter and Light Source for multimode optical fiber. Perform verification acceptance tests.
3. Performance Tests - Perform testing for each outlet as follows:
a. Perform Category 6 link tests in accordance with EIA TIA/EIA-568-C.1 and EIA TIA/EIA-568-C.2. Tests shall include wire map, length, insertion loss, NEXT, PSNEXT, ELFEXT, PSELFEXT, return loss, propagation delay, and delay skew.
b. Optical fiber Links. Perform optical fiber end-to-end link tests in accordance with EIA TIA/EIA-568-C.3.
4. Final Verification Tests - Perform verification tests for UTP and optical fiber systems after the complete telecommunications cabling and workstation outlet/connectors are installed.
a. Voice Tests - These tests assume that dial tone service has been installed. Connect to the network interface device at the demarcation point. Go off-hook and listen and receive a dial tone. If a test number is available, make and receive a local, long distance, and DSN telephone call.
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b. Data Tests - These tests assume the network is installed and is available for testing. Connect to the network interface device at the demarcation point. Log onto the network to ensure proper connection to the network.
c. Video Tests - Equipment and systems shall be tested demonstrating that the coaxial cable premises distribution system conforms to the specified requirements, and that the required equipment and systems are entirely operational.
END OF SECTION
***
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SECTION 16711
NETWORK SWITCHING/ROUTING PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Provide network switching/routing hardware, software, and
configuration/programming/commissioning services as specified herein and as indicated on the Drawings. Integration with WMU’s existing network is required.
B. Base bid supplier for this Section is Box Lake Networks. Contact Jake Stier, 859-737-4400.
1.02 RELATED WORK
A. Drawings and General Provisions of this Contract including General and Supplementary Conditions and Division 1 Specifications Sections, apply to work of this Section.
B. Section 16010 – General Electrical Requirements C. Section 16710 – Building Telecommunications Cabling System
1.03 SUBMITTALS
A. Shop Drawings/Product Data (submit prior to procurement/installation)
1. Network Architecture & Security Submittal – Provide a submittal
including key networking components, proposed IP addressing of each component, Layer 3 switch config, VLAN config, remote access/VPN config, and security protocols.
2. Product data – Submit all network hardware for approval
B. Operation and Maintenance Manuals (submit when installation is
substantially complete) 1. Include operation and maintenance information, including user
manuals for all equipment. 2. Include all information in the shop drawing/product data submittal
with updated as-built information and drawings.
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1.04 QUALITY ASSURANCE
A. The Network professional shall be a Cisco Certified Network Professional or Microsoft Certified Network Engineer. Submit documentation of current certification for key person.
1.07 ENVIRONMENTAL REQUIREMENTS
A. Hardware shall be rated for operation under ambient conditions 40 to
120 degrees F and in the range of 0 to 95 percent relative humidity, noncondensing.
1.08 WARRANTY
A. The warranty shall comply with the General Conditions of this Contract. 1.09 SPARE PARTS
A. Provide one spare 24 port switch and one spare 10 port fiber switch. 1.10 NETWORK ARCHITECTURE AND SECURITY REQUIREMENTS
A. The network and security architecture shall be designed by a certified network professional as specified above. System shall be designed to prevent unauthorized intrusion or attack. The network architecture shall include secure VPN links to Strodes Creek WWTP and WMU central office.
B. The network shall be segmented into VLANs – one for control/SCADA system and one for general data. A third VLAN should be configured for the video surveillance system.
C. The router/security appliance shall be configured for secure VPN access to the network by authorized personnel. Capacity for at least 5 simultaneous remote connections shall be included.
D. The approved network professional will be responsible for IP addressing, managed switch/router, configuration, and router/security appliance configuration. Coordination with SCADA programmer and Filter Control system supplier is required.
E. A submittal must be prepared and submitted to Engineer for approval, and O&M manuals must be submitted documenting equipment installed, configuration settings, IP addressing, procedures for VPN connection, etc.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Cisco to match existing equipment.
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2.02 ETHERNET SWITCHES
A. Switch shall be managed type and have Layer 3 functionality with 24 10/100 ports. Each port shall support POE. Switch shall support VLAN functionality and IGMP snooping. Status indicators shall be included for each port.
B. Switch shall be 19” rack-mounted inside the network cabinet. It shall only require 1U of rack space. Power supply shall be 120VAC.
C. Switch shall have (4) gigabit SFP ports, 2 of which shall allow either copper or fiber termination.
D. Provide appropriate fiber modules and fiber patch cables for each switch.
E. Switches shall be Cisco SF300-24PP or better.
2.03 FIBER SWITCH
A. Switch shall be managed type and have Layer 3 functionality with 10 gigabit SFP ports. Switch shall support VLAN functionality and IGMP snooping. Status indicators shall be included for each port.
B. Switch shall be 19” rack-mounted inside the network cabinet. It shall only require 1U of rack space. Power supply shall be 120VAC.
C. Provide appropriate fiber modules and fiber patch cables for each port.
D. Switch shall be Cisco SG300-10SFP or better.
2.04 ROUTER
A. The existing Cisco 1941 router shall be utilized for this project unless it is determined that it does not have the capacity to satisfy the requirements specified herein and indicated on the Drawings. Otherwise supply a new Cisco VPN router/firewall with appropriate specifications.
2.04 WIRELESS ACCESS POINTS (WAPs)
A. Provide Cisco 500 series or better access points. WAPs shall be POE
powered and shall have brackets for wall or ceiling mounting. They shall support multiple VLANs and multiple SSIDs. WAPs shall include IEEE 802.11b/g/n wireless support at a minimum, with a 1gbps Ethernet port.
PART 3 - EXECUTION 3.01 INSTALLATION
A. Coordinate with network cabling supplier for proper installation of network hardware. All equipment and cables shall be labeled.
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B. All hardware shall be installed per manufacturer’s instructions.
C. Provide programming/configuration of all supplied equipment as per the approved network submittal.
3.02 TESTING
A. Coordinate with various suppliers (including Filter supplier, SCADA supplier, video supplier, etc) to ensure that network equipment is operating properly and appropriate support personnel have functioning VPN accounts. Ensure WMU personnel have access to appropriate network resources at home office. Ensure wireless functions in all buildings.
END OF SECTION
***
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SECTION 16726
LIFE SAFETY ALARM SYSTEM-ADDRESSABLE/VOICE PART 1 - GENERAL 1.01 SCOPE OF WORK
A. The work covered by this section of the Specifications includes the furnishing of all labor, equipment, materials, and performance of all operations associated with the installation of the Life Safety Alarm System for the Chemical Building as shown on the Drawings and as herein specified. The Alarm System shall satisfy the requirements of the Kentucky Building Code for both a Fire Alarm System and an Emergency Alarm System for hazardous occupancies. Its initiating devices and notification appliances shall distinguish between the two different types of alarms as specified herein.
B. The requirements of the conditions of the Contract, Supplementary
Conditions, and General Requirements apply to the work specified in this section.
C. The complete installation shall conform to the applicable sections of
NFPA-72, Local Code Requirements and National Electrical Code with particular attention to Article 760.
D. All new systems furnished under this Contract shall be the same brand.
E. One year of UL listed monitoring shall be included.
1.02 RELATED WORK SPECIFIED ELSEWHERE
A. Division 16 1.03 QUALITY ASSURANCE
A. Each and all items of the Alarm System shall be listed as a product of a SINGLE alarm system manufacturer under the appropriate category by Underwriters’ Laboratories, Inc. (UL), and shall bear the “UL” label. All control equipment shall be listed under UL category UOJZ as a single control unit. Partial listing shall NOT be acceptable.
B. All control equipment must have transient protection to comply with UL
864 requirements.
C. Where Fire Alarm circuits leave the building, additional transient protection must be provided for each circuit. Devices must be UL listed under standard #497B (Isolated Loop Circuit Protectors).
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D. In addition to the UI- UOJZ requirement mentioned above, the system controls shall be UL listed for Power Limited Applications and all circuits must be marked in accordance with NEC Article 760-23.
1.04 GENERAL
A. Furnish and install a complete Alarm System as described herein and as shown on the Drawings, to be wired, connected, and left in first class operating condition. Include sufficient control panels, manual stations, automatic fire detectors, smoke detectors, alarm indicating appliances, wiring, terminations, electrical boxes, and all other necessary material for a complete operating system. This includes all modules needed in the Life Safety Control Panel (LSCP) for operations as specified.
B. The alarm system shall allow for loading and editing special instructions
and operating sequences as required. The system shall be capable of onsite programming to accommodate system expansion and facilitate changes in operation. All software operations shall be stored in a non-volatile programmable memory within the alarm control panel. Loss of primary and secondary power shall not erase the instructions stored in memory.
C. Full flexibility for selective input/output control functions based on
ANDing, ORing, NOTing, timing, and special coded operations shall also be incorporated in the resident software programming of the system.
D. Resident software shall allow for full configuration of initiating circuits so
that additional hardware shall not be necessary to accommodate changes in, for instance, sensing or normally open contact devices to sensing of normally closed contact devices, or from sensing or normally open contact devices to sensing a combination of current limited and non-current limited devices on the same circuit and being able to differentiate between the two, or changing from a non-verification circuit to a verification circuit or vice-versa.
E. Resident software shall also allow for configuration of indicating
appliance and control circuits so that additional hardware shall not be necessary to accommodate changes in, for instance, changing a non-coded indicating appliance circuit to a coded circuit, or from a slow march time (20 BPM) to a fast march time (120 BPM).
F. The system shall have the capability of recalling alarms and trouble
conditions in chronological order for the purpose of recreating an event history.
G. All panels and peripheral devices shall be the standard product of a
single manufacturer and shall display the manufacturer’s name on each component. Acceptable manufacturers are Notifier, EST, Fike, or equal. Proprietary systems will not be accepted. If there are not at least (2)
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independent manufacturer partners with 150 miles of the project site then the system will be considered proprietary and will not be accepted.
H. Verification of Dimensions
1. The Contractor shall become familiar with all details of the work,
verify all dimensions in the field, and shall advise the A/E of any discrepancy before performing the work.
1.05 OPERATION
A. The following description sets forth the minimum requirements of the alarm system. Some operational features described herein may not be utilized at this time, but the system shall have the capability.
B. The system alarm operation subsequent to the alarm activation of any
manual station or automatic detection device shall be as follows:
1. All audible alarm indicating appliances shall sound a march time pattern until silenced by the alarm silence switch at the control panel.
2. All visible alarm indicating appliances shall flash continuously until
the system is reset.
3. The alarm condition shall be logged to the alarm Historical Log for future recall and review by the Owner’s operator. Refer to Control Panel operations for full logging details.
4. Any subsequent zone alarm shall reactivate the alarm indicating
appliances.
5. All doors normally held by door control devices shall release.
6. The mechanical controls shall activate the air handling systems in accordance with NFPA 90A.
7. Upon reset of the Life Safety control panel, air handling systems
shall sequentially start up to minimize power demand.
8. The alarm shall be displayed on an 80 character LCD display. The top line of 40 characters shall be the point label and the second line shall be the device type identifier. The system alarm LED shall flash on the control panel until the alarm has been acknowledged. Once acknowledged, this same LED shall latch on. A subsequent alarm received from another zone shall flash the system alarm LED on the control panel. The LCD display shall show the new alarm information. To accommodate and facilitate job site changes, the 40 character custom label shall be on-site programmable by local service personnel.
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9. A pulsing alarm tone shall occur within the control panel until the
event has been acknowledged.
10. The control panel shall have the capability to display the number of times (tally) a zone has gone into a verification mode. Should this smoke verification tally reach a pre-programmed number, a trouble condition shall occur.
11. Alarm verification zones shall be able to be divided into 8 separate
groups whereby only verification zones from the same group will confirm the first activation and cause the alarm sequence to occur.
12. The control panel shall have a dedicated supervisory service LED
and a dedicated supervisory service acknowledge switch.
13. A manual evacuation (drill) switch shall be provided to operate the alarm indicating appliances without causing other control circuits to be activated. However, should a true alarm occur, all alarm functions would occur as described previously.
14. Activation of an auxiliary bypass switch shall override the selected
automatic functions.
15. The system shall have a single key that will allow the operator to display all alarms, troubles, and supervisory service conditions including the time of each occurrence.
16. All doors normally held open by door control devices shall release
upon AC power failure.
17. The actuation of the “enable walk test” program at the control panel shall activate the “Walk Test” mode of the system which shall cause the following to occur:
a. Control relay functions shall be bypassed.
b. The control panel shall show a trouble condition.
c. The alarm activation of any initiation device shall cause the
audible signals to activate for 2 seconds.
d. The panel shall automatically reset itself after signaling is complete.
e. Any momentary opening of an initiating or indicating
appliance circuit wiring shall cause the audible signals to sound for 4 seconds indicating a trouble condition.
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f. The system shall have the capacity of 8 distinctive walk test groups, such that only a portion of the system need be disabled during testing.
g. Bypass the digital communicator circuit.
1.06 SUPERVISION
A. The system shall contain a minimum of 2 Class “B: (Style “B”) independently supervised initiating device circuits. The alarm activation of any initiation circuit shall not prevent the subsequent alarm operation of any other initiation circuit.
B. There shall be a minimum of 4 independently supervised and
independently fused indicating appliance circuits for alarm speakers and flashing alarm lamps. Disarrangement conditions of any circuit shall not affect the operation of other circuits.
C. Auxiliary manual controls shall be supervised so that an “off normal”
position of any switch shall cause an “off normal” system trouble.
D. Each independently supervised circuit shall include a discrete LCD readout to indicate disarrangement conditions per circuit.
E. The incoming power to the system shall be supervised so that any power
failure must be audibly and visually indicated at the control panel. A green “power on” LED shall be displayed continuously while incoming power is present.
F. The system batteries shall be supervised so that a low battery condition
or disconnection of the battery shall be audibly and visually indicated at the control panel.
G. The System Modules shall be electrically supervised for module
placement. Should a module become disconnected, the system trouble indicator shall illuminate and the audible trouble signal shall sound.
H. The system shall have provisions for disabling and enabling all circuits
individually for maintenance or testing purposes. 1.07 POWER REQUIREMENTS
A. The control panel shall receive 120 VAC power (as noted on the Drawings) via a circuit breaker. The Contractor shall label the breaker and furnish and install a locking device.
B. The system shall be provided with sufficient battery capacity to operate
the entire system upon loss of normal 120 VAC power in a normal supervisory mode for a period of 4 hours with 5 minutes of alarm operation at the end of this period. The system shall automatically
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transfer to the standby batteries upon power failure. All battery charging and recharging operations shall be automatic. Substantiating battery calculations shall be submitted for supervisory and alarm power requirements. Ampere- hour requirements for each system component and each panel component shall be submitted with the calculations.
C. All external circuits requiring system operating power shall be 24VDC
and shall be individually fused at the control panel. 1.08 SUBMITTALS
A. Shop Drawings
1. Shop drawings shall be submitted in accordance with General and Special Conditions and shall consist of a complete set of equipment and materials, including manufacturer’s descriptive and technical literature; performance charts and curves; catalog cuts; and installation instructions. Shop Drawings shall also contain complete wiring and schematic diagrams and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment relationships to other parts of the work including clearances for maintenance and operation. A floor plan drawing indicating alarm devices and wiring only shall be submitted by the Contractor for job site use. These drawings must be approved by the State Fire Marshal’s Office. The Contractor is responsible for paying any fees and for obtaining State approval of the Alarm System. The Contractor shall submit Shop Drawings, including wiring schematics and floor plans, to the Engineer for acceptance prior to making submittal to DHBC for approval. A copy of the approval shall be sent to the A/E once obtained. The Contractor's submittal shall be signed by a registered fire protection designer who is regularly engaged in fire protection and detection design.
B. The Contractor shall furnish 3 Operation and Maintenance manuals to be
turned over to the Owner upon acceptance of the installation. Each manual shall be bound in a hard cover 3-ring binder, and indexed based on the CSI standard. The index shall include vendors name, address, and telephone number for all equipment purchased on the project.
C. The Operation and Maintenance manuals shall contain copies of the State
approved Shop Drawings, manufacturer’s operating and service manuals, parts lists, and manufacturer’s warranty listing the Owner by name. If the service manual from any one vendor covers several different model numbers, the model used on the project must be highlighted. The binders shall not be more than 2/3 full; if so, additional binders shall be furnished. Final payment to the Contractor will not be made until Maintenance Manuals have been received and accepted.
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D. Shop Drawings shall be clearly marked and or highlighted as to which product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles / configurations represented on the literature.
PART 2 - PRODUCTS 2.01 LIFE SAFETY CONTROL PANEL
A. Control Panel construction shall be modular with solid state, microprocessor based electronics. It shall display only those primary controls and displays essential to operation during an alarm condition. Keyboards or keypads shall not be required to operate the system during alarm conditions. A local audible device shall sound during Alarm, Trouble or Supervisory conditions. This audible device shall sound differently during each condition to distinguish one condition from another without having to view the panel. This audible device shall also sound during each keypress to provide an audible feedback to ensure that the key has been pressed properly.
B. The following primary controls shall be visible through a front access
panel:
1. Eighty character liquid crystal display 2. Individual red system alarm LED 3. Individual yellow supervisory service LED 4. Individual yellow trouble LED 5. Green “power on” LED 6. Alarm acknowledge key 7. Supervisory acknowledge key 8. Trouble acknowledge key 9. Alarm silence key 10. System reset key
C. The following secondary control switches and LED’s shall be available
behind an access door:
1. Manual evacuation (drill) 2. Elevator bypass 3. Door holder release bypass 4. Future
D. The control panel shall provide the following:
1. Setting of time and date 2. LED testing 3. Alarm, trouble, and abnormal condition listing 4. Enabling and disabling of each monitor point
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5. Activation and deactivation of each control point separately 6. Changing operator access levels 7. Walk test enable 8. Running diagnostic functions 9. Displaying software revision level 10. Displaying historical logs 11. Displaying card status 12. Point listing
E. For maintenance purposes, the following lists should be available from
the point lists menu:
1. All points lists by address 2. Monitor point list 3. Signal/speaker list 4. Auxiliary control list 5. Feedback point list 6. Pseudo point list 7. LED/switch status list
Scrolling though menu options or lists shall be accomplished in a self-directing manner in which prompting messages shall direct the user. These controls shall be located behind an access door.
F. Primary Keys, LED’s and LCD Display
1. The Control Panel shall have a 2 line x 40 character liquid crystal
display which shall be backlit for enhanced readability. So as to conserve battery standby power, it shall not be lit during an AC power failure unless an alarm condition occurs or there is keypad activity.
2. The display shall support both upper and lower case letters. Lower
case letters shall be used for softkey titles and prompting the user. Upper case letters shall be used for System Status Information. A cursor shall be visible when entering information.
2.02 SYSTEM FRONT PANEL OPERATION AND CAPABILITIES
A. Under normal condition, the front panel shall display a “System is Normal” message and the current time and date.
B. Should an abnormal condition be detected, the appropriate LED (Alarm,
Supervisory or Trouble) shall flash. The panel audible signal shall pulse for alarm conditions and sound steady for trouble and supervisory conditions.
C. The LCD shall display the following information relative to the abnormal
condition of a point in the system.
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1. 40 character custom location label 2. Type of device (i.e. smoke, pull station, waterflow) 3. Point status (i.e. alarm, trouble)
D. Two methods of acknowledgment for each abnormal condition shall be
provided. One may be chosen depending on the NFPA requirements.
1. For NFPA 72 requirements: Pressing the appropriate acknowledge button shall globally acknowledge every point in the list.
These acknowledge functions may be passcode protected if the user has insufficient privilege to acknowledge such conditions. A message shall indicate insufficient privilege but allow the user to view the points without acknowledging them. Should the user have sufficient privilege to acknowledge, a message will be displayed informing the user that the condition has been acknowledged.
E. After all points have been acknowledged, the LEDs shall glow steady and
the Sonalert will be silenced. The total number of alarms, supervisory and trouble conditions shall be displayed along with a prompt to review each list chronologically. The end of the list shall be indicated by an end of list message “END of LIST.”
F. Alarm Silencing
1. Should the “Alarm Silence” button be pressed, all alarm signals
shall cease operation.
2. Signals shall not be silenced during alarm silence inhibit mode.
G. System Reset
1. The SYSTEM RESET button shall be used to return the system to its normal state after an alarm condition has been remedied. The LCD display shall step the user through the reset process with simple English Language messages. Messages, “SYSTEM RESET IN PROGRESS,” will first be displayed followed by the message, “SYSTEM RESET COMPLETED,” and finally, “SYSTEM IS NORMAL,” should all alarm conditions be cleared.
2. Should an alarm condition continue to exist, the message “SYSTEM
RESET IN PROGRESS,” will be followed by the message, “SYSTEM RESET ABORTED,” and the system will remain in an abnormal state. System control relays shall not reset. The Sonalert and the Alarm LED will be on. The display will indicate the total number of alarms and troubles present in the system along with a prompt to use the ACK keys to review the points. These points will not require acknowledgment if they were previously acknowledged.
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3. Should the Alarm Silence Inhibit function be active, the (SYSTEM RESET) key press will be ignored. The message, “SYSTEM RESET INHIBITED,” will be displayed for a short time to indicate the action was not taken. As feedback to the operator, the message “SYSTEM RESET NO LONGER INHIBITED” will be displayed when the inhibit function times out.
H. Function Keys: Additional function keys shall be provided to access status
data for the following points:
1. Initiating device circuits 2. Indicating appliance circuits 3. Auxiliary relays 4. Feedback points 5. All other input/output points
The following status data shall be available:
6. Primary state of point 7. Zone, PID and card type information 8. Class “A” status 9. Current priority of outputs 10. Disable/enable status 11. Verification tallies of initiating devices 12. Automatic/manual control status of output points 13. Acknowledge status 14. Relay status
I. History Logging
1. The system shall be capable of logging and storing 300 events in
an alarm log and 300 events in a trouble log. These events shall be stored in a battery protected random access memory. Each recorded event shall include the time and date of that event’s occurrence.
2. The following Historical Alarm log events shall be stored:
a. Alarms b. Alarm acknowledgment c. Alarm silence d. System reset e. Alarm historical log cleared
J. The following Historical Trouble Log events shall be stored:
1. Trouble conditions 2. Supervisory alarms 3. Trouble acknowledgment 4. Supervisory acknowledgment
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5. Alarm verification tallies 6. Walk test results 7. Trouble historical log cleared 8. Silent walk test with history logging
K. The system shall be capable of being tested by one person. While in
testing mode, the alarm activation of an initiating device circuit shall be silently logged as an alarm condition in the historical data file. The panel shall automatically reset itself after logging of the alarm.
L. The momentary disconnection of an initiating or indicating device circuit
shall be silently logged as a trouble condition in the historical data file. The panel shall automatically reset itself after logging of the trouble condition.
M. Should the walk test feature be on for an appropriate amount of time (8
hours), it shall revert to the normal mode automatically.
N. The control panel shall be capable of supporting up to 8 separate testing groups whereby one group of points may be in a testing mode and the other (non-testing) groups may be active and operate as programmed per normal system operation. After testing is considered complete, testing data may be retrieved from the system in chronological order to ensure device/circuit activation.
O. Should an alarm condition occur from an active point, not in walk test
mode, it shall perform operations described in Section 1.04.
P. LED Supervision
1. All sleeve module LEDs shall be supervised for burnout or disarrangement. Should a problem occur, the LCD shall display the module and LED location number to facilitate location of that LED.
Q. System Trouble Reminder
1. Should a trouble condition be present within the system and the
audible trouble signal silenced, the trouble signal shall resound at the preprogrammed time intervals to act as a reminder that the alarm system is not 100 percent operational. Both the time interval and the trouble reminder signal shall be programmable to suit the Owner’s application.
R. Access Levels
1. There shall be 4 access levels with level 4 being the highest level.
Level 1 actions shall not require a passcode. Passcodes shall consist of up to 10 digits. Changes to passcodes shall only be made by authorized personnel.
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2. In order to maintain security when entering a passcode, the digits
entered will not be displayed but a cursor will move along filling the position with an X to indicate that the digit has been accepted. All key presses will be acknowledged by a local audible sound.
3. When a correct passcode is entered, the message, “Access
Granted” shall be displayed. The new access level shall be in effect until the operator manually logs out or the keypad has been inactive for 10 minutes.
4. Should an invalid code be input, the operator shall be notified with
the message, “ERROR... INCORRECT PASSCODE,” and shall be allowed up to 3 chances to enter a valid code. After 3 unsuccessful tries, the message, “ACCESS DENIED,” shall be displayed. The level shall not be altered, and the operator shall no longer be in the menu option.
5. Access to a level will only allow the operator to perform all actions
within that level plus all actions of lower levels, not higher levels.
6. The following keys/switches shall have access levels associated with them:
a. Alarm Silence b. System Reset c. Set Time/Date e. On/Off/Auto Control f. Disable/Enable g. Clear Historical Alarm Log h. Clear Historical Trouble Log I. Walk Test j. Change Alarm Verification
7. Acknowledge keys shall also require privileged access to
acknowledge points. If the operator presses an (ACK) key with insufficient access, an error message will be displayed. The points will scroll with (ACK) key presses to view the points on the list, but the points will not get acknowledged in the database.
S. Communications Output – shall include capability to add a future
Ethernet communication port.
T. Equipment Enclosures
1. Provide cabinets of sufficient size to accommodate the aforementioned equipment. Cabinet shall be equipped with locks and transparent door panel providing freedom from tampering yet allowing full view of the various lights and controls.
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2.03 ADDRESSABLE NETWORK
A. Communication with Addressable Devices
1. The system must provide communication with initiating and control devices individually. All of these devices will be individually annunciated at the control panel. Annunciation shall include the following conditions for each point:
a. Alarm b. Trouble c. Open d. Short e. Device missing/filed
B. All addressable devices shall have the capability of being disabled or
enabled individually.
C. Up to 127 addressable devices may be multidropped from a single pair of wires. Systems that require factory reprogramming to add or delete devices are unacceptable.
D. Systems requiring different circuits for various device types (i.e. smoke
detectors on one circuit and pull stations on another circuit) shall not be acceptable. Systems requiring separate conduits for different circuits such as speaker circuits and addressable circuits shall not be acceptable.
E. Format
1. The communication format must be a completely digital
poll/response protocol to allow t-tapping of the circuit wiring. A high degree of communication reliability must be obtained by using parity data bit error checking routines for address codes and check sum routines for the data transmission portion of the protocol. Systems that do not utilize full digital transmission protocol are not acceptable.
F. Identification of Addressable Devices
1. Each addressable device must be uniquely identified by an address
code entered on each device at time of installation. The use of jumpers to set address will not be acceptable due to the potential of vibration and poor contact. Device identification schemes that do not use uniquely set addresses but rely on electrical position along the communication channel are unacceptable. These systems cannot accommodate t-tapping and the addition of an addressable device between existing devices requires reprogramming all existing electrically further devices. The system must verify that proper type device is in place and matches the desired software configuration.
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G. Wiring Type, Distances, Survivability and Configurations
1. Wiring types will be approved by the equipment manufacturer.
The system shall allow a line distance of up to 2,500 feet to the furthest addressable device on a Class B circuit. To minimize wire routing and to facilitate future additions, t-tapping of the communications channel will be supported.
H. Addressable Device Types
1. General
a. The system control panel must be capable for
communicating with the types of addressable devices specified below. Addressable devices shall be located as shown on the Drawings.
2. Addressable Detector Bases
a. All addressable smoke and heat detector heads as specified
below will be pluggable into their bases. The base will contain electronics that communicate the detector status (normal, alarm, trouble) to the control panel over 2 wires. The same 2 wires shall also provide power to the base and detector. Different detector heads (smoke or heat) must be interchangeable. Upon removal of the head, a trouble signal shall be transmitted to the control panel. Bases shall contain an LED to provide local alarm indication.
3. Photoelectric Detector Head
a. The photoelectric type detector shall be a plug-in unit which
mounts to a twist-lock base, and shall be UL approved.
b. The detectors shall be of the solid state photoelectric type and shall contain no radioactive material. They will use a pulsed infrared LED light source and be sealed against rear air flow entry.
c. The detector shall fit into a base that is common with both
the heat detector and ionization type detector and shall be compatible with other addressable detectors, addressable manual stations, and addressable Zone Adapter Modules on the same circuit. The detector shall also fit into a non-addressable base that is capable of being monitored by an addressable Zone Adapter Module.
d. There shall be no limit to the number of detectors or Zone
Adapter Modules which may be activated or “in alarm”
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simultaneously. Cover all smoke detection devices with plastic bags immediately after installation to maintain cleanliness, if field conditions so require.
4. Addressable Thermal Detector Head
a. Thermal detector heads must be UL listed. They will be a
combination rate-or-use and fixed temperature (135 degrees F) type, automatically restorable. Fixed temperature 190 degree F units shall be used in boiler rooms or other hot areas.
5. Addressable Pull Stations
a. Addressable pull stations shall contain electronics that
communicate the station’s status (alarm, normal) to the transponder over two wires which also provide power to the pull station. The address shall be set on the station. They shall be manufactured from high impact red Lexan. Station shall mechanically latch upon operation and remain so until manually reset by opening with a key common to all system locks. Pull stations shall be double action.
b. The front of the station is to be hinged to a backplate
assembly and must be opened with a key to reset the station. The key shall be common with the control panels. Stations which use Allen wrenches or special tools to reset, will not be accepted. The station shall consist of high impact Lexan plastic, red in color.
c. The addressable manual station shall be capable of field
programming of its “address” location of an addressable initiating circuit. The manual station shall be fitted with screw terminals for field wire attachment.
d. There shall be no limit to the number of stations, detectors
or Zone Adapter modules, which may be activated or “in alarm” simultaneously.
e. The addressable manual station shall be Underwriter’s
Laboratories, Inc. listed.
f. Emergency alarm pull stations shall be distinct from fire alarm pull stations and shall not include the text “Fire.” They shall be labeled “HazMat” or similar.
6. Addressable Photoelectric Duct Detector
a. Not required on this project
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7. Zone Adapter Module (ZAM) (Monitor Module)
a. Zone Adapter Modules shall be used for monitoring of waterflow, valve tamper, Halon Control Panels, non-addressable detectors, and for control of evacuation indicating appliances and AHU systems.
b. An addressable interface module shall be provided for
interfacing normally open direct contact devices to an addressable initiating circuit. the device shall be a Simplex type Zone Adapter Module (ZAM).
c ZAMs will be capable of mounting in a standard electric
outlet box. ZAMS will include cover plates to allow surface or flush mounting. ZAMs will receive their 24VDC power from a separate two wire pair running from an appropriate power supply.
d. There shall be 2 types of devices:
Type 1: Monitor ZAM Type 2: Control ZAM
e. For Type 1 above:
(1) For conventional 2-wire smoke detector and/or
contact device monitoring with Class B or Class A wiring supervision. This type of addressable device module will provide power to and monitor the status of a zone consisting of conventional 2-wire smoke detectors and/or N/O contact devices such as rangehood connections. The supervision of the zone wiring will be Class B. These ZAMs will communicate the zone’s status (normal, alarm, trouble) to the transponder.
f. For Type 2 above:
(1) Zone Adapter Module for Non-supervised Control
(a) This type of addressable device will provide
double pole, double throw relay switching for loads up to 120 VAC. It will contain an easily replaceable 2 amp fuse, one on each common leg of the relay. These ZAMs will be used for AHU shutdown. This will allow testing of duct smoke detectors without shutting down the Air Handling Units.
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(b) The ZAM shall be supervised and uniquely identified by the control panel. Device identification shall be transmitted to the control panel for processing according to the program instructions. Should the ZAM become non-operational, tampered with, or removed, a discrete trouble signal, unique to the device, shall be transmitted to, and annunciated at, the control panel.
(c) The ZAM shall be capable of being
programmed for its “address” location on the addressable device initiating circuit. The ZAM shall be compatible with addressable manual stations and addressable detectors on the same addressable initiating circuit.
8. Door Holders – Not required on this project.
9. Addressable Device Supervision
a. All devices shall be supervised for trouble conditions. The
system control panel will be capable of displaying the type of trouble condition (open, short, device missing/failed).
b. Should a device fail, it will not hinder the operation of other
system devices.
10. A Digital Communicator shall be included with the Life Safety Control Panel and wired to the panel for reporting alarms, trouble and supervisory signals to the UL listed central station digital receiver. The Contractor shall include the first year central station monitoring fee in his bid.
2.04 ONE-WAY VOICE COMMUNICATION
A. Provide one-way voice communication and tone generating capabilities.
B. A central audio control module shall be provided for the necessary alarm message/tone generation, main and remote microphone connections, music inputs and mixer/pre-amplifier circuits. Continuous supervision shall be provided. Audio outputs shall have individual gain control.
C. A hand-held push-to-talk microphone shall be provided recessed within a
protective panel-mounted enclosure. The microphone shall be a dynamic communication type with a frequency range of 200 Hz to 4000 Hz and shall be equipped with a self winding five foot coiled cable. An LED indicator shall be provided to indicate microphone push-to-talk button has been pressed and speaker circuits are ready for transmission. Microphones shall be supervised from disconnection.
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D. An audio control switch module shall be furnished to provide manual to
the audio functions. These switches and associated LED indicators shall be supervised from disarrangement or failure.
E. Audio power amplifiers shall be furnished with self-contained filtered
24VDC power supply, transformer, and amplifier monitor circuits. Amplifiers shall provide a 25 VRMS output with a frequency response of 120 Hz to 12000 Hz. Provide a sufficient quantity of amplifiers to operate all system speakers simultaneously plus 10 percent spare capacity.
F. In addition, provide at least one backup amplifier capable of
automatically replacing any failed amplifier.
G. Speaker circuits shall be supplied which are capable of supplying audio signals at 25 VRMS supplied by the system amplifiers. Supervision for open, short or ground fault conditions shall be provided. Individual and distinct trouble indications shall be provided for each fault. Provide one circuit for each zone or area of distinct communication.
H. Tones
1. Digitized tones for alarm or auxiliary requirements shall be
available. Tone requirements are as follows:
a. The Slow Whoop shall be a slowly ascending tone from to 200 to 830 Hz in 2.5 seconds.
b. The Wail shall ascend and descend from 600 to 940 Hz. c. The Beep shall be a 470 Hz tone. The time duration shall be
0.7 seconds on and 0.7 seconds off. d. The Horn shall be a continuous 470 Hz tone. e. The Stutter shall be a 470 Hz tone which is on for 100
milliseconds and off for 100 milliseconds. f. The Coded Horn shall be a 470 Hz tone designed
specifically for use on a coded system. g. The Hi/Lo shall be a free running tone with a high frequency
of 544 Hz and a low frequency of 440 Hz. The “on time” (Hi) shall be 100 milliseconds and the “off time” (Lo) is 400 milliseconds.
I. A pre-recorded digitized voice message capability shall be provided for
automatic transmission to building occupants during alarm conditions. Three messages shall be provided, one for fire alarm, one for chemical release alarm, one for testing. This message player shall not rely on a tape or other mechanical means of transmitting the evacuation message. Two standard evacuation messages shall be provided under this Contract; however, the message player must be capable of transmitting a customized message of up to 4 minutes long.
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A self-contained speaker shall provide testing of the message(s) without disturbing the occupants of the facility.
J. Automatic Voice Evacuation Sequence
1. The audio alarm signal shall consist of an alarm tone for a
maximum of 10 seconds followed by automatic pre-selected voice evacuation messages. At the end of each voice evacuation message, the alarm tone shall resume. The alarm tones shall sound until the alarm silence switch at the Life Safety Control Panel has been operated.
2. All audio alarm operations (speaker circuit selection and alarm
tone/voice message timing variations) shall be activated by the system software so that any required future changes to the evacuation sequence can be facilitated by authorized personnel without any component rewiring.
K. Manual Voice Paging Sequence
1. The system shall be configured to allow selective voice paging.
Upon activation of any speaker manual control switch, 2 seconds of tone shall sound over the speakers indicating an impending voice message will occur. Provide speaker selector switches to allow selection of one circuit per floor for selective operation.
2. If any speaker manual control switches are activated, the control
panel operator shall be able to make announcements via the push-to-talk paging microphone over the preselected speakers.
3. Facility for total building evacuation and paging shall be provided
to allow for activation of speakers. This shall be accomplished by the means of an “All Circuit” switch.
L. Alarm Signals
1. Provide speakers and visual alarm signals for all locations
requiring wall mounted audio-visual alarm signals as shown on the Drawings. Any surface mounted speaker/visual unit will require backboxes and adapter plates.
2. Visual alarms should consist of White Xenon strobe units meeting
ADA requirements, 75 candela minimum, 1-3 Hertz pulse rate, 0.2 second pulse duration.
3. Emergency alarm strobes shall have white paint with “Alert” text.
Fire alarm strobes shall be red with “Fire” text.
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M. Remote Annunciator
1. Where shown on the drawings, provide and install 80 character backlit LCD display annunciator. The annunciator(s) shall have a brushed aluminum finish and provide one supervision lamp, one alarm lamp, and one trouble lamp per initiation device circuit. The annunciator shall communicate to the control panel over one twisted shielded pair of wire and operating power shall be 24 VDC and be fused at the control panel. Point-wired annunciators will not be considered as equal. The serial annunciator shall provide a common alarm and trouble circuit consisting of:
a. Control pushbutton switches for: Alarm silence, trouble
silence, system reset and manual evacuation duplicating the control panel switches. A key “enable” switch shall be provided to activate or deactivate the control switches.
b. Tone Alert - Duplicates the control panel tone alert during
alarm and trouble conditions.
N. Graphic Display
1. The graphic display shall have a plan view of each building floor. Each alarm zone shall be clearly labeled on the plans. Plan views shall be approximately to scale and in no case smaller than 18 inches wide or long. Provide display in a surface mounted enclosure with full size or plastic viewing plate. Enclosure shall have piano hinged door and key lock. See drawings for additional requirements. The graphic display is required to be installed beside the remote annunciator. The graphic display is NOT required to be an electronic display.
2.06 SPECIAL TOOLS
A. Special tools necessary for the maintenance of the equipment shall be furnished. Two spare sets of fuses of each type and size required and 5 spare lamps and LED’s of each type shall be furnished. Two percent of the total number of each detector, but no less than two each, shall be furnished. Fuses and lamps shall be mounted in the Life Safety Control Panel.
2.07 FIRE ALARM LOW VOLTAGE CABLES
A. Fire Alarm Cables
1. All cables and conductors shall be installed in conduit.
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B. Fire Alarm Conductors (Conduit Use)
1. Conductors for use in conduit for fire alarm systems shall comply with NEC Article 760, and cables specified in B1 above may be used in conduit if so desired. Conductors and insulation types as specified for non-power limited fire protective signaling circuits in Article 760 may be used on power limited systems for this project in conduit. Conductors shall be rated 600 volts, UL listed, copper, minimum #16 AWG, but in no case smaller than recommended by the fire alarm manufacturer.
PART 3 - EXECUTION 3.01 INSTALLATION/APPLICATION/ERECTION
A. Furnish and install the system in accordance with the Drawings and Specifications, all applicable codes and the manufacturer’s recommendations. All wiring shall be installed in strict compliance with all the provisions of NEC Article 760 A and C, Power-Limited Fire Protective Signaling Circuits or if required may be reclassified as non-power limited and wired in accordance with NEC Article 760 A and B. Upon completion, the Contractor shall so certify in writing to the Owner and general Contractor.
B. All fire alarm junction boxes shall be sprayed red and labeled “Fire
Alarm.” Wiring color code shall be maintained throughout the installation.
C. Installation of equipment and devices that pertain to other work in the Contract shall be closely coordinated with the appropriate subContractors.
D. The Contractor shall clean all dirt and debris from the inside and the
outside of the fire alarm equipment after completion of the installation.
E. The manufacturer’s authorized representative shall provide on-site supervision of installation.
F. Grounding shall be provided to building ground.
3.02 TESTING
A. The completed alarm system shall be fully tested in accordance with NFPA-72 by the Contractor in the presence of the Owner’s representative and the state DHBC inspector. Upon completion of a successful test, the Contractor shall so certify in writing to the Owner.
3.03 OWNER TRAINING
A. The system manufacturer shall train the Owner’s representative (operator) on the system operation: History Log review and use; switch
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operation and use; alarm review, reset and evacuation operations; systems drills; trouble review and reset operations. See Section 16010 for additional requirements.
3.04 WARRANTY
A. The Contractor shall warrant the completed alarm system wiring and equipment to be free from inherent mechanical and electrical defects for a period of 1 year from the date of the completed and certified test.
B. The equipment manufacturer shall make available to the Owner a
maintenance contract proposal to provide a minimum of 2 inspections and tests per year in compliance with NFPA-72 guidelines.
END OF SECTION
***
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SECTION 16745
VIDEO SURVEILLANCE EQUIPMENT PART 1 - GENERAL 1.01 SCOPE OF WORK
A. The Contractor shall provide video surveillance system (VSS) equipment and software as described herein and as shown on the Contract Drawings. Video system programming/configuration will be provided by others.
B. The Contractor shall provide raceways and cabling required for the VSS as
specified herein. 1.02 REFERENCES
A. The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.
1. ELECTRONIC INDUSTRIES ALLIANCE (EIA)
2. INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
3. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) 4. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 5. UNDERWRITERS LABORATORIES (UL)
1.03 SYSTEM DESCRIPTION
A. General - The Contractor shall install the equipment as described herein and as shown on the Contract Drawings. The equipment shall include all cabling, connectors, adapters, and terminators necessary to interconnect all equipment. Software license shall be turned over to Owner.
B. Cabling - See Section 16710 for requirements. Each camera will require
an Ethernet cable which will transmit both data and power to/from the camera.
C. Environmental Conditions
1. Field Equipment - The cameras and all other field equipment shall be rated for continuous operation under ambient environmental conditions of minus 20.0 degrees C to 55 degrees C (-4 degrees to 131 degrees F). Equipment shall be rated for continuous operation under the ambient environmental temperature, humidity, wind loading, ice loading, and vibration conditions specified or encountered for the installed location.
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D. Electrical Requirements - Equipment shall be able to tolerate variations in
the voltage source of plus or minus 10 percent, and variations in the line frequency of plus or minus 2 percent with no degradation of performance.
1.04 SUBMITTALS
A. All items of computer software and technical data (including technical data which relates to computer software), which are specifically identified in this specification shall be delivered strictly in accordance with Division 1 submittal requirements. All data delivered shall be identified by reference to the particular specification paragraph against which it is furnished.
B. Product Data (submit prior to procurement/installation)
1. Manufacturers' Data - The data package shall include manufacturers' data for all materials and equipment and software licenses provided under this specification. Selected options shall be clearly indicated, and non-applicable equipment shall be clearly marked out.
C. Operation and Maintenance (O&M) Manuals – Submit the manufacturer’s user manual for the cameras and the end user manual for the software license. 1.05 COMMISSIONING
A. General - The Contractor shall provide personnel for onsite commissioning of the system in coordination with the programmer. This will include ensuring the cameras are properly installed, cabled, and focused/aimed. 1.06 TRAINING
A. Training will be provided by others. PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Axis, Salient, or equal. 2.02 EXTERIOR CAMERAS (Quantity 3)
A. Axis P1365-E or equal rated -40 to 122°F with NEMA-4X rating. POE with day/night functionality with infrared cut filter, HDTV 1080p resolution at 30 images per second (configurable), remote back focus. H.264 compression, CMOS 1/3” progressive scan varifocal lens with P-Iris, wide dynamic range, IP with IP security and standard IP protocols, with color picture down to 0.11 lux and black/white picture down to 0.01 lux. Motion detection and email functionality is required. Provide wallmount brackets.
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2.03 VIDEO SERVER & MONITOR A. Provide a server with the same specifications as the SCADA server in
Section 17200, except provide a 2 Terabyte Harddrive for video storage. Also provide HDMI video output for HDTV monitor.
B. Provide minimum 42” plasma HDTV with HDMI input and 1080p
capability. Panasonic or equal. This HDTV shall be mounted in the Laboratory. Provide HDMI cable from HDTV to server in the electrical room.
2.04 VIDEO SOFTWARE
A. Provide video management software licensed for (5) cameras. The software shall be Salient Completeview Pro version to match existing software. License can be procured from Access Control Systems, Billy Jernigan, [email protected], (615) 642-8214
2.05 WIRE AND CABLE
A. Provide per Section 16710. PART 3 - EXECUTION 3.01 INSTALLATION
A. The Contractor shall install all system components in accordance with the manufacturer's instructions, IEEE C2 and as shown, and shall furnish all necessary connectors, terminators, interconnections, services, and adjustments required for a complete and operable system. Raceways shall be furnished and installed as specified in Section 16130 RACEWAYS. Cabling shall not be pulled into conduits or placed in raceways, compartments, outlet boxes, junction boxes, or similar fittings with other building wiring. All other electrical work shall be as specified in the above sections including grounding to preclude ground loops, noise, and surges from adversely affecting system operation.
B. Enclosure Penetrations - All enclosure penetrations shall be from the
bottom unless the system design requires penetrations from other directions. Penetrations of interior enclosures involving transitions of conduit from interior to exterior, and all penetrations on exterior enclosures shall be sealed with rubber silicone sealant to preclude the entry of water. The conduit riser shall terminate in a hot-dipped galvanized metal cable terminator. The terminator shall be filled with an approved sealant as recommended by the cable manufacturer, and in such a manner that the cable is not damaged.
C. Cold Galvanizing - All field welds and brazing on factory galvanized
boxes, enclosures, and conduits shall be coated with a cold galvanized paint containing at least 95 percent zinc by weight.
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D. Cameras - The Contractor shall install the cameras as recommended by
the manufacturer; connect Ethernet cable to the camera; aim camera to give field of view as needed to cover the alarm zone; and coordinate with Owner to focus the lens to give a sharp picture over the entire field of view.
END OF SECTION
***
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SECTION 16821
TELEPHONE SYSTEM PART 1 - GENERAL 1.01 SCOPE OF WORK
A. The work covered by this section of the Specifications includes the furnishing and labor, equipment, materials, and configuration/programming associated with the installation of a telephone system as shown on the Drawings and as herein specified. A complete, functional system is required. This installation is required to be an expansion of the existing NEC phone system that serves the wastewater treatment plant on the same site. The existing phone controller is located at the existing MDF. Provide all necessary expansion modules/equipment necessary for the performance specified herein.
B. The requirements of the conditions of the Contract, Supplementary
Conditions, and General Requirements apply to the work specified in this section.
C. Contractor is required to perform all coordination with the phone utility. D. The base bid supplier for this Section is as follows. Refer to the form of
proposal for write-in of alternates: Iset Service Attn: Chad Mattingly 4517 Poplar Level Rd. Louisville, KY 40213 502-409-7191
1.02 RELATED WORK SPECIFIED ELSEWHERE
A. All work shall conform to all sections in Division 16. B. Section 16720 – Building Telecommunications Cabling System 1.03 SUBMITTALS
A. Data sheets shall be provided on all equipment being provided.
B. A system block diagram shall be provided, along with wiring diagrams showing typical connections to be performed.
C. Equipment list, itemizing major system components.
D. O&M manuals shall be provided including individual specification sheets,
schematics, inter-panel and intra-panel wiring diagrams, equipment manuals, and configuration data sheets. In addition, all information
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necessary for the proper maintenance and operation of the system must be included. A PDF electronic copy of the O&M manual is required in addition to hard copies.
1.04 QUALITY ASSURANCE
A. The Contractor shall be an authorized distributor of the supplied equipment with full warranty and technical support privileges.
B. The Contractor shall maintain at his facility the necessary spare parts in the
proper proportion as recommended by the equipment manufacturer to maintain and service the equipment being supplied.
C. Record Drawings that include any changes to wiring, wiring designations,
junction box labeling and any other pertinent information shall be supplied upon completion of project.
D. All equipment shall conform to appropriate U.L. Listings.
E. Wiring Practices: System wiring shall be in accordance with good
engineering practices as established by the EIA and NEC. Wiring shall meet all established state and local electrical codes and other portions of these specifications. All wiring shall test free from grounds and shorts.
PART 2 - PRODUCTS 2.01 PHONE SYSTEM
A. The following areas require new handsets:
1. Administration Building Laboratory 2. Administration Building Supervisor Office 3. Administration Building Secondary Office 4. Filter Building Office 5. High Service Building Electrical Room (at Backboard) 6. Chemical Building Electrical Room (at Backboard)
B. Amplified P.A. speakers are required in each of the (4) buildings. The speakers shall annunciate when an incoming call is received. The system shall also allow an operator to press a handset button to manually annunciate a message over all plant P.A. speakers. The speakers shall have individual volume controls and shall be ruggedized for industrial locations. Minimum sound pressure level shall be 120 dB at 4 feet with rated input at 1 kHz. Frequency response shall be from 275 to 14 kHz. Temperature range on interior units shall be 50 to 104 degrees Fahrenheit. Temperature range on exterior units shall be -20 to 110 degrees Fahrenheit.
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C. Phone System Requirements: NEC
1. Shall support a minimum of 24 handsets. 2. Shall support all-call paging and paging of individual locations. 3. Phone ringing shall be annunciated via the amplified P.A. speakers in
the industrial/exterior areas. 4. Shall include at least 5 voicemail accounts. 5. Shall include Attendant with directory by list programming and
automatic three mode day/night/special operation. 6. Shall include Caller I.D., music-on-hold, muting, paging, three-
way/conferencing, speaker-phone support, speed-dialing (20 per station), text messaging, and volume controls.
D. Provide all cabling, wiring, and conduit necessary for a complete, functional
system. See applicable Division 16 sections for requirements. PART 3 - EXECUTION 3.01 INSTALLATION
A. Provide all equipment, speaker mounting brackets, wiring, conduit and outlet boxes required for the installation of a complete and operating system in accordance with applicable local, state and national codes, the manufacturers' recommendations, these plans and specifications. All cabling shall be installed in conduit except for low voltage cabling above acoustical tile ceiling in the Administration building. All circuits not in conduit must be wired with power limited or non-power limited cable as listed under NEC 725 Class II wiring. Color coded wires shall be used throughout. Wiring shall conform to the practices in the National Electrical Code.
B. The manufacturers' authorized representative shall completely
configure/program the system in coordination with the Owner, provide supervision of final system connections, perform a complete functional test of the system, and submit a written report attesting to satisfactory operation of the system. In addition on-site instruction shall be provided to the Owner's designated personnel.
3.02 OWNER TRAINING
A. The system manufacturer shall train the Owner’s representative (operator) on the system operation. Minimum 4 hour training required.
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3.03 WARRANTY
A. The Contractor shall warrant the completed system, wiring, and equipment to be free from inherent mechanical and electrical defects for a period of 1 year from the date of the completed and certified test.
END OF SECTION
***
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SECTION 16900
CONTROLS AND CONTROL PANELS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Equipment controls and control panels shall be as specified herein and as shown on the Contract Drawings.
1.02 RELATED WORK
A. Drawings and General and Supplementary Conditions of the Contract and Division 1 Specifications sections apply to this Section.
B. All motor controls, starters, pushbuttons, pilot lights, and other
miscellaneous devices shall comply with Section 16440 – MOTOR CONTROL.
1.03 SUBMITTALS
A. Panel and enclosure plan and elevation drawings depicting all
components and wiring duct
B. Complete wiring diagrams C. Catalog cut-sheets on all components, with options clearly indicated and
non-applicable items clearly excluded
D. Enclosure heat gain calculation – Shall indicate the maximum temperature inside the enclosure on a 100°F day taking into account heat losses and inefficiencies of all panel components. Heat gain shall include the effects of radiation (if located outside) and air-conditioners or ventilation fans. The maximum operating temperature of all major equipment and panel components shall be listed. The heat transfer calculation shall be based on the enclosure manufacturer’s published heat transfer data. This manufacturer’s data or curve shall be submitted with the calculation for review.
E. Shop Drawings shall be clearly marked and or highlighted as to which
product, type, option, etc. is being submitted. Product literature with one or more styles / configurations for a single product shall have a written description of use for each of the styles / configurations represented on the literature. For example: Device boxes – Styles shall be listed as: For masonry walls, for electrical devices, for ceiling mounted light fixtures, etc
F. O&M manuals shall be submitted in accordance with Section 16010. They
shall include all field modifications made such that the wiring diagrams
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exactly match the field-installed equipment and control panels. They shall also include complete cut-sheets, product data, operation, and maintenance information.
1.04 REFERENCES
A. NFPA 79 – All control panels shall comply with NFPA 79. B. NEC – All control panels shall comply with NEC article 409.
C. UL508 – All control panels shall be listed to UL508 and shall bear the UL
label. 1.05 GENERAL REQUIREMENTS
A. All control panels furnished under this Contract shall be manufactured in accordance with industry standards and as herein specified. The Contractor shall coordinate all subcontractors and vendors to ensure that the control panels are furnished and meet the requirements specified herein.
B. Control panels shall be as manufactured by ControlWorks, Inc., Quality
Controls, ADGO, or other UL or ETL qualified panel vendor. Panel construction shall comply with OSHA requirements and shall be either UL or ETL listed.
C. Control panels to be furnished on this project shall be wired to function
according to schematics shown on the Contract Drawings. All Control Panels shall be manufactured using “relay logic”, or PLCs (Programmable Logic Controllers) as shown on schematics (control circuits) located in the Contract Drawings. In addition to the requirements shown on the Contract Drawings, the panels shall adhere to additional requirements as written herein, and in the utilization equipment specifications.
D. Interior enclosures shall be dead front with all operators devices
accessible without opening the enclosure door. All enclosures mounted outside shall have operator controls/displays mounted on an inner swing-out door with an outdoor door that is blank.
D. All components shall be mounted with threaded screws to a subpanel
inside the enclosure such that they are replaceable without removing the subpanel. All wiring must be stranded and protected by a circuit breaker. Supplementary circuit breakers may be utilized for circuits that require wiring smaller than 14 gauge. Wiring ducts for cable/conductor management are required to be utilized for routing of conductors and cables. Ducts are also required to be provided for field-wiring at the top and bottom of the panels. All field wires should terminate at a terminal strip upon entering the control panel enclosure.
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F. All terminal strips and lugs shall be of a type UL listed to terminate the size and quantity of wires encountered. Where conduits enter the boxes, if they are NEMA 4 or 3R, sealing locknuts or hubs must be used to maintain the box rating. The exterior of steel panels shall be painted ANSI 49 light gray, lacquer or enamel.
G. Enclosures shall be provided with a locking hasp and any exterior
hardware shall be stainless steel or other corrosion resistant material. Enclosures for interior use in dry areas shall be NEMA 12 enclosed, unless otherwise indicated. Wet location or outdoor mounted enclosures shall comply with Article 1.04 below.
H. Elementary control schematics and connection diagrams showing the
spatial relationship of components and wiring shall be submitted for review. Also, a bill of materials, drawing of device arrangement on front, and enclosure fabrication drawings shall be submitted. Further, descriptive literature is required on all components. A copy of the as-built wiring diagrams and BOM shall be stored in a pocket inside the control panel enclosure.
H. Sleeve type wire markers or other “permanent” type marker shall be
installed on all wires, keynoted back to the elementary schematic or the connection diagram, and all terminals identified.
I. Short circuit ampacity: The minimum short circuit ampacity of the control
panel shall be as follows: 1. 480V control panels: 65kA 2. 208/240V control panels: 10kA 3. 120V control panels: 10kA
PART 2 - PRODUCTS 2.01 ENCLOSURES
A. Control panel enclosure shall be wall-mount type where sized at 30” width x 42” height or less. Otherwise, it shall be floor-mount type. All panels indicated on the Drawings to be floor-mounted shall be floor-mounted regardless of size. Enclosures shall be single or double-door as required. Enclosure shall include a NEMA flange-mounted lockable disconnect for three-phase power supply, or an IEC style rotary lockable disconnect for single phase power supply. Enclosures shall be manufactured by Hoffman, or equal.
B. Enclosure NEMA rating shall be as indicated for the area on the Drawings.
Enclosures to be located outside shall be NEMA 4X. NEMA 1/12/4 enclosures shall be steel with ANSI 61 gray finish unless painting is required in Division 9. NEMA 4X enclosure material shall be stainless steel type 304, except in chemical areas, which shall be fiberglass-reinforced
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plastic. The enclosure shall be sized to provide 25% spare panel space. Seams shall be continuously welded and ground smooth.
C. Enclosure door shall have a 3-point latch. Screw clamps are not
acceptable. The latch handle shall have a padlock hasp. D. The enclosure shall have an interior dead-front swing out panel for panel-
mounting of all pilot devices and displays. It shall also have an interior pocket for holding wiring diagrams, and an interior sub-panel for mounting control equipment.
2.02 WIRING REQUIREMENTS
A. Wire and cable shall comply with Section 16120 except Type MTW conductors shall be used inside the control panel for control circuits. Control circuit wiring shall be 18 gauge or larger.
B. Control wiring shall be terminated using crimp-type ferrule, fork, or ring
terminals. Power wiring shall utilize compression lugs. C. Wiring shall extend to terminal blocks for connection to external
equipment. 2.03 TEMPERATURE CONTROL DEVICES
A. Electric Heater for Control Panels
1. Not applicable on this project. All control panels shall be located in a conditioned environment.
B. Air Conditioners for Control Panels
1. Not applicable on this project. 2.04 MOTOR CONTROLS
A. Starters
1. All magnetic starters and contactors shall be steel mounted, front wired with all terminals accessible for wiring directly from the front. Movable contact blocks shall depend on gravity only and not the use of springs for operation to the open position.
2. Starters shall be NEMA type and sized appropriately for the motor to be controlled, but in no case shall any starter or contactor be smaller than NEMA size 1 or smaller than as indicated on the Drawings. IEC starters are not acceptable.
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3. All contactors shall be double break, solid silver cadmium oxide alloy, or equal. Bare copper or silver flashed copper contacts which require periodic filing or cleaning maintenance will not be permitted.
4. Operating coils shall be pressure molded and so designed that, if
accidentally connected to excessive voltage they will not expand, bubble or melt. When a coil fails under and condition, the starter shall open and shall not "freeze" in the closed (on) position. Coils shall be replaceable from the front of the starter without having to remove the starter from the panel or enclosure.
5. Combination starters shall be of the molded case circuit breaker
type. Trip elements of multi-pole breakers shall be effectively insulated from one another. Multi-pole breakers shall be designed such that an overload on one pole opens all poles simultaneously. Breakers shall be quick-make, quick-break and shall be entirely trip free to prevent the contacts being held in a closed position against a short circuit. Breakers for full voltage starters shall be the magnetic only type. All others shall be thermal magnetic.
6. Each starter leg shall have a thermal overload device in each
ungrounded leg. The overload shall be bimetal, ambient compensated, thermal element type. Solid state overload devices, are not acceptable. If the adjustable trip type are used, a lockable cover must be provided to prevent unauthorized adjustment.
2.05 POWER SUPPLIES
A. DC Power Supplies 1. DC power supplies shall be switched mode and Din-rail mountable. 2. Input power range shall be from 85-264 VAC. 3. Output voltage range shall be as needed with a tolerance of 1%.
Output voltage shall be adjustable up and down at least 10% from the nominal value.
4. The power supply shall include an internal input fuse. 5. Power supply shall have a “DC Ok” signaling LED. 6. Operating temperature rating shall be –25 C to +70 C and up to
95% relative humidity. 7. Output power shall be buffered for full output power ridethrough
for 20 milliseconds in the event of a power outage. 8. The power supply shall be able to supply 150% of its continuous
capacity for short periods of time. 9. The power supply shall have internal short circuit protection with
automatic recovery. 10. The power supply shall be Phoenix Contact, Sola, Allen-Bradley, or
equal.
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2.06 OVERCURRENT PROTECTION
A. Main 3-Phase Breakers – Shall be thermal-magnetic, molded-case, Type FA or KA as needed, Square D or equal. Provide service entrance rating where indicated on the Drawings as being used in a service entrance application. See short circuit rating requirements above. Provide cable assembly to connect to flange-mounted disconnect.
B. Main Single-Phase Breakers – Shall be Din-rail mountable with clear “on,”
“off,” and “tripped” positions, Square D QOU or equal. Where a substantial number of breakers are used, provide a panelboard mounting base.
C. Combination Starters – Circuit breakers for use with combination starters
shall be magnetic-only, Square D MagGuard, or equal, with adjustable trip settings.
D. Supplementary Protectors – Shall be Din-rail mountable UL489 listed. Trip
rating shall match load served.
E. Power Fuses – Breakers are required unless fuses are necessary for fault current limiting.
2.07 MISCELLANEOUS PANEL COMPONENTS
A. Terminal Blocks, #10 conductor size and smaller.
1. Terminal blocks shall be Din-rail mountable IEC style with minimum width of 6.2 mm. They shall be rated for conductors from #10 to #24 AWG. Current rating shall be 30A, minimum. Terminal blocks shall be finger-safe. Double level terminal blocks may be utilized where necessary to conserve space.
2. Screw clamp terminal blocks are required. Terminal blocks that rely upon spring pressure only for conductor termination are not acceptable.
3. Provide cross connection bridges, partition plates, end anchors, zack strip labels, and all other components necessary for a complete installation. Each block shall be labeled with a machine-printed label. No more than 2 conductors may be landed under on single terminal block terminal screw.
4. Utilize the following terminal block colors: a. 120V Power – Black b. 120V Control – Red c. 120V Neutral – White d. Equipment Grounding – Green or Green/Yellow e. DC Positive – Blue f. DC Negative/Grounded – Gray g. Conductor energized from remote source: Yellow
5. Terminal blocks shall be manufactured by Phoenix Contact, Allen-Bradley, or equal.
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B. Fuse blocks (control circuits) – Fuse blocks shall be finger safe and shall have LED indication when the fuse is blown. Fuses may be used only where indicated on the Drawings; otherwise use circuit breakers.
C. Conductor Labels – Shall be the heat-shrink type, machine printed. Brady,
or equal. D. Component nameplates – Shall be engraved, rigid, laminated plastic with
adhesive back and letter height of 3/16” minimum. Nameplates shall be white with black letters.
E. Intrinsic Safety Barriers – Provide UL listed intrinsic safety barriers for
circuit extensions into hazardous areas. The barriers shall be Phoenix Contact, or equal.
F. Transient/Surge protectors shall comply with Section 16280. G. Control transformers shall be machine tool type transformers with epoxy
encapsulated coils or resin impregnated coils, high quality silicon steel laminations, copper magnet wire, molded-in terminals, and 55°C rise insulation system.
H. Voltage/Phase Monitor – Shall continually measure the voltage of all
phases of incoming power and provide protection for any motors or other equipment that could be damaged. The phase monitor shall sense under and overvoltage, voltage unbalance, phase loss, and phase reversal. It shall have a relay output.
I. Pilot Devices
1. Selector switches shall be NEMA 4X, 30mm, oil-tight construction,
and of the quick-make, quick-break type. 2. Pushbuttons shall be NEMA 4X oil-tight, 30mm. 3. Pilot lights shall be 30mm, oil-tight, push-to-test, NEMA 4X LED
type. 4. Elapsed time meters shall be non-resettable. 5. Timing relays shall have an adjustable time range suitable for the
application, with the time delay occurring after energization. J. Control Relays
1. Control relays shall be magnetic, general purpose, "ice cube" type with 3-pole (minimum), double throw contacts rated at 5 amperes (minimum), 120 volts (minimum). Coils shall be rated to operate at the indicated control voltage.
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2. Provide proper bases, mounting track, etc. for a complete installation. All relays shall be have a retainer clip, manual operator, and pilot light. Coils connected to solid-state digital outputs shall have transient surge protection.
K. PLC I/O Interposing Relays
1. Interposing relays shall be Allen-Bradley 700-HL series or equal with 6A single-pole double-throw contact, LED indicator, and built-in transient protection.
PART 3 - EXECUTION 3.01 LABELING
A. Provide labels for all conductors and components. B. Legends for starter nameplates shall be taken from the one-line diagram
in the Contract Drawings. Wire and miscellaneous component labels shall match the O&M manual wiring diagrams.
3.02 GROUNDING A. Enclosures shall be grounded in accordance with the NEC.
B. Each analog signal loop shall be grounded at a single point for the loop at the location of the DC power supply for the loop.
3.03 PROTECTION
A. All electrical and electronic components of the Control Panel shall be
protected against damage due to electrical transients induced in interconnecting lines from lightning discharges and surges in nearby electrical systems. Provide a surge protection device (SPD).
B. All control panels shall be equipped with a voltage/phase monitor.
3.04 INSTALLATION/ERECTION
A. Equipment furnished under this section shall be fabricated, assembled, erected, and placed in proper operating condition in full conformity with the Drawings, Specifications, manufacturer Shop Drawings, and manufacturer installation instructions.
END OF SECTION
***
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SECTION 17100
PROCESS INSTRUMENTATION PART 1 – GENERAL 1.01 SCOPE OF WORK
A. The Contractor shall provide instrumentation as indicated on the Contract drawings. Provide all materials, labor, spare parts, start-up services, as shown and specified and as required to install a complete, functional, calibrated instrumentation system.
B. Provide surge protection on instrumentation loops and power supplies as
specified herein.
C. Provide instrumentation calibration, commissioning, and training services. 1.02 RELATED WORK
A. Installation of all electrical equipment, conductors, and related items shall be in accordance with all applicable sections of Division 16 of these specifications.
B. General Requirements are included in Division 1. C. Division 11 – Equipment
1.03 SUBMITTALS
A. Shop drawing approval is required before the Contractor purchases or installs any equipment.
B. Operation and Maintenance Manuals shall be submitted and shall include
approved shop drawing information along with manufacturer user manuals and as-built information such as parameter settings and calibration sheets.
1.04 QUALITY ASSURANCE
A. Manufacturer NIST or equal calibration certificate is required for all
instruments with an analog current or voltage signal output.
1.05 WARRANTY AND SERVICE
A. One year warranty from date of substantial completion is required.
1.06 SPARE PARTS
A. Provide calibration kits for all instruments where offered by the manufacturer.
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1.07 TRAINING
A. Training is required on the following instrumentation. Provide
manufacturer’s authorized representative to perform training: 1. Weight Scales 2. Flow Meters 3. Dissolved oxygen analyzer 4. Pressure/level transmitters 5. Level alarm systems
1.08 DELIVERY AND STORAGE
A. Store and deliver per manufacturer’s instructions.
PART 2 – PRODUCTS 2.01 GENERAL
A. Acceptable manufacturers/suppliers for the instrumentation equipment shall be Rosemount, Foxboro, Endress-Hauser, ABB, or equal. Manufacturers of small peripheral equipment are listed with each piece of equipment.
B. All equipment shall be UL listed where a listing exists.
C. All electronic instrumentation equipment shall be of the solid-state type
and shall utilize linear transmission signals of 4 to 20 mA dc. No zero based signals will be allowed for remote transmission.
D. All instrumentation supplied shall be of the manufacturer’s latest design
and be compatible for the industry it is being applied.
E. All scales and readouts shall be direct reading in process units. Conversions are not acceptable.
F. All transmitters shall be provided with indicators, either integral or remote
mounted, but must be within site of the transmitter unless specifically indicated otherwise on the Contract drawings.
G. All equipment must be able to reset after a power outage without having to
be manually reset.
H. All circuit boards in instruments mounted outdoors, or in damp locations, shall be fungus proofed.
I. All equipment mounted outdoors shall be protected from the sunlight, and
extreme temperatures between –20 degrees and 140 degrees Fahrenheit. Provide all necessary shielding, heaters, or air conditioners as required. All
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externally mounted panels shall have self-sacrificing corrosion inhibitors installed.
2.02 INSTRUMENTATION EQUIPMENT
A. Float (Level) Switches (LS)
1. The float switch shall be oval-shaped, direct-acting, with a single
pole mercury switch which activates when the liquid level is slightly above horizontal and de-actuates when the liquid level falls below horizontal. Electrical rating shall be 4.5A minimum at 120V; 2.25A minimum at 230V (resistive). The float body shall have polypropylene casing that is impact and chemical resistant. It shall be a suspended-style unit with built-in counterweight.
2. The switch shall have a cable which is oil-resistant, 18 gauge, 2
conductor, extra hard usage STOOW-type and is rated for 600V. The cable shall be furnished of a length sufficient to terminate as shown on the Contract drawings. The switch and cable assembly shall be UL listed.
3. The float switch shall be Roto-Float Signal-Duty Internally Weighted
Float Switch, or equal. B. Submersible Level Sensor (LE) for stilling well use
1. Sensor shall be submersible type, 316L SS, with a stainless steel
diaphragm and a ceramic measuring cell that is resistant to overload, alternating loads, and aggressive media
2. The sensor shall be designed for level measurement of water or
wastewater 3. The sensor shall be a two-wire device that provides a 4-20mADC
output. 4. The sensor shall be loop-powered from 12-30VDC. 5. All electronics shall be completely potted with compound to
protect from moisture damage. 6. The support cable shall have a hard-wearing conical seal of the
probe tube and climactic protection in the pressure compensation tube.
7. The unit shall have a range as indicated on the Contract drawings. 8. The sensor accuracy shall be 0.5% of full scale, minimum.
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9. A mounting clamp and NEMA 4X junction box shall be furnished with the sensor for field installation. The cable shall be of a length sufficient to meet the requirements of the Contract drawings.
10. The sensor range shall be as indicated on the Contract drawings 11. The sensor shall be Endress-Hauser Water-Pilot, or equal.
C. Level Indicating Transmitter for use with sensor/stilling well (LIT)
1. Indicator shall be Endress+Hauser Model RIA 452, or equal, for
displaying process values.
2. Indicator shall operate on a power supply from 90 to 150V, minimum.
3. Displayed value shall be a programmable linear function of the
input signal.
4. The display shall provide a 24V power supply for the level sensor and shall read and convert the 4-20mA signal into units of “feet”.
5. The display shall have an analog display enumerated in
percentage.
6. The display shall have programmable limit setpoints and at least two alarm relays.
7. The display shall be mounted in an IP-65/NEMA-4X rated field
housing. D. Ultrasonic Level Sensor and Transmitter (LIT for filter system)
1. The ultrasonic instrumentation shall be the Filter Supplier’s
recommended instrument with NEMA 4X rating, stainless steel bracket, and 4-20mA loop-powered signal transmission. Local level display is required.
E. Pressure Switches (PSL)
1. Pressure switches shall be industrial type NEMA 4X epoxy-coated
aluminum body with UL listing. 2. The pressure switch shall have a single pole double throw relay
output. The setpoint shall have an adjustable range suitable for operation in the conditions shown on the Drawings and in the equipment specifications.
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3. The switch shall be rated for operation in –25°F to 130°F ambient. Setpoint shall drift no more than 1.5% for a 50°F ambient temperature change.
4. Setpoint repeatability shall be within 1.5% of adjustable range,
maximum. 5. Electrical connection shall be either a ½” or ¾” threaded
connection. 6. Pressure connection shall be NPT. 7. Provide isolation valve and bleed valve suitable for removing the
pressure switch from its connection under pressure. 8. The pressure switch shall be Omega, or equal.
F. Differential Pressure Cell & Transmitter (PIT)
1. The transmitter shall be Foxboro Model IDP10, or equal, for
measuring differential pressure. Where utilized for level application, it shall read directly in FT H2O units.
2. The transmitter shall loop-powered
3. The transmitter shall transmit a 4-20 mA signal when supplied with voltage in a range from 11.5 to 42 VDC
4. The transmitter shall have an LCD display with on-board pushbuttons
5. The transmitter shall have an external zero adjustment
6. The transmitter shall be configurable to cutoff to zero at flows <10% of maximum flow
7. The transmitter shall have a Type 316 stainless steel cover and housing. It shall be rated NEMA 4X.
8. The transmitter range shall be as indicated on the Contract drawings.
9. The transmitter shall be equipped with a three-valve manifold, stainless steel
10. The transmitter shall be FM approved for use in Class 1 Division 1 Group A, B, C, and D locations.
11. Accuracy shall be +/-0.2 percent of calibrated span, minimum. Repeatability shall be better than 0.5 percent of calibrated span.
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12. The transmitter shall be equipped with HART communications.
13. The transmitter shall be furnished with a stainless steel mounting bracket.
14. Manufacturer warranty shall be 5 years, minimum.
G. Pressure Cell & Transmitter for Bulk Tank Level (LIT)
1. The transmitter shall be Foxboro Model IGP20, or equal, for measuring gauge pressure. It shall be programmable to read in direct level units (FT) based on liquid density. The unit shall include a capillary with flange-mounted diaphragm sensor for measuring tank level.
2. The transmitter shall loop-powered
3. The transmitter shall transmit a 4-20 mA signal when supplied with voltage in a range from 11.5 to 42 VDC
4. The transmitter shall have an LCD display with on-board pushbuttons
5. The transmitter shall have an external zero adjustment
6. The transmitter shall have a Type 316 stainless steel cover and housing. It shall be rated NEMA 4X.
7. The transmitter range shall be as indicated on the Contract drawings.
8. The transmitter shall be FM approved for use in Class 1 Division 1 Group A, B, C, and D locations.
9. Accuracy shall be +/-0.075 percent of calibrated span, minimum. Repeatability shall be better than 0.5 percent of calibrated span.
10. The transmitter shall be equipped with HART communications.
11. Mounting bracket shall be stainless steel. Provide pipe stand per detail on Drawings.
12. Manufacturer warranty shall be 5 years, minimum.
H. Bulk Tank Level Alarm System (LAH)
1. Provide Morrison Bros. Model 918AC or equal. Unit shall have the number of input channels (up to 4) indicated on the Drawings.
2. Unit shall have an audible alarm with silence button that will be activated when any of the input channels are triggered. Alarm shall be 95dBa at 2 feet, min.
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3. Unit shall have a visual alarm pilot light for each input channel.
4. Unit shall be NEMA 4X and listed for ambient temperature of -20 to 104 degrees F and full sunlight/rain exposure.
5. Power supply shall be 120VAC +/- 10%.
6. Inputs shall accept dry contacts and shall be intrinsically safe where indicated on the Drawings.
I. Turbidimeter System, Low Range
1. The Turbidimeter system shall be a Hach Model 1720E with SC200 controller, or equal, to continuously indicate and transmit low range turbidity based upon nephelometric measurement.
2. The system shall be suitable for regulatory reporting, and shall comply with USEPA 180.1 criteria.
3. The turbidimeter shall be suitable for continuous sample flow, and shall not be affected by flow or pressure variations.
4. The controller shall support datalogging, alarm history, and plug-and-play swap-out of turbidimeter.
5. Accuracy shall be +/- 2% of reading or +/-0.015 NTU(whichever is greater), minimum.
6. The turbidimeter shall measure turbidity in the range of 0.001-100 NTU, and shall be scaled as indicated on the Contract drawings.
7. The turbidimeter body shall be constructed of corrosion-resistant polystyrene.
8. Calibration of the instrument shall be either formazin-based or instrument comparison-based calibration method. All necessary materials and equipment for calibration shall be provided.
9. The turbidimeter shall have a 4-20mA analog output, and at least one alarm contact output.
10. Controller shall be NEMA 4X enclosed, suitable for 120VAC power supply.
11. Manufacturer warranty shall be 2 years, minimum.
J. Turbidimeter System, High Range
1. The Turbidimeter system shall be a Hach Surface Scatter 7 turbidimeter, or equal, to continuously indicate and transmit high range turbidity based upon nephelometric measurement.
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2. The turbidimeter shall be suitable for continuous sample flow, and shall not be affected by flow or pressure variations.
3. Accuracy shall be +/- 5% of reading from 0-2000 NTU, minimum.
4. The turbidimeter shall measure turbidity in the range of 0-2000 NTU, and shall be scaled as indicated on the Contract drawings.
5. Calibration of the instrument shall be formazin-based. All necessary materials and equipment for calibration shall be provided.
6. The turbidimeter shall have a 4-20mA analog output, and at least one alarm contact output.
7. Controller shall be NEMA 4X enclosed, suitable for 120VAC power supply, with a digital LED display
8. Manufacturer warranty shall be 2 years, minimum.
K. pH Analyzer/Transmitter & Sensor
1. The pH analyzer shall be Hach, or equal, for measuring pH of water.
2. The sensor shall be a digital differential style with replaceable salt bridge with minimum range 0-14 pH and sensitivity of 0.01 pH. It shall accept flow rates from 0 to 10 ft/second. It shall include a thermistor for automatic temperature compensation. Pressure rating shall be 100 psi minimum. Cable shall be included with sufficient length to reach the transmitter as indicated on the Drawings.
3. The sensor case shall be PEEK for chemical resistance.
4. The sensor shall be flow-through style which can easily be installed and removed from a tee fitting.
5. The analyzer/transmitter shall have an LCD display and LED backlighting. It shall support (2) digital sensors.
6. The analyzer shall have two isolated 4-20 mA outputs. Provide a cord for plugging into standard 120VAC receptacle for power supply.
7. Accuracy shall be 0.1% of span, minimum.
8. Enclosure shall be NEMA 4X non-metallic.
L. Chlorine Analyzer
1. The chlorine analyzer shall be Hach Model CL17, or equal.
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2. The chlorine analyzer shall employ a DPD colorimetric method of measurement using DPD indicator and a buffer solution.
3. The analyzer shall be capable of measuring free or total residual chlorine as indicated on the Contract drawings. It shall be capable of switching between free or total chlorine measurement by changing the indicator and buffer solutions.
4. A measurement shall be taken every 2.5 minutes and results displayed by a three digit LCD readout in the range of 0-5 mg/L
5. The analyzer shall be designed for 30-days unattended operation and use only 473 mL of each reagent per month.
6. The analyzer shall provide a minimum detection limit of 0.035 mg/L or better, precision better than +/- 5% or 0.005 mg/L of Cl2, and accuracy better than +/-5% or 0.035 mg/L of Cl2.
7. The analyzer shall provide a 4-20mA recorder output and 2 relay alarms. The alarms shall be user-selectable for sample concentration alarms (high or low and fully adjustable through the entire range), analyzer system warnings, or analyzer system shutdown alarms.
8. The analyzer shall be housed in an IP-62 rated, ABS plastic enclosure designed for wall mounting. The enclosure shall have two clear polycarbonate windows for viewing the measurement readout and reagent levels.
9. The analyzer shall operate from voltage of 115 VAC +/-10%, 60Hz.
M. Dissolved Oxygen Probe & Transmitter
1. The dissolved oxygen probe shall be a continuous-reading probe that utilizes luminescent sensor technology.
2. The probe material shall be foamed Noryl® and 316 stainless steel. All parts of the probe shall be corrosion resistant and fully-immersible.
3. The sensor material shall be polybutyl methoacrolate.
4. The measurement range shall be 0.00 to 20.00 mg/L dissolved oxygen.
5. The operation of the analyzer shall not be affected by H2S, pH, K+1, Na+1, Mg+2, Ca+2, NH4+1, Al+3, Pb+2, Cd+2, Zn+2, Cr (total), Fe+2, Fe+3, Mn+2, Cu+2, Ni+2, Co+2, CN-1, NO3-1, SO4-2, S-2, PO4+3, Cl-1, anion active tensides, crude oils, or Cl2-1.
6. The probe shall provide electrolyte-free operation without the requirements of sample conditioning.
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7. The probe shall be furnished with choice of pole or ballfloat mount kit.
8. The sensor cap shall be warranted for one full year against defects in material and workmanship.
9. The probe shall be listed for a Class 1 Div. 2 Group D hazardous area.
10. The probe shall be warranted for three full years against defects in material and workmanship.
11. The probe shall be HACH LDO® Probe for dissolved oxygen measurement, manufactured by Hach Company, or equal.
12. The probe shall be provided complete with ball-float mounting hardware suitable for mounting to handrail or other support. The operator must be able to service the probe without entering the wetwell or basin.
13. The transmitter controller shall be a microprocessor-based instrument. Connections between the sensors and the controller shall be “plug and play.” The controller shall have RS485/MODBUS® serial input/output capability for two-way communication to a computer and have wireless downloading capability through an IR Port located on the interface unit to download and print realtime data, calibration history, and current set points in a CSV format.
14. The Interface unit shall allow operators to control sensor and interface functions with menu-driven software. The interface unit shall have a built-in data logger with the capacity to store data on 15-minute intervals for up to 6 months with two sensors per controller.
15. The interface unit shall include two analog 4-20 mA outputs and 3 unpowered SPDT form ‘C’ alarm contacts. The interface unit shall include two independent PID control functions.
16. The interface unit shall be housed in a NEMA-4X/IP66 metal enclosure with corrosion-resistant finish. The controller shall be mounted horizontal or vertical on surface, panel, or pipe. The AC power supply shall be housed in the interface unit and automatically accept input in the range of 100 to 230 Vac, 50/60 Hz. All system components shall be certified by ETL to UL 61010A-1.
17. The controller shall be warranted for two full years against defects in material and workmanship.
18. Where indicated to be mounted in a hazardous area, the controller shall be listed for a Class 1 Div. 1 Group D hazardous area.
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19. The controller shall be Hach Model sc200 Controller, or equal.
N. Flow Switch – Water (FS)
1. The flow switch shall have a repetitive accuracy of +/- 5% of actual flow setting.
2. Switch actuation shall be adjustable over the operating flow range.
3. Flow switch shall be rated for use and constructed of suitable materials for installation in the environment encountered.
4. The flow switch shall have Form C contacts.
5. The flow switch range shall be as indicated on the Contract drawings.
O. Electromagnetic Flowmeter and Transmitter (FE/FIQT)
1. The electromagnetic flow meter shall consist of a flow sensor based on Faraday’s Law of Electromagnetic Induction and microprocessor-based signal converter & transmitter.
2. The sensor flow tube liner material shall be EPDM rubber for drinking water applications. Measurement and grounding electrodes shall be 316 stainless steel. Flow tube shall have corrosion resistant epoxy coating. Drinking water flow meters shall be approved by NSF.
3. Where located in a vault below grade with potential of flooding, flowtube shall be rated NEMA 6P with 3 foot submersion capability for up to 30 minutes.
4. Operating temp: Operating Temp: -5 to +120° F minimum acceptable band
5. Display: Background illumination with alphanumeric 3-line, 20-character display to indicate flow rate, totalized values, settings, and faults
6. Power supply: 115/230 VAC or 24VDC as indicated on Contract Drawings.
7. Outputs: 4-20 mA into 800 ohms max. One relay rated at 42 VAC/2 A, 24 DC/1A. Provide Digital pulse for external display of flow rate or totalizer.
8. Flow Range: 1.5 fps to 33 fps for accuracies stated below.
9. Accuracy: 0.5% of actual flow.
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10. Separation: Allowable distance of 900 feet between signal converter and sensor without the use of any additional equipment
11. Provide Bi-directional flow capabilities
12. Totalizer: Two eight-digit counters for forward, net, or reverse flow.
13. The transmitter shall be mounted integrally or remotely as indicated on the Drawings.
14. Insertion type flow meters will not be accepted.
P. Weight Scale and Transmitter (WE/WIT)
1. The scale platform shall have a 2-part epoxy finish and shall be sized to accept a tank of the dimensions indicated on the Contract drawings and in the equipment specifications. Four adjustable hold-down lugs shall be provided on the platform to increase lateral stability and to allow the use of hold-down straps for securing the vessel to the platform. Scale shall be of the single-load cell design. Weight shall be transferred via a pivoted platform to a single NTEP approved load cell of the shear beam strain gauge type. Flexible cable shall connect load cell to indicator to allow easy remote installation of the readout. Scale shall be Force Flow Equipment, or equal.
2. Transmitter shall be housed in a NEMA 4X, UL-approved enclosure. It shall independently monitor up to 4 scales. Digital display shall be a 2 line, 16 character, backlit alphanumeric LCD type. It shall be equipped with a numeric keypad for easy input of tare and level alarm values.
3. Operator shall be able to monitor chemical by weight, volume, or percent full. An auto-load function shall automatically compensate for tank tare weight during tank change. Each channel shall have a user-selectable, two-digit scale ID number and shall display Net Remaining, Feed Rate, Daily Usage, Total Amount Used, Days Until Empty, Gross Weight, and Tare Weight. A data log function shall store the daily usage for each of the previous 10 days. All of this data shall be available via Modbus RS-485 communication link.
4. Each scale shall have an independent adjustable 4-20mA output signal configurable for net weight or feedrate.
5. The Transmitter shall have up to 4 low-level alarm relays with adjustable setpoints.
6. The primary cable shall be provided in a length sufficient to meet the requirements as indicated on the Contract drawings.
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7. Full-scale accuracy shall be 0.25%, minimum.
8. The transmitter shall be the Force Flow Equipment Wizard 4000, or equal.
Q. Instrument Valves (1/4” through ¾”)
1. Shutoff valves shall be provided on each pressure line to an instrument and accessory item, and shall be bronze ¼ turn ball valves with Teflon seats as manufactured by Whitey Co., Gould, Hoke, Apollo, or equal. Valves shall have a corrosion resistant handle.
2. Throttling valves where required and/or shown on the Contract Drawings shall be bronze globe valves, NUPRO “J” Series, Hoke 3700-3800 Series, or equal. Valves shall have a corrosion resistant handle.
R. Tubing
1. Tubing for pressure lines to transmitters shall be hard drawn copper or 316 stainless steel. Bulkhead fittings, bushings, etc., shall be those especially designed for the tubing and used at all terminations. Tubing shall be Type “L” copper bent with bending tools, so as to have a minimum number of joints. Solder joint fittings are not allowed; compression type shall be utilized, Swagelok or equal.
2. All runs of tubing shall be straight, parallel to walls with a slope to a drip leg at each connection to a transmitter, where the transmitter is below the primary element. Horizontal liquid-filled lines shall slope at least 1 inch per foot downward toward the measuring element to ensure that air or gas bubbles return to the main flow line or tank.
2.03 SURGE PROTECTION FOR INSTRUMENTATION
A. Local Surge Protection Device for Analog 4-20mA loops.
1. The local surge protection device shall be installed at the location of the instrument it is protecting.
2. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 40V (Conductor to conductor) and 450V (conductor to ground). The response time shall be less than or equal to 1 nanosecond (conductor to conductor) or 100 nanoseconds (conductor to ground). The resistance of the device shall be no more than 10 ohms.
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3. The device shall be Class 1, Div. 2 certified under UL1604 if it is located in a hazardous area as indicated on the Contract drawings.
4. The device shall be housed in a stainless steel pipe stub or similar
for installation on a field-mounted conduit body. Temperature range shall be –40°C to 80°C.
5. The device shall be suitable for use on a 4-20mA analog circuit
with 28VDC continuous operating voltage and up to 270mA continuous current.
6. The device shall be a Phoenix Contact “Pipetrab” surge protection
device, or equal. B. Din-Rail-Mounted Surge Protection Device for Analog 4-20mA loops &
Power Supply
1. The Din-Rail-Mounted surge protection device shall be installed at the termination end of the instrumentation loop where it enters the I/O cabinet.
2. The device shall have a surge handling capacity of 20kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 40V (Conductor to conductor) and 450V (conductor to ground). The response time shall be less than or equal to 1 nanosecond (conductor to conductor) or 100 nanoseconds (conductor to ground). The resistance of the device shall be no more than 2.2 ohms.
3. The device shall be suitable for din-rail mounting, and shall be no
more than 17.5 mm thick. Temperature range shall be –40°C to 80°C.
4. The device shall be suitable for use on a 4-20mA analog circuit
with 28VDC continuous operating voltage and up to 450mA continuous current.
5. Where the instrument being protected has a separate 24VDC
power supply in addition to the analog current loop, the 24VDC supply circuit shall also be protected with a total surge current rating of 700A (8/20microsecond), clamping voltage less than or equal to 180V (conductor to conductor) or 550V (conductor to ground. Response time shall be 25nanoseconds (conductor to conductor) or 100 nanoseconds (conductor to ground).
6. The device shall be a Phoenix Contact “MCR-Plugtrab PT” surge
protection device, or equal.
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2.04 MISCELLANEOUS ACCESSORIES
A. Flange Adapters – Dresser Style 128 or equal for steel, ductile iron, or cast iron piping. Contractor must ensure the proper type of flange is procured. Provide restraints where specified in Division 2.
PART 3 EXECUTION 3.01 EQUIPMENT INSTALLATION
A. General
1. All piping to and from field instrumentation shall be provided with
necessary unions, tees, adapters, and shut-off valves. 2. Install all equipment in accordance with the manufacturer’s
installation and maintenance information. 3. Provide and install all necessary mounting equipment, brackets,
required for mounting of equipment. 4. Instrument cables shall be pulled without undo stress that may
aggravate the number of twists per foot. Shields shall be continuous and shall be only grounded at one end.
5. Place duct seal around the wires in each conduit entering every
instrument enclosure for the project. 6. All instruments and equipment shall be left free from shipping
burrs, paint overspray, grease, etc. All scratches shall be touched up with manufacturer’s matching paint.
7. Provide a local surge protection device at each instrument if the
loop extends underground beyond the building perimeter. 8. Provide a Din-rail-mounted surge protection device at the I/O
cabinet termination on each 4-20mA loop and 24VDC instrumentation power supply circuit.
9. Install on each instrument, transmitter, recorder, indicator, etc., a
plastic engraved white with black letters nameplate secured to the panel. Nameplates shall be permanently secured with stainless steel screws if it does not interfere with the NEMA rating of the box. Instruments shall be supplied with a stainless or aluminum engraved tag with black letters if no flat spot exists for a nameplate. Chain shall be stainless steel.
10. Locate instruments as shown on the electrical drawings and
primary elements as shown on the electrical or plant process drawings.
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11. Transmitters or indicators shall not be mounted from process
piping or hangers, only the building structure. 12. Remove all shipping tags, lifting rings, from enclosures. Plug all
non-used holds in enclosures. 13. The system supplier shall coordinate the installation through the
Contractor. 14. The placing and location of system components, their connections
to the process equipment panels, cabinets and devices, shall be coordinated with the Engineer’s acceptance.
15. Magmeters shall be installed with flange adapters to facilitate
installation and removal. 3.02 STARTUP SERVICES
A. After equipment and materials have been shipped to the job site, the
Contractor shall furnish the services of a factory-trained service technician or engineer to assist and advise the Contractor during installation and to provide calibration/adjustment at initial startup.
B. Following installation, checkout, and final adjustment of all panels,
instruments, meters, monitoring, and control devices, the Contractor shall schedule a performance test in the presence of the Engineer on all equipment. The Contractor shall furnish the services of servicemen, all special tools, calibration equipment, and labor to perform the tests.
C. Meters shall be tested at 0 percent, 25 percent, 50 percent, 75 percent,
and 100 percent of scale, if possible. All status and alarm switches as well as all monitoring and control functions shall also be checked. Testing shall be done from the signal source to the final element or device including all field wiring.
D. If, during running of the tests, one or more points appear to be out by
more than the system accuracy statement, the Contractor shall make such adjustments or alterations as are necessary to bring equipment up to specification performance. Following such adjustment, the tests shall be repeated for all specified points to ensure compliance.
END OF SECTION
***
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SECTION 17200
SCADA PANELS PART 1 – GENERAL 1.01 SCOPE OF WORK
A. The Contractor shall furnish and install SCADA panels, as shown on the Drawings and specified herein. Note: SCADA PLC programming will be provided by Owner under a separate contract.
B. Provide as-built panel Drawings which shall include revisions due to Contractor & Engineer markups due to field wiring changes.
1.02 RELATED WORK
A. Installation of all electrical equipment, conductors, and related items shall be in accordance with all applicable sections of Division 16 of these specifications.
B. General Requirements are included in Division 1. C. Section 16900 – Control Panels
1.03 SUBMITTALS
A. Shop drawing approval is required before the Contractor purchases or installs any equipment. Complete wiring diagrams are required.
B. Operation and Maintenance Manuals shall be submitted and shall include
approved shop drawing information along with manufacturer user manuals and as-built drawings. Include time for preparing as-built/as-installed Drawings from field-marked submittal drawings.
1.04 WARRANTY
A. The Contractor shall guarantee all work including equipment, materials, and workmanship. This guarantee shall be against all defects of the electrical system or improper equipment operation. It shall last for the period of time specified in the General Conditions of the Contract, but not less than one year from the date of substantial completion.
1.05 SPARE PARTS
A. Furnish one spare CompactLogix processor. B. Furnish one spare CompactLogix I/O Module for each unique I/O module
type installed.
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C. Furnish one spare power supply for each unique power supply installed. This includes PLC power supply, DC power supplies, and UPS units.
D. Ten fuses of each size/type in the system.
1.06 TRAINING
A. Not required for SCADA hardware. 1.07 TERMINOLOGY
A. DCC – Distributed Control Cabinet: Includes compact programmable controller, inputs, outputs, and other required equipment. The compact controller can communicate with the main controller and other compact controllers via the plant network.
B. IOC – Input-Output Cabinet: Includes inputs and outputs which are
addressed and controlled from the main programmable controller. C. PLC – Programmable logic controller
PART 2 – PRODUCTS 2.01 GENERAL
A. Acceptable manufacturers of SCADA hardware shall be Allen-Bradley/Rockwell to match existing equipment. Manufacturers of small peripheral equipment are listed with each piece of equipment.
B. All equipment must be able to reset after a power outage without having to
be manually reset.
C. All equipment mounted outdoors shall be protected from the sunlight, and extreme temperatures between –20 degrees and 140 degrees Fahrenheit. Provide all necessary shielding, heaters, or air conditioners as required. All externally mounted panels shall have self-sacrificing corrosion inhibitors installed.
2.02 SCADA CABINETS
A. Four SCADA cabinets are required to be provided, and they shall include
all of the I/O points indicated on the Drawings. Also see the SCADA Panel Details on the Drawings. The four cabinets to be provide are as follows: 1. DCC-FB (Filter Building) 2. DCC-HS (High Service Building) 3. DCC-Chem (Chemical Building) 4. IOC-Admin (Admin Building)
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B. General: All control cabinets shall be provided compliant with Section 16900, the wiring diagrams in the Drawings and with the following features: 1. Enclosure: Sized for 20% spare panel space with a single 3-point
roller latch. Screw clamps are unacceptable. NEMA 12 painted steel cabinet is required. Components installed in the exterior of the enclosure shall maintain the NEMA rating of the enclosure. All enclosures shall have a padlock hasp.
2. Rotary IEC style lockable main disconnect with main circuit breaker
and transient voltage surge suppression with alarm contact. 3. Uninterruptible power supply (UPS) with alarm contact. A power
relay shall be provided and wired such that, if the UPS fails the relay shall drop out and the panel shall be powered from utility power.
4. Provide 24VDC power supply, miscellaneous breakers, fuses,
terminal blocks, wiring duct, and other panel components 5. Interior GFCI protected duplex receptacle 6. Provide prewired with all field wiring landed on terminal blocks for
field installation 7. Alarm audible horn and visual strobe, NEMA 4X, with alarm silence
button 8. An interposing relay shall be installed for each PLC output. 9. Provide cabinet surge protector in each cabinet, and provide surge
suppression blocks for each I/O point where required in the I/O Table on the Drawings.
C. Distributed Control Cabinets (DCC) – Provide each with the following
features:
1. Compact programmable controller, modular with all required inputs and outputs and communications modules as required to meet the requirements of the Contract drawings and these specifications. Provide 10% spare I/O of each type installed and wired to terminal blocks. Also leave panel and terminal spare space arranged for future I/O modules.
2. In DCC-HS only, provide a Calamp Viper SC ethernet radio with
antenna adapter cable, and antenna surge protection, Polyphaser IS-50NX-C2 or equal. Frequency of operation shall be 173.3125 Mhz.
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3. In DCC-FB only, provide a Calamp Vanguard 3000 cellular router with cellular duckie antenna mounted to the exterior of the enclosure via a bulkhead fitting. Provide antenna cable to connect router to antenna.
4. In DCC-CHEM only, provide a Moxa MGate MB3270 2-channel
Modbus gateway to convert Modbus serial RS-485 to Modbus TCP ethernet. Provide wiring out to terminal blocks to serve the Modbus loops indicated on Drawings.
D. Input/Output Cabinet (IOC) – Provide with the following features:
1. Ethernet/IP communications adapter with all required inputs and
outputs and communications modules as required to meet the requirements of the Contract drawings and these specifications. Provide 10% spare I/O of each type installed and wired to terminal blocks. Also leave panel and terminal spare space arranged for future I/O modules.
E. Compact Programmable Controller and chassis-based I/O
1. The compact programmable controller shall be Allen-Bradley CompactLogix series. Provide with SD card for non-volatile memory storage.
2. The compact programmable controller shall include a chassis, power supply, processor, I/O modules, end cap, expansion cables, and all other components required to make a complete, functional system.
3. Processor Unit: 1769-L36ERM
4. Discrete Input Modules: 1769-IQ16
5. Discrete Output Modules: 1769-OB16
6. Analog Input Modules: 1769-IF4I (with isolated channels), except the 1769-IF8 non-isolated module may be utilized for loop-powered transmitters only.
7. Analog Output Modules: 1769-OF4CI
8. Remote I/O: Remote I/O shall be CompactLogix Type 1769 I/O as specified above with a 1769-AENTR Ethernet/IP adapter module.
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2.03 SURGE SUPPRESSION
A. Cabinet Power Supply Surge Protective Device (SPD)
1. The power supply SPD shall be a Din-Rail-Mounted device and shall be installed to protect the equipment in the cabinet from harmful surges and voltage spikes.
2. The SPD shall have nominal ratings of 120VAC and 26A minimum.
Temperature range shall be –40°C to 80°C. 3. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 500V. The response time shall be less than or equal to 25 nanoseconds.
4. The device shall be a Phoenix Contact “Mains-Plugtrab PT Series,”
or equal. B. Analog I/O SPD
1. The Din-Rail-Mounted surge protection device shall be installed to protect the analog SCADA I/O.
2. The device shall have a surge handling capacity of 20kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 40V (Conductor to conductor) and 450V (conductor to ground). The response time shall be less than or equal to 1 nanosecond (conductor to conductor) or 100 nanoseconds (conductor to ground). The resistance of the device shall be no more than 2.2 ohms.
3. The device shall be suitable for din-rail mounting, and shall be no
more than 17.5 mm thick. Temperature range shall be –40°C to 80°C.
4. The device shall be suitable for use on a 4-20mA analog circuit
with 28VDC continuous operating voltage and up to 450mA continuous current.
5. The device shall be a Phoenix Contact “MCR-Plugtrab PT” surge
protection device, or equal. C. Digital 24VDC I/O SPD
1. The SPD shall be DIN-rail-mountable and shall be installed to protect the digital 24VDC SCADA I/O. Temperature range shall be –40°C to 80°C.
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2. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 42VDC. The response time shall be less than or equal to 25 nanoseconds. The resistance of the device shall be no more than 4.7 ohms.
3. The device shall be suitable for use on 24VDC circuit with up to
300mA continuous current. 4. The device shall be a Phoenix Contact “MCR-Plugtrab PT” surge
protection device, or equal. 2.04 MISCELLANEOUS EQUIPMENT
A. Din Rail Mount Uninterruptible Power Supply (UPS) – For use inside enclosures.
1. The UPS shall be manufactured by Allen-Bradley, Sola or equal.
2. The UPS shall be designed for Din rail mounting inside industrial control panel enclosures. It shall have screw terminations for all wiring points.
3. The UPS shall operate off of 120V +/-10% with a capacity of 800VA minimum.
4. The UPS shall be UL 1778 recognized.
5. The UPS shall have a dry contact to indicate alarms.
6. The UPS shall have integral overload protection.
7. Operating temp shall be 0-50 degrees C.
8. The output must have a simulated sine wave. Square wave output is not acceptable.
9. The UPS shall handle normal shock and vibration of industrial use without damage.
PART 3 EXECUTION
3.01 EQUIPMENT INSTALLATION
A. Install all equipment in accordance with the manufacturer’s installation and maintenance information.
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B. Provide and install all necessary mounting equipment, brackets, required for mounting of equipment.
C. Place duct seal around the wires in each conduit entering every SCADA
cabinet for the project. D. All equipment shall be left free from shipping burrs, paint overspray,
grease, etc. All scratches shall be touched up with manufacturer’s matching paint.
E. Locate equipment as shown on the electrical drawings. F. Remove all shipping tags, lifting rings, etc. from enclosures. Plug all non-
used holes in enclosures. G. The placing and location of system components, their connections to the
process equipment panels, cabinets and devices, shall be coordinated with the Engineer’s acceptance.
END OF SECTION
***
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SECTION 17250
SCADA COMPUTER HARDWARE
PART 1 – GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish and install computer hardware as shown on the Drawings and specified herein.
B. Coordinate with Section 16710 supplier to install SCADA hardware in IDF-ADMIN rack.
C. All software licenses shall be licensed to Winchester Municipal Utilities.
1.02 RELATED WORK
A. Installation of all electrical equipment, conductors, and related items shall be in accordance with all applicable sections of Division 16 of these specifications.
B. General Requirements are included in Division 1.
1.03 SUBMITTALS
A. Shop drawing approval is required before the Contractor purchases or installs any equipment.
B. Operation and Maintenance Manuals shall be submitted and shall include shop drawing information along with manufacturer user manuals.
1.04 WARRANTY AND SERVICE
A. Minimum three year warranty on computer hardware from date of procurement.
B. For the servers, provide manufacturer’s onsite service support package for the duration of the warranty period.
1.06 SPARE PARTS
A. None required under this Section.
1.07 TRAINING
A. Not required under this Section.
PART 2 – PRODUCTS
2.01 GENERAL
A. Acceptable manufacturers of SCADA computers are HP, Dell, or Lenovo.
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2.02 SERVERS AND ACCESSORIES
A. SCADA Servers: Provide (2) SCADA servers installed in IDF-ADMIN with the following features:
1. Provide HP DL360, or equal
2. Processor: (2) Intel Xeon, minimum 8 cores each
3. 16 GB memory, minimum
4. Windows Server 2016 Standard Edition
5. Read & Write DVD/RW (16X) Drive
6. Storage array #1: 500 GB RAID 1 harddrive array
7. Storage array #2: 2 TB RAID 1 harddrive array
8. (2) 10/100/1000 Ethernet NICs minimum
9. Microsoft Office 2016 with Word and Excel – provide license
B. Monitor & Keyboard/Mouse KVM system
1. Provide (1) rack-mount monitor, 17” size that supports 1920x1080P resolution
2. Provide a USB keyboard and USB mouse on pullout rack tray.
3. Provide a 4-channel KVM switch to allow use of the (1) monitor/mouse/keyboard with all servers.
C. Rack-mount Uninterruptible Power Supply (UPS)
1. The UPS shall be an American Power Conversions (APC), Liebert, or equal.
2. The supply voltage shall be capable of 120VAC +/- 23%.
3. The UPS shall be capable of operating properly within a frequency range of 60 Hz +/- 3%.
4. Operating Ambient Temperature Range: 32 to 104 F minimum.
5. The UPS shall be rack-mount type with minimum 1440VA rating.
6. The UPS shall provide 120VAC output voltage with voltage regulation within +/- 4% for both normal and battery operation.
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7. The UPS shall be equipped with circuitry to protect itself from overloads and short-circuits.
8. The UPS shall be able to withstand 110% overload for at least five (5) minutes.
9. The UPS shall have a maximum transient recovery time of 30 milliseconds.
10. The UPS shall maintain a battery recharge rate designed to prolong battery life. The battery charger shall maintain a constant voltage and current charge and maintain the battery in a fully charged state. Recharge time shall be three (3) hours maximum to 95% capacity after discharge into a full load.
2.03 WORKSTATIONS AND ACCESSORIES
A. Provide (4) SCADA workstations each with the following features:
1. Provide HP Z240 small form factor, or equal.
2. Processor: Intel Core i7, 4 cores
3. 16 GB memory, minimum
4. Windows 10 Professional Edition
5. Read & Write DVD/RW (16X) Drive
6. 500GB harddrive
7. 10/100/1000 Ethernet NIC
8. Displayport adapter for monitor, and speaker output.
9. Microsoft Office 2016 with Word and Excel – provide license
10. Provide 24” monitor, minimum 1920x1080P resolution, 16:9 aspect ratio, with adjustable mounting stand and integral speakers.
B. Provide (1) mobile tablet SCADA workstation with the following features:
1. Provide Microsoft Surface or equal.
2. Processor: Intel Core i7
3. 8 GB memory, minimum
4. Windows 10 Professional Edition
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5. 256GB solid-state harddrive
6. Wireless ethernet 802.11 AC/a/b/g/n, Bluetooth, USB3.0, microSD card reader
7. 12.3” touch display, 2736x1824 resolution
8. Front and rear facing cameras
2.04 MISCELLANEOUS EQUIPMENT
A. Uninterruptible Power Supply (UPS) – Provide one for each workstation excluding the tablet.
1. The UPS shall be an American Power Conversions (APC), Liebert, or equal.
2. The supply voltage shall be capable of 120VAC +/- 23%.
3. The UPS shall be capable of operating properly within a frequency range of 60 Hz +/- 3%.
4. Operating Ambient Temperature Range: 32 to 104 F minimum.
5. The UPS shall have an output rating of at least 150% of the load to be served, but shall not be less than 420VA. It shall be sized for 30-minute minimum backup power.
6. The UPS shall provide 120VAC output voltage with voltage regulation within +/- 4% for both normal and battery operation.
7. The UPS shall be equipped with circuitry to protect itself from overloads and short-circuits.
8. The UPS shall be able to withstand 110% overload for at least five (5) minutes.
9. The UPS shall have a maximum transient recovery time of 30 milliseconds.
10. The UPS shall maintain a battery recharge rate designed to prolong battery life. The battery charger shall maintain a constant voltage and current charge and maintain the battery in a fully charged state. Recharge time shall be three (3) hours maximum to 95% capacity after discharge into a full load.
B. Color Laser Printer
1. Provide (1) color laser printer with the following features:
a. 28 pages/minute black or color, minimum
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b. Time to first page: 13 seconds color, maximum
c. 600x600dpi
d. USB & Ethernet ports, networkable.
e. Shall include two-sided printing capability
f. HP Laserjet Pro, or equal
PART 3 - EXECUTION
3.01 EQUIPMENT INSTALLATION
A. Install all equipment in accordance with the manufacturer’s installation and maintenance information.
B. Provide and install all necessary mounting equipment, brackets, required for mounting of equipment.
C. All equipment shall be left free from shipping burrs, paint overspray, grease, etc. All scratches shall be touched up with manufacturer’s matching paint.
D. Locate equipment as shown on the Drawings.
E. Remove all shipping tags, lifting rings, etc. from enclosures. Plug all non-used holes in enclosures.
END OF SECTION
***
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SECTION 17350
FILTER CONTROL SYSTEM PART 1 – GENERAL 1.01 SCOPE OF WORK
A. This section requires the furnishing and installation of a filter control system and instrumentation as shown on the Contract drawings. The filter manufacturer is required to furnish the filter control system.
1.02 RELATED WORK
A. Installation of all electrical equipment, conductors, and related items shall be in accordance with all applicable sections of Division 16 of these specifications.
B. Division 11 – Equipment C. Section 16900 – Control Panels D. Section 17100 – Process Instrumentation
1.03 PERFORMANCE AND DESIGN REQUIREMENTS
A. General Requirements: A complete filter control system shall be provided for controlling and monitoring the operation of the filter system. The control system shall include all instrumentation, equipment, and programming required for a complete and operational filter control system.
1.04 QUALITY ASSURANCE
A. Manufacturer: Roberts Filter, Leopold, or equal B. NSF Certification: All materials used in contact with the water shall meet
National Sanitation Foundation (NSF) Standard 61 Drinking Water System Components - Health Effects
C. The Contractor shall coordinate all work performed by instrumentation and filter
suppliers to ensure a complete and operable filter control system.
1.05 SUBMITTALS
A. The supplier shall submit to the ENGINEER complete shop drawings showing all control panel layouts, schematics, bills of material, programmable controller (PLC) memory maps, instrumentation and equipment data sheets, applicable calculations, and description of operation.
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1.06 OPERATION AND MAINTENANCE MANUALS
A. Complete operation and maintenance instructions shall be included.
B. Manuals shall include all the info included in the shop drawing submittal, with updates for complete record drawings indicating final installation, interconnections among field mounted equipment, and as-built wiring.
C. Include complete addresses of all equipment manufacturing representatives and phone numbers of each.
D. Include complete manufacturer’s installation, operations, and maintenance manual for each piece of equipment and software supplied.
E. Complete parts lists with stock numbers.
F. Include a configuration record for each piece of equipment, including all parameter settings and set points.
G. Backup of all PLC ladder-logic programs fully documented, parameters, and other electronic information developed in the course of the project on compact disc.
H. Manufacturers' standard instruction bulletins for all functional components.
1.07 SPARE PARTS
A. Furnish one spare PLC processor (pre-loaded with final program for Master CP)
B. Furnish one spare HMI (pre-loaded with final program for Master HMI)
C. Furnish one spare I/O Module for each unique I/O module type installed.
D. Furnish one spare power supply for each unique power supply installed.
E. Five fuses of each size/type in the system.
F. Furnish two spare relays for each type installed in the system
G. Furnish one spare instrument for each unique instrument supplied.
PART 2 - PRODUCTS 2.01 GENERAL REQUIREMENTS
A. A complete filter control system shall be provided. The control system shall include all equipment and instrumentation as indicated on the Drawings and as required for a complete and operational filter system.
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2.02 FILTER CONTROL CONSOLES
A. Provide (5) Filter Control Consoles for controlling and monitoring the operation of the filters. Each filter console shall include a PLC & HMI. Also provide a master filter system control cabinet. The master CP shall be a wall-mount cabinet, while the consoles shall be slope-front console type. All enclosures shall be NEMA 4X FRP non-metallic. The system shall be designed and implemented such that any individual filter can be taken out of service while the rest of the system remains in operation.
B. The console shall be a PLC-based system and shall be provided complete with a Human-Machine Interfaces (HMIs), the necessary control devices, equipment, and functional programming to perform the control and monitoring functions specified.
C. Functional Description
1. The console shall have the capability of controlling the filtration and backwash sequence for each filter. It shall have the capability for semi-automatic, automatic, and manual control.
2. In the automatic mode, the backwash sequence shall be initiated by high turbidity, high loss-of-head, or exhausted filter runtime. The PLC shall perform the backwash sequence without operator intervention. The controller shall confirm that filter water level is below the trough prior to initiating backwash pump operation to prevent media carryover.
3. In the semi-automatic mode, the backwash sequence shall be manually initiated by the operator following a system alert based on the above-mentioned conditions. Occurrence of any of these conditions shall illuminate a BACKWASH REQUIRED indicator. The operator shall initiate the backwash sequence by pressing the START BACKWASH pushbutton. The controller shall confirm that filter water level is below the trough prior to initiating backwash pump operation to prevent media carryover. The PLC shall then perform the backwash sequence without further operator intervention. An ABORT BACKWASH pushbutton shall be provided to end the backwash sequence before its completion. The HMI shall include an EXTEND HIGH BACKWASH pushbutton that will extend the high rate backwash for an adjustable amount of time.
4. In the manual mode, the backwash sequence shall be completely manual in operation, using the selector switches and indicators on the HMI. Manual operation shall be independent of the PLC.
5. NOTE: Backwash buffer tank level must be verified (via Ethernet communications from DCC-FB SCADA panel) to have a good signal and within an acceptable range to permit backwash. Backwash pump shall be stopped immediately upon high level in buffer tank.
6. Positioning/flow-rate PID loop control shall be provided for the effluent and backwash control valves. The HMI shall include AUTO/MANUAL and
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an INCREASE/DECREASE buttons. In AUTO mode, the unit shall accept a setpoint and position the flow control valve to maintain the flow setpoint. In MANUAL mode, the provided a % Open setpoint for the valve. The HMI shall have a display for indicating the flow setpoint, actual flow in GPM, and valve actual position.
7. The HMI shall have position setpoints/selectors for manual control of the effluent and backwash control. The console shall have OPEN/CLOSE selector switches for manual control of the influent, drain, backwash inlet, air wash, backwash waste, and filter-to-waste valves.
8. The console shall provide dry-contact open and dry-contact close outputs for each valve controlled from the console. If the valve is a modulating type, the console shall provide 4-20mA position control and accept 4-20mA position feedback. The console shall accept dry-contact limit switch inputs from each valve and shall have HMI indication of fully-opened and fully-closed position. Motors shall be controlled via a single maintained dry-contact that shall close when the motor is to run. The console shall accept a dry-contact running signal for proof that the motor is running.
9. HMI displays shall be provided for loss of head and turbidity.
10. Adjustable alarm setpoints shall be provided for each monitored parameter, including combined filter effluent turbidity. The alarm setpoints shall be secured under supervisor level authority.
11. Provide an automatic shutdown of each individual filter if that filter’s effluent exceeds 0.3 NTU (adjustable).
12. Components:
a. The enclosure shall be NEMA 4X fiberglass, slope-front console type. Comply with Section 16900. Provide visual alarm strobe and audible horn with silence button.
b. The operator interface and PLC are specified below. c. Miscellaneous circuit breakers, pushbuttons, selector switches,
pilot lights, relays, terminal blocks and other controls shall be as specified in 16900.
d. Instrumentation shall be provided as specified in Section 17100.
D. Interface to SCADA system: Provide memory registers/tags such that the Plant SCADA system can monitor the following information for each filter over the Plant Ethernet network:
1. Turbidity
2. Loss of Head
3. Effluent Flow Rate
4. Backwash Status
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5. Backwash Needed
6. Level
7. Alarms
2.03 CONTROLLERS AND I/O
A. Compact Programmable Controllers and chassis-based I/O
1. The compact programmable controller shall be Allen-Bradley CompactLogix, or equal.
2. The compact programmable controller shall include a chassis, power supply, processor, I/O modules, communications modules, cables, and all other components required to make a complete, functional system.
3. Processor Unit:
a. Processor Memory: 2 megabytes, battery backed RAM, minimum b. Capability of controlling up to (16) I/O modules c. Shall have typical throughput Time of 0.08 ms/K based upon a 1K
ladder logic program consisting of simple ladder logic and communications servicing.
d. Shall have Bit Execution Time of less than 0.51 microseconds e. Shall support Proportional Integral Derivative Control with up to
451 microsecond execution time f. Shall support online programming including runtime editing g. Memory Back-up provided through minimum two year lithium
battery. Also, a removable flash card is required. h. LED indicators for: POWER, RUN, CPU Fault, Forced I/O, Battery
Low, i. Shall include one USB port j. Shall support a Real Time Clock k. The processor shall support Ethernet communications via RJ-45
connection.
4. Discrete Input Modules
a. Sixteen Inputs, minimum b. Removable terminal block c. LEDs to indicate the status of each I/O point d. Optical isolation between digital and field circuits
5. Discrete Output Modules
a. Shall be a relay output module with individually isolated outputs. Otherwise provide interposing relays for transistor output modules.
b. Continuous current rating per point: 2.5A ac not to exceed 1440 VA for the module
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c. Continuous current rating per module: 16 A ac, 2.5A / common d. Removable terminal block e. LEDs to indicate the status of each I/O point f. Optical isolation between digital and field circuits
6. Analog Input Modules
a. Current Rating of 0 to 20mA, 4 to 20mA b. Resolution of 14 bits c. Input channel configuration via configuration software screen or
the user program d. Input Group to Bus Isolation of 500Vac for (1) minute e. Removable terminal block f. LEDs to indicate the status of each I/O point
7. Analog Output Modules
a. Current Rating of 0 to 20mA, 4 to 20mA b. Loading
(1) Inductive load of 0.1mH maximum for current outputs (2) Resistive load of 0 to 500 Ohm on current output (3) Load range of greater than 1kOhm at 10Vdc
c. Resolution of 15 bits d. Open and short-circuit protection e. Output voltage protection f. Input Group to Bus Isolation of 500V ac for (1) minute g. Removable terminal block h. LEDs to indicate the status of each I/O point
2.04 CONTROLLER AND I/O SOFTWARE
A. Development version of software is not required on this project.
2.05 OPERATOR INTERFACE
A. Human Machine Interface (HMI)
1. The operator interface panel shall be Allen-Bradley, Wonderware, or equal. The operator interface panel shall be a Color Flat Panel.
2. The display type shall be Active Matrix Thin Film Transistor (TFT) color.
3. The display size shall be 15 inch, minimum.
4. Communications shall be Ethernet/IP
5. Provide minimum memory of 512 MB non-volatile and 512 MB RAM. Also provide external storage via SD card or similar.
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6. The unit shall include a battery-backed real time clock and shall timestamp critical data.
7. The display shall have a field replaceable backlight.
8. The HMI must support trending and datalogging.
2.06 SURGE SUPPRESSION
A. Cabinet Power Supply Surge Protective Device (SPD)
1. The power supply SPD shall be a Din-Rail-Mounted device and shall be installed to protect the equipment in the cabinet from harmful surges and voltage spikes.
2. The SPD shall have nominal ratings of 120VAC and 26A minimum.
Temperature range shall be –40°C to 80°C. 3. The device shall have a surge handling capacity of 10kA
(8/20microsecond) minimum. It shall have hybrid technology for “fine” voltage clamping and “coarse” surge current handling. The clamping voltage shall be less than or equal to 500V. The response time shall be less than or equal to 25 nanoseconds.
4. The device shall be a Phoenix Contact “Mains-Plugtrab PT Series,” or
equal.
2.07 MISCELLANEOUS EQUIPMENT
A. Loop Isolator and Signal Converters: The loop isolator or signal converter shall be provided where indicated or specified, to isolate signals or to increase the load capacity of a system required to have many devices in the loop. Isolators shall provide 3-way isolation and shall have a power supply voltage of 120VAC unless otherwise indicated. Isolators and converters shall be Action Instruments, Phoenix Contact, or equal, and enclosed as appropriated for the application or as indicated.
2.08 DATA HIGHWAYS AND ASSOCIATED EQUIPMENT
A. Ethernet Switches – Unmanaged
1. The Unmanaged Ethernet switch shall be IEEE 802.3 compliant.
2. Port Densities: All switches shall be sized for two (2) spare ports in addition to the ports indicated on the plans.
3. Port Configurations: All switches shall be Copper 10/100TX with RJ-45 connections. Fiber optic ports are required in lieu of using media converters.
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4. Auto-negotiation: All Copper TX ports shall support auto negotiation. Each TX port will be able to interface to 10/100 meg or full/half duplex devices.
5. AutoCross: All TX ports will provide cable autocross capability.
6. The address table shall have a minimum capacity of 4000 addresses.
7. The switch shall contain an alarm contact that can be configured via standard web browser to annunciate the drop out of either or both power supply inputs and/or to annunciate the active link status of any combination of ports. An LED shall be provided to indicate the status of the alarm contact.
8. The switch shall also have power supply, link active, and communications status LEDs
9. The Switch shall be din rail mountable out of the box and without the need to add/assemble adaptor or similar mounting plates.
10. All power and alarm connections shall be wired using removable connectors.
11. The switch shall be powered by a nominal 24VDC, 120VAC, or as shown on the Contract Drawings
12. The Switch shall have provision for supporting redundant power inputs. Power supply switchover will not interrupt switch operation.
13. Provision will be made such that the loss of one or more power supply may be user configurable to trigger a hardware alarm (ie relay contact)
14. The Switch shall have an operating temperature range of 0° to 55° C or greater
15. The switch shall withstand a maximum continuous operating humidity of 95% without condensation.
16. Electrical Noise Immunity: The switch shall conform to the IEC61000-4-2 to 4-8 series of noise specifications
17. Shock and Vibration: The switch shall conform to IEC60068-2-27 and withstand a shock pulse of 25G or more for 11ms. The operating vibration spec shall conform to IEC60068-2-6 (Criterion 3) at 5G 150Hz, in all 3 axis.
18. Agency Certifications: The switch will be certified for UL/Cul 508
19. The switches shall be Phoenix Contact Unmanaged Ethernet Switches, or equal.
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PART 3 - EXECUTION 3.01 SOFTWARE DEVELOPMENT
A. General: Software services shall include program development, testing, documentation, and work necessary to implement a complete and fully operating system as shown on Drawings and as specified.
B. HMI Screens: Provide graphic representation of processes and control over filter
system equipment. There shall be an overall filter system screen and individual filter detail screens. At the master, turbidities shall be logged to a CSV file every 15 minutes as a backup for SCADA logging. Create a new file each day timestamped with the date.
C. Software required application features:
1. Video displays shall be color. Install operating system drivers as
necessary. Use colors, function keys, and navigational controls consistently.
2. Alarm Management: For each process or system event classed as an alarm
provide facilities for displaying and logging in database, acknowledgment, and purging of stale messages. Alarm events shall be derived from discrete inputs, analog trip values, logic combinations and computations as needed. Log and display both alarm events and returns to normal. Provide date/time stamps for events, descriptive message, and event type code. Use color combinations to distinguish following alarm states: Alarm-Unacknowledged, Alarm-Acknowledged, Normal-Unacknowledged, and Normal-Acknowledged.
3. Graphic Displays:
a. Provide process-oriented displays showing current process status and accepting operator input for setpoint and status changes.
b. For each display, show process elements such as pumps, valves, tanks, pipe lines, etc., with their current operational status. Emphasis shall be placed on depicting the system in a “P&ID” format that allows easy conceptualization of process flow rather than depicting equipment in actual physical location or scale.
c. Not running state: graphic shall be natural color with no motion. d. Running state: Graphic shall be green color and shall rotate or
show other type of motion as appropriate. Both color and motion shall be depicted.
e. Red color shall be reserved for alarm graphics. f. Tanks shall include both analog and digital indication of current
fill/level status. Also, static text must be added to indicate level at bottom of tank and top (or overflow) of tank.
g. Indicators shall use an appropriate number of significant digits and dead band to produce steady values.
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4. Trending: Provide on-screen trending displays that are user definable that operate from either previously collected historical trend groups (named file) or from a group of real-time variables. Provide facilities for user selection of colors, time (horizontal), and measurement (vertical) scales. Accommodate real-time sampling intervals as short as 1 second. Real-time trends shall show alarm setpoints. Historical trend displays shall have time-scale panning controls. All trends must have an adjustable cursor that indicates both Y and X axis values at the user-selected location.
5. Security: Using operator interface and operating system software,
implement a security system to restrict access to parts of system. Coordinate usernames/passwords with the SCADA contractor. Provide the following as a minimum:
a. Programmer - Access to all facilities including changing displays and
logic. b. Supervisor - Access to all displays, change master set points and
purge stale alarm messages. c. Operator - Access to all displays, change normal operational
sequences and acknowledge alarms.
6. Trending a. For each tag selected to be trended on the Contract Drawings,
provide a pre-configured trend that shows both real-time and historical values. Certain tags may be added to the same trend where appropriate as long as they are uniquely identified via color and label.
b. Provide a custom trend screen whereby the operator has the ability to trend any tag in the database.
7. Reports: a. Reporting requirements shall consist of both live HMI screens that
dynamically update the values for “today” and also published historical reports (CSV logs). Turbidity values are required to be logged every 15 minutes.
b. Daily totals shall be published at 11:59:55 PM and reset to zero at midnight. Monthly totals shall be published at 11:59:55 PM on the last day of the month and reset at midnight.
c. Totalization time slices shall not exceed 5 seconds. d. The following parameters shall be reported:
(1) Backwash & Filter Run times: Report “Run Time Today” and
“Run Time Yesterday”. (2) Flow Totals: For each flow meter, report “Flow Total Today”,
“Flow Total Yesterday”, “Flow Total This Month”, and “Flow Total Last Month.”
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e. Data Export: Establish a simple method of data export to Excel via memory stick or similar method.
3.02 FILTER CONTROL INSTALLATION AND START-UP SERVICE
1. The Contractor shall be responsible for installation of the filter control consoles and all wiring from the console to field devices, instruments, and other systems.
2. Factory service technicians are required to startup/commission the
system. The lead technician shall have a minimum of five years experience in the start-up of water filter backwash systems.
3. Start-up shall be performed with all final elements, field devices,
instruments installed, calibrated and wired in the circuit. 4. The Contractor shall ensure that all of the relevant personnel are
available and onsite for coordination of the filter startup.
3.03 PERFORMANCE TEST
A. Following installation, checkout, and final adjustment of filter system and software, the Contractor shall schedule a performance test in the presence of the Engineer and the Owner.
B. Demonstrate to the Engineer and Owner that each I/O point scheduled on the
Contract Drawings has been integrated and is functioning properly. C. Demonstrate trending, reporting, and alarm messaging has been configured
properly and is operational. D. Software development shall not be accepted until the Filter system functions for
at least one week with no nuisance alarm. Nuisance alarms shall be as defined by the Engineer.
3.04 TECHNICAL DIRECTION
A. Install all items in accordance with the instruction of the filter equipment manufacturer, under the direct technical supervision of the manufacturer. The filter equipment manufacturer's technical director shall supervise the installation of all filter control systems.
B. Upon completion of the installation, the technical director shall furnish a
certificate of compliance detailing that the filter control system has been installed in accordance with the manufacturer's instructions.
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3.05 TRAINING
A. A minimum of two 8-hour days of on-site training of supervisors and shift operators shall be provided at the time of start-up to familiarize personnel with the hardware and to instruct them in day-to-day operations of the controls, preventative and regular maintenance, trouble-shooting techniques, and system diagnostics.
END OF SECTION
***
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SECTION 17400
SCADA SOFTWARE
PART 1 – GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall provide SCADA software licensing as specified herein. SCADA software development will be provided by Owner under a separate contract.
1.02 RELATED WORK
A. General requirements are located in Division 1.
1.03 SUBMITTALS
A. Submit proposed bill of materials and cutsheets.
1.04 TRAINING
A. SCADA software training will be provided by others.
PART 2 – PRODUCTS
2.01 MANUFACTURERS
A. SCADA software licenses shall be provided by Rockwell Automation to match the existing WMU SCADA software. Licenses can be procured from Consolidated Electrical Distributors (CED).
2.02 Software Maintenance/Support
A. The software manufacturer’s software maintenance/support plan shall be included for all licenses provided or upgraded, for a length of time sufficient to extend one year beyond the scheduled substantial completion date.
2.03 EXISTING LICENSES TO BE UPGRADED
A. The following licenses are already owned by WMU and will be upgraded and/or moved to the new water plant. Provide Rockwell’s update to these licenses so that the software can be upgraded to latest version:
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DESCRIPTION SERIAL # DESTINATION
FT VIEW STUDIO FOR FTV ENTERPRISE 2529038587 WTP-SERVER1
FT VIEW SE CLIENT 2524067188 WTP-CLIENT1
FT VIEW SE SERVER 100 DISPLAY 2527022062 WTP-SERVER1
FT VIEWPOINT 3 CLIENT READ-ONLY 2928006128 REMOTE BROWSER CLIENTS
RSLOGIX 5000 PROFESSIONAL ON LAPTOP 2022073453 STAY ON EX. LAPTOP
RSNETWORX for ETHERNET/IP 1669154994 STAY ON EX. LAPTOP
RSLINX CLASSIC OEM 1005238870 STAY ON EX. LAPTOP
FT GATEWAY DISTRIBUTED 5000 TAG 2350017508 STAY ON WWTP SERVER1
FT GATEWAY DISTRIBUTED 5000 TAG 2350018273 STAY ON WWTP SERVER2
FT HISTORIAN 500 TAG 3318005279 STAY ON WWTP HISTORIAN
FT VIEW STUDIO FOR FTV ENTERPRISE 2529035247 STAY ON WWTP SERVER1
FT VIEW SE CLIENT 2524061383 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061384 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061385 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061386 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061387 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061388 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061389 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061390 STAY ON WWTP CLIENT
FT VIEW SE CLIENT 2524061391 STAY ON WWTP CLIENT
FT VIEW SE SERVER 250 DISPLAY 2528013181 STAY ON WWTP SERVER1
FT VIEW SE SERVER 250 DISPLAY 2528013182 STAY ON WWTP SERVER2
FT VIEW SE SERVER 250 DISPLAY 2528013183 STAY ON WWTP HISTORIAN
FT VIEW SE SERVER 250 DISPLAY 2528013184 STAY ON STRODE CREEK PC
FT VIEWPOINT 3 CLIENT READ-ONLY 2928005879 STAY ON WWTP SERVER1
RSLOGIX 5000 PROFESSIONAL 2022068646 STAY ON EX. LAPTOP
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2.04 NEW LICENSES AND FUNCTIONAL UPGRADES
A. The following new licenses shall be provided:
DESCRIPTION SERIAL # DESTINATION UPGRADE FT VIEW SE SERVER 100 TO 250 DISPLAY 2527022062 WTP-SERVER1 UPGRADE FT HISTORIAN 500 TAG TO 1000 TAG 3318005279 WWTP HISTORIAN
FT VIEW SE SERVER 250 DISPLAY WTP-SERVER2
FT VANTAGEPOINT 3 CONCURRENT USERS WWTP HISTORIAN
KEPSERVER ENTERPRISE FOR FT VIEW SE WTP-SERVER1
KEPSERVER ENTERPRISE FOR FT VIEW SE WTP-SERVER2
FT VIEW SE CLIENT READ/WRITE WTP-CLIENT2
FT VIEW SE CLIENT READ/WRITE WTP-CLIENT3
FT VIEW SE CLIENT READ/WRITE WTP-CLIENT4
FT VIEW SE CLIENT READ/WRITE WTP-CLIENT5
PART 3 - EXECUTION
3.01 SOFTWARE SERVICES
A. Software development services will be provided by Owner under a separate Contract.
B. Provide electrical personnel to coordinate with Owner’s personnel during SCADA system commissioning to repair any wiring problems that may be found.
END OF SECTION
***
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SECTION 17500
ANTENNA TOWER SYSTEM PART 1 GENERAL 1.01 SCOPE OF WORK
A. Provide an antenna tower system for communication between the WTP & the existing water tanks.
1.02 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Divisions 0 and 1 Specification Sections, apply to this Section.
B. Section 17200: SCADA Panels – Includes radio transmitter specification.
1.03 REFERENCES
A. Code of Federal Regulations (CFR): 47 CFR 15 Radio Frequency Devices
B. IEEE C62.41 Surge Voltages in Low-Voltage AC Power Circuits
C. NFPA 780 Installation of Lightning Protection Systems 1.04 SUBMITTALS
A. General: Submit each item in this Article according to the Conditions of the Contract and Division 1 Specification Sections.
B. Provide installation drawings and cutsheets for approval.
1.05 OPERATION & MAINTENANCE MANUALS
A. Provide approved shop drawing submittal plus manufacturer’s operation/maintenance instructions.
1.06 WARRANTY
A. Equipment supplied under this section shall be warranted for a period of two years dating from final completion. Warranty shall include all parts, labor, and expenses as required to repair the system and restore it to full operational status.
PART 2 - PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS
A. Rohn or equal.
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2.02 ANTENNA SYSTEM
A. Antenna shall be TCIC model Y1503 or equal with 7 dB gain in VHF band.
B. Antenna grounding conductors shall be minimum, No. 12 AWG copper. C. Ground rods shall be as specified in Division 16. D. Transmission line between the transmitter and the antenna shall be 50-
ohm impedance rated ½” Heliax cable. Minimum requirement shall be cable that exhibits an attenuation not exceeding 0.9 dB per 30.5 m (100 feet) at 174 MHz.
E. The Contractor shall be responsible for providing all mounting as
required to support the antenna. Provide Rohn “G Series” or equal self supporting tower, 40’ height. See antenna tower detail on the Drawings for requirements.
2.03 CONDUIT
A. Conduit shall be as specified in Division 16. PART 3 - EXECUTION 3.01 INSTALLATION
A. All system components and appurtenances shall be installed in
accordance with the manufacturer's instructions and as shown. All necessary interconnections, services, and adjustments required for a complete and operable data transmission system shall be provided.
B. Antenna: All tubular radiator elements shall be plugged to prevent wind
vibration fatigue. All vertical tubular elements shall have drain holes near the bottom. All outside connectors shall be snug, filled with silicone grease, and properly taped over with plastic tape suitable for cold weather.
C. Interior Work: All interior electrical work shall be installed as specified in
Division 16 and as shown.
D. Exterior Work
1. Underground: Except as otherwise specified, underground electrical work shall be installed as specified in Division 16 and as shown.
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2. Enclosure Penetrations: Enclosure penetrations shall be from the bottom and shall be sealed with duct seal to preclude the entry of water.
END OF SECTION
***
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SECTION 17610
ELECTRIC VALVE ACTUATORS PART 1 - GENERAL 1.01 SCOPE OF WORK
A. Provide valve actuators as indicated on the Contract drawings and as
specified herein. The actuators shall be factory-installed onto the valves and tested and shall be shipped as a complete assembly. Note: This section does not include pump control or raw water flow control valve actuators. Refer to Division 15 for pump control and raw water flow control valve actuators.
1.02 RELATED WORK
A. Division 15 – Valves
1.03 SUBMITTALS
A. Shop drawing approval is required. Valve and actuator submittal shall be combined into a single submittal. Include complete wiring diagrams and electrical information.
B. Operation and Maintenance Manuals shall be submitted in accordance with
Section 17010.
1.04 QUALITY ASSURANCE
A. See Section 17010 for requirements. B. Actuators shall comply with AWWA C540.
1.05 WARRANTY AND SERVICE
A. See Section 17010 for requirements.
1.06 TRAINING
A. Training shall be in accordance with Section 17010.
PART 2 - PRODUCT
2.01 MANUFACTURERS
A. Acceptable manufacturers for large motorized actuators shall be Limitorque,
EIM, Auma, or equal. B. Acceptable manufacturers for smaller actuators shall be Hayward or equal.
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2.02 LARGE VALVE ACTUATOR CONSTRUCTION
A. Actuators shall consist of an electric motor, worm gear reduction, electronic
torque sensor, mechanically and electrically interlocked reversing motor contactor, electronic control, protection, and monitoring package, manual override handwheel, valve interface bushing, LCD (Liquid Crystal Display), and local control switches. Actuator design life shall be at least one million drive sleeve turns.
B. Actuator Housing: Actuators installed above grade shall be NEMA 4X.
Actuators installed below grade shall be NEMA 6 & IP-68 rated to 15 meters for 96 hours. Actuators proposed for hazardous areas (as indicated on the Drawings) shall be FM certified for the indicated hazardous area.
C. Actuators indicated as two-position actuators shall have limit switches to
indicate position status. Modulating actuators shall have an absolute position encoder and shall accept 4-20mA input position control signal and shall generate a 4-20mA position feedback signal.
D. The power transmission shall be completely bearing-supported, and consist
of a hardened alloy steel worm and bronze alloy worm gear; oil-bath lubricated using synthetic oil designed specifically for extreme pressure worm and worm gear transmission service.
E. The actuator voltage rating shall be as indicated on the Drawings. If the
voltage is not indicated on the Drawings, the actuator shall be 120V single phase for valves 16” and less, and 208-230/460V three phase for valves over 16” in diameter. The motor shall have Class F insulation and a thermistor embedded within the motor windings to prevent damage due to overload. The motor shall be easily removed through the use of a plug-in connector and shaft coupling. Valve motors shall be listed for continuous duty operation.
F. An electronic torque sensor shall be included. The torque limit may be
adjusted from 40-100% of rating in 1% increments. The motor shall be deenergized if the torque limit is exceeded. A boost function shall be included to prevent torque trip during initial valve unseating and during extreme arctic temperature operation (-50°C), and a “Jammed Valve” protection feature, with automatic retry sequence, shall be incorporated to de-energize the motor if no movement occurs.
G. A Phase Correction circuit shall be included to correct motor rotation faults
caused by incorrect site wiring. The phase correction circuit shall also detect the loss of a phase and disable operation to prevent motor damage. The monitor relay shall trip and an error message shall be displayed on the LCD screen when loss of phase occurs and indicate the fault for Remote operation.
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H. A monitor relay shall be included and shall trip when the actuator is not available for remote operation. Both N/O and N/C contacts shall be included, rated 125VAC, 0.5A and 30VDC, 2 amps. The monitor relay shall be configurable for three additional fault indications; lost phase, valve jammed, and motor overtemp. The yellow LED shall blink when the monitor relay is active.
I. A padlockable LOCAL-STOP-REMOTE switch and an OPEN-CLOSE switch shall
be included for local valve actuator control. The control switches shall not penetrate the controls cover and shall be designed to electrically isolate the actuator’s internal components from the external environment. The OPEN-CLOSE switch may be configured for maintained or push-to-run (inching) control.
J. Double sealed terminal compartment & Terminal block - All customer
connections shall be located in a terminal chamber that is separately sealed from all other actuator components. Site wiring shall not expose actuator components to the environment.
K. Coatings - The actuator shall be coated with a polymer powder coat. The
coating system shall be suitable for an ASTM B117 salt spray test of 1500 hours. External fasteners shall be stainless steel or high-strength carbon steel that has been chromate-hexavalent coated, and then top coated with a high-strength, high-endurance polymer. The fasteners shall be suitable for an ASTM B117 salt spray test of 500 hours.
L. A handwheel and declutch lever shall be provided for manual operation. The
handwheel shall not rotate during electric operation nor can a seized motor prevent manual operation. Changing from motor to manual operation is accomplished by engaging the declutch lever. Energizing the motor shall return the actuator to motor operation. The lever to enable the declutch shall be padlockable to permit motor operation only.
M. The actuator shall include a removable torque or thrust bushing to mate with
the valve shaft. N. Factory testing - Every actuator shall be factory tested to verify: rated output
torque, output speed, handwheel operation, local control, control power supply, valve jammed function, all customer inputs and outputs, motor current, motor thermistor, LCD and LED operation, direction of rotation, microprocessor checks, and position-sensor checks. A report confirming successful completion of testing shall be included with the actuator.
O. Communications: Fieldbus communications are not required on this project. P. Actuators to be installed in un-conditioned areas shall include an internal
anti-condensation heater.
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2.03 CHEMICAL VALVE ACTUATOR CONSTRUCTION
A. Actuator shall be designed for corrosive environment with glass-filled
polypropylene housing. Hardware shall be 303 stainless. Enclosure shall be NEMA 4X and IP-67 rated. Power supply shall be 120VAC and actuator shall include integral thermal overload protection. The actuator shall be listed for ambient temperature operation from 4 to 160°F. Cycle time shall be no longer than 30 seconds.
B. Actuator shall have a standardized mounting base and shall be installed and tested with the valve prior to shipment to the project site.
C. Actuator shall include a position indicator and a minimum of two limit switches indicating fully open and fully closed status.
D. Actuator shall include a manual override and position indicator.
E. Actuator shall include a status indicator that indicates power status and fault
status.
F. Actuator shall be Hayward ECP series or equal.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Install the valve and actuator per manufacturer’s instructions. B. Test to ensure proper operation. C. For modulating actuators – tune control loops to achieve stable operation
with reasonable response time and accurate setpoint control.
END OF SECTION
***